In Space Manufacturing and Extraterrestrial Construction
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In space manufacturing↗
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Geopolymer Lunar Concrete under Reduced-Pressure Curing and Vacuum Exposure
Geopolymer concrete has emerged as a promising material for constructing habitats, roads, landing pads, and other necessary infrastructure on the lunar surface. Proper in-situ resource utilization (ISRU) is an important aspect of any candidate lunar construction material. Geopolymer concrete is effective at ISRU, as the lunar regolith can be used in the “as found” condition and mixed with an alkaline solution, such as sodium silicate and sodium hydroxide, which could also be mostly produced in-situ. It is envisioned that any concrete material on the lunar surface would be deposited with additive manufacturing techniques and would require a temporary environmental enclosure to mitigate the harsh lunar environment during construction and curing, such as pressure and temperature. Data are needed to set a benchmark for the conditions to be achieved within the deployable environmental enclosure during printing, as well as the resultant material properties after the enclosure is removed. This novel study investigated the influence of reduced atmospheric pressures during the initial curing period on the compressive strength of geopolymer lunar concrete created with two types of lunar regolith simulant. The simulants used in the study represent the regolith for the lunar mare (OPRL2N) and lunar highlands (OPRH2N) regions. Results show a noticeable decline in strength with a reduction in pressure and visible degradation. After the deployable environmental enclosure is removed from the printed segment of infrastructure on the lunar surface, it would then be exposed to the harsh vacuum environment. To understand the importance of curing time required within the deployable enclosure before it is removed, samples were cast and cured for different lengths of time and then exposed to a vacuum chamber capable of achieving 100 mTorr. Control samples were also cast at the same time but left in a standard laboratory environment after curing. The weight change and compressive strength as a function of time in the vacuum chamber were monitored for up to 56 days. The results showed that exposure to the vacuum limits further reaction and strength gain in comparison to control samples left in the laboratory environment. This research is in strong alignment with the 2020 NASA Technology Taxonomy materials area (12.1) and the in-situ resource utilization area (7.1), as it provides necessary data on the geopolymer lunar concrete material to support safe and sustainable options for maintaining a human presence on the Moon.
Moon to Mars Planetary Autonomous Construction Tec↗
Exploration case studies
NASA's Office of Exploration has undertaken four case studies for prospective expansion of manned space activities beyond earth orbit. The subjects of these studies are (1) an expedition to the Martian moon Phobos; (2) a three-mission expedition to Mars; (3) the construction of a man-tended lunar observatory; and (4) the construction of a lunar outpost to serve as the basis for construction of a Martian outpost. The fourth alternative would follow the recommendation of the National Commission on Space for the creation of a 'bridge between worlds' in which explorers would develop ways in which to 'live off the land' in a space environment.
Underwood, Jimmy M.↗
The NASA MMPACT Project – Autonomous Construction of Infrastructure for a Sustainable Presence on the Lunar Surface.
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Additive construction, regolith, lunar surface inf↗
Overview of Lunar Safe Haven Seedling Study for NASA/APL Excavation & Construction TIM
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lunar safe haven↗
Ilmenite-rich pyroclastic deposits - An ideal lunar resource
With a view of investigating possible economic benefits that a permanent lunar settlement might provide to the near-earth space infrastructures, consideration was given to the ilmenite-rich pyroclastic deposits as sources of oxygen (for use as a propellant) and He-3 (for nuclear fusion fuel). This paper demonstrates that ilmenite-rich pyroclastic deposits would be excellent sources of a wide variety of valuable elements besides O and He-3, including Fe, Ti, H2, N, C, S, Cu, Zn, Cd, Bi, and Pb. It is shown that several ilmenite-rich pyroclastic deposits of regional extent exist on the lunar surface. The suitability of regional pyroclastic deposits for lunar mining operations, construction activities, and the establishment of permanent lunar settlements is examined.
Hawke, B. R.↗
Challenges and Benefits of Excavation and Construction on the Moon
This presentation covers some of the challenges and benefits to excavation and construction on the Moon. Challenges include the lunar surface environment, materials that can survive in the lunar environment, the materials available in-situ to utilize, as well as the technology development that must occur to enable lunar excavation and construction. There are numerous benefits to excavation and construction on the Moon, including cost effectiveness and sustainable logistics.
excavation↗
Relevant Environment Additive Construction Technology (REACT)
Advancing the TRL of technologies developed during the NASA 3D Printed Habitat Centennial Challenge. Focused on the design and construction of a lunar unpressurized radiation protection shelter called LINA.
lunar infrastructure↗
Design of a device to remove lunar dust from space suits for the proposed lunar base
The National Aeronautics and Space Administration plans to begin construction of a lunar base soon after the turn of the century. During the Apollo missions, lunar dust proved to be a problem because the dust adhered to all exposed material surfaces. Since lunar dust will be a problem during the establishment and operation of this base, the need exists for a device to remove the dust from space suits before the astronauts enter clean environments. The physical properties of lunar dust were characterized and energy methods for removing the dust were identified. Eight alternate designs were developed to remove the dust. The final design uses a brush and gas jet to remove the dust. The brush bristles are made from Kevlar fibers and the gas jet uses pressurized carbon dioxide from a portable tank. A throttling valve allows variable gas flow. Also, the tank is insulated with Kapton and electrically heated to prevent condensation of the carbon dioxide when the tank is exposed to the cold (- 240 F) lunar night.
Harrington, David↗
The use of high temperature superconductors to levitate lunar telescope
The objective of this paper was to assist in the construction of a lunar telescope mirror model by conducting research on composite materials and other lightweight, rigid materials, and by determining how much weight can be levitated by available superconductors. It is believed that with the construction of four magnets suspended over four bulk superconductors (or vice versa), there should be no problems lifting a model mirror and stabilizing it at different positions. It may be necessary to increase the size and quality of the superconductors and/or magnets in order to achieve this.
Brown, Beth A.↗
Material Concerns: Evaluating Sulfur Concrete for use in the Lunar Environment
On Earth sulfur "concrete" is an established construction material that has good mechanical properties, generally better than Portland cement, and can be used in corrosive environments. Troilite (FeS) has been found on the moon and raises the question of using extracted sulfur as a lunar construction material, an attractive alternative to conventional concrete as it does not require water. Troilite reduction to elemental sulfur and using it to make concrete in a lunar setting has been previously discussed. However, little has been experimentally done to evaluate its performance in the extreme lunar environment. This study subjected sets of sulfur concrete samples, prepared using JSC-1 lunar simulant, to I ) extended periods of high vacuum and 2) extreme temperature cycles. Here an overview of sulfur concrete and experimentally assessed properties, put in context of the lunar environment, is presented and discussed.
Grugel, Richard N.↗
OAST Space Theme Workshop. Volume 2: Theme summary. 2: Space industrialization (no. 8). A. Theme statement. B. 26 April 1976 presentation. C. Summary statement. D. Initiative action (form 5)
Enabling technology needs and other requirements to support space industrialization include: large space structures; fabrication and joining processes; single stage to orbit and heavy lift launch vehicles; nuclear and solar space power systems; robotics, manipulators, and teleoperators; biotechnology in space; artificial gravity; the utilization of lunar materials for construction; and the extraction of oxygen and metals from lunar resources. New initiatives (FY 1978) directly supportive or partly related to space industrialization are listed.
Source record↗
Smart Structures for Vibration Control on Long-Term Space Exploration and Habitation Missions
The current vision for space exploration focuses on human missions to the Moon, Mars, and beyond. To support these goals, it is certain that new vehicles and intermediate bases will be developed, whether that means simply re-direction of the ISS as a "mission research facility" or construction of a lunar base. Since these facilities are expected to be constructed from inherently light-weight materials, this work examines some of the potential sources of vibration and noise as well as means for controlling these vibrations. Many of the operating components within these facilities, such as pumps, fans, and motors, will produce vibrations during operation. These vibrations become structure in which they are housed. Resonances can impact acoustic noise levels and noise quality within the environment, possibly affecting crew health and productivity. For long-term missions in particular, it is expected that crew members will spend significant portions of their time restrained in the structure, such as in seats. As a result, the general health and well-being of the crew can be improved by limiting the harmful effects of human exposure to long-term audible and tactile vibration input. Besides the human factor, this work also examines some operational considerations in which vibrations play an important role. Vibrations can impact the environment for science and in-situ manufacturing research within these vehicles. Since a benign vibratory environment is beneficial for most types of science experiments, there is a need for various forms of vibration control. Because the operational characteristics of a vehicle can change during a long-term mission, it is further expected that the characteristics of many of the vibratory excitations will change with time. Consequently, the form of vibration control needed to improve overall habitability and usefulness of the vehicle or element for exploration missions will rely to some degree on the vibration control system's ability to adapt. To address these needs, this work also examines the development and use of smart materials to tune the dynamic characteristics of the structure in a passive sense. One prime example is the use of an adaptive electrical shunt connected to a piezoelectric patch in order to provide tuned passive vibration damping. The work also examines the use of active vibration control, such as by applying power to that same piezoelectric patch. The overall goal is to examine the use of smart structures that can react to the environment thereby improving the overall living, working, and learning environment for these long-term missions.
Gattis, Christy B.↗
Design of an autonomous teleoperated cargo transporting vehicle for lunar base operations
At the turn of the century NASA plans to begin construction of a lunar base. The base will likely consist of developed areas (i.e., habitation, laboratory, landing and launching sites, power plant) separated from each other due to safety considerations. The Self-Repositioning Track Vehicle (SRTV) was designed to transport cargo between these base facilities. The SRTV operates by using two robotic arms to raise and position segments of track upon which the vehicle travels. The SRTV utilizes the semiautonomous mobility (SAM) method of teleoperation; actuator-controlled interlocking track sections; two robotic arms each with five degrees of freedom; and these materials: titanium for structural members and aluminum for shell members, with the possible use of light-weight, high-strength composites.
Holt, James↗
Lunar observer laser altimeter
Understanding the global topography of the Moon is especially important for answering questions concerning lunar origin and evolution. Many outstanding problems in lunar science can be addressed with high resolution topographic data. The severe power, mass, size, and data-rate limitations imposed by the Lunar Geoscience Observer (LGO) and other Observer-class missions are major challenges for all instruments capable of measuring topography. A radar altimeter that meets these strict requirements could obtain a global prespective of lunar topography with a few kilometers spatial resolution and 10 m vertical resolution from a lunar orbit of 100 km. A prototype model is being constructed of the Lunar Observer Laser Altimeter (LOLA) capable of continuously measuring the range to the lunar surface with sub-meter vertical resolution within a 30 to 300 m diameter surface footprint. This same instrument is also designed to provide a direct measure of the surface height distribution in the footprint by waveform analysis of the backscattered laser pulse. Both these measurements are to be made in a continuous, nadir profile across the lunar surface from a 100 km orbit. The wavelength of the altimeter is 1064 nm. A short-pulse (2 nsec), diode-pumped Nd:YAG laser combined with a 25 cm diameter telescope, silicon avalanche photodiode detector, ranging electronics, and instrument computer was designed to make these measurements and meet all the requirements of the LGO mission.
Bufton, J. L.↗
Thermal investigation of a large lunar telescope
Recent interest in construction of a large telescope on the lunar surface (Nein and Davis, 1991; Bely, Burrows, and Illingworth, 1989) has prompted this feasibility study of a thermal control system for a 16 meter diameter telescope located near the lunar equator. In addition to detailed analyses for a telescope located in a flat area near the equator, the thermal effect of locating the telescope in a crater, on a hill, and at higher latitude sites is discussed. Because an unprotected telescope experiences a wide range of temperature swings, several thermal protection schemes have been examined, including domes, sunshades, and ground shields to limit the temperature excursions of the primary mirror. Results of these analyses indicate that mirror temperature excursions can be limited to less than 100 Kelvin (K) per lunar cycle with an appropriate passive thermal protection system (dome), and that the telescope primary mirror can be maintained at less than 100 K for at least 7 days of each lunar cycle. However, such a dome precludes observations during the lunar day. Mirror temperature excursions can be reduced by incorporating thermal enclosures or shades in the design or by placing the telescope at a higher latitude.
Walker, Sherry T.↗
Direct Electrolysis of Molten Lunar Regolith for the Production of Oxygen and Metals on the Moon
When considering the construction of a lunar base, the high cost ($ 100,000 a kilogram) of transporting materials to the surface of the moon is a significant barrier. Therefore in-situ resource utilization will be a key component of any lunar mission. Oxygen gas is a key resource, abundant on earth and absent on the moon. If oxygen could be produced on the moon, this provides a dual benefit. Not only does it no longer need to be transported to the surface for breathing purposes; it can also be used as a fuel oxidizer to support transportation of crew and other materials more cheaply between the surface of the moon, and lower earth orbit (approximately $20,000/kg). To this end a stable, robust (lightly manned) system is required to produce oxygen from lunar resources. Herein, we investigate the feasibility of producing oxygen, which makes up almost half of the weight of the moon by direct electrolysis of the molten lunar regolith thus achieving the generation of usable oxygen gas while producing primarily iron and silicon at the cathode from the tightly bound oxides. The silicate mixture (with compositions and mechanical properties corresponding to that of lunar regolith) is melted at temperatures near 1600 C. With an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in production of molten metallic products at the cathode and oxygen gas at the anode. The effect of anode material, sweep rate, and electrolyte composition on the electrochemical behavior was investigated and implications for scale-up are considered. The activity and stability of the candidate anode materials as well as the effect of the electrolyte composition were determined. Additionally, ex-situ capture and analysis of the anode gas to calculate the current efficiency under different voltages, currents and melt chemistries was carried out.
Sirk, Aislinn H. C.↗
Physical properties of concrete made with Apollo 16 lunar soil sample
This paper describes the first phase of the long-term investigation for the construction of concrete lunar bases. In this phase, petrographic and scanning electron microscope examinations showed that the morphology and elemental composition of the lunar soil made it suitable for use as a fine aggregate for concrete. Based on this finding, calcium aluminate cement and distilled water were mixed with the lunar soil to fabricate test specimens. The test specimens consisted of a 1-in cube, a 1/2-in cube, and three 0.12 x 0.58 x 3.15-in beam specimens. Tests were performed on these specimens to determine compressive strength, modulus of rupture, modulus of elasticity, and thermal coefficient of expansion. Based on examination of the material and test results, it is concluded that lunar soil can be used as a fine aggregate for concrete.
Lin, T. D.↗