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NASA NTRS2013

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗

NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗

DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗

NASA NTRS2018

Creating Innovative Frameworks to Spur Cultural Change at NASA Armstrong Flight Research Center

Changing the culture of an organization is a monumental task that often takes years and has no set formula. Steps can be taken, however, to spur cultural change by creating spaces and infrastructure to serve as the initial driving force. An innovation space and a bicycle sharing (bike share) program were implemented at the National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California) with a vision toward connecting Center personnel, fostering collaboration and innovation, retaining newer employees, promoting flexibility, and improving the culture and workplace atmosphere. This paper discusses the steps taken, challenges faced, novel culture-change-focused design elements, lessons learned, acquired metrics, and how these initiated cultural change at AFRC. For both the innovation space and the bike share program, funding was negotiated and provided through the NASA Convergent Aeronautics Solutions (CAS) project, which was seeking to improve the innovation and collaboration capabilities at each of the four NASA aeronautics Centers. Key stakeholders across AFRC from upper management, facilities, safety, engineering, and procurement were identified early in the process and were consulted and included throughout execution to ensure that any encountered roadblocks could be easily navigated. Research was then conducted by attending conferences and visiting culture-changing organizations both inside and outside United States Government agencies. Distilling the research, identifying available space, and deciding on specific design elements for the space was conducted by a subset of individuals of diverse backgrounds to enable quick, effective decision-making. Decisions were made with the intent to increase usage and diversity of users of the space; care was taken to ensure a well-crafted atmosphere that would foster the desired culture change. The allocated physical space required major structural modifications, new furniture, and new capabilities that would bring people in. Decisions and desires underwent a rapid reiterative process in order to stay within budget and short deadlines, while holding firm to what was seen as fundamental elements of an innovation space. The framework for cultural change being established, the more difficult task began: incubating the desired culture. Intentional workday use of the innovation space was encouraged, and organized events coordinated in order to truly foster culture change. Such incubation supports the organic spread of culture change to all areas of AFRC. This framework was complemented and expanded by the implementation of the bike share program. Steps for implementation included bike selection based on lessons learned, creating bike stations and signage, implementing bike share rules, and building a volunteer maintenance infrastructure. A novel user-reporting feedback system at each bike station is a low-impact method of capturing usage metrics. Due to the nature of the work conducted at AFRC, the bike share program and feedback system were negotiated and vetted through various organizations including legal, safety, and operations. The innovation space and the bike share program together are an effective initial framework for innovation and collaboration. Culture change takes time, but the innovation space and the bike share program are already showing signs of making a positive impact on the AFRC workforce.

rooms↗

NASA NTRS1989

Electrical, Electronic, and Electromechanical (EEE) parts management and control requirements for NASA space flight programs

This document establishes electrical, electronic, and electromechanical (EEE) parts management and control requirements for contractors providing and maintaining space flight and mission-essential or critical ground support equipment for NASA space flight programs. Although the text is worded 'the contractor shall,' the requirements are also to be used by NASA Headquarters and field installations for developing program/project parts management and control requirements for in-house and contracted efforts. This document places increased emphasis on parts programs to ensure that reliability and quality are considered through adequate consideration of the selection, control, and application of parts. It is the intent of this document to identify disciplines that can be implemented to obtain reliable parts which meet mission needs. The parts management and control requirements described in this document are to be selectively applied, based on equipment class and mission needs. Individual equipment needs should be evaluated to determine the extent to which each requirement should be implemented on a procurement. Utilization of this document does not preclude the usage of other documents. The entire process of developing and implementing requirements is referred to as 'tailoring' the program for a specific project. Some factors that should be considered in this tailoring process include program phase, equipment category and criticality, equipment complexity, and mission requirements. Parts management and control requirements advocated by this document directly support the concept of 'reliability by design' and are an integral part of system reliability and maintainability. Achieving the required availability and mission success objectives during operation depends on the attention given reliability and maintainability in the design phase. Consequently, it is intended that the requirements described in this document are consistent with those of NASA publications, 'Reliability Program Requirements for Aeronautical and Space System Contractors,' NHB 5300.4(1A-l); 'Maintainability Program Requirements for Space Systems,' NHB 5300.4(1E); and 'Quality Program Provisions for Aeronautical and Space System Contractors,' NHB 5300.4(1B).

Source record↗

NASA NTRSDate not supplied

Genesis Solar Wind – Capture, Return, Curate and Analyze: Looking Backward Reviewing Sample Collection Hardware

Genesis, as the first U.S. spacecraft to return astromaterial samples since Apollo, not only integrated the mission planning and flight teams, but also the science and sample curation teams during the mission development period. Since Genesis is a sample return mission, the Science Team was essential in certifying the collectors (sample containers for solar atoms). Burnett and the science team defined the purity of collector materials and ability to analyze solar wind composition to the precision required for planetary science. The science team’s choices included a variety of very pure materials which are described, including rationale for selection. The JPL Project Scientist networked with specialty vendors refining specifications and fabricating several of the materials. JPL engineering team designed and fabricated the collector arrays. LANL designed and built an electrostatic concentrator. JSC procured these materials with exacting specifications.

SOLAR WIND↗

DOE OSTI2020

M&V in ESPC: The U.S. Federal Experience and Implications for Developing ESPC Markets

The United States Federal Government has been conducting guaranteed savings energy savings performance contracts for over 20 years and now relies on ESPC for the majority of its energy efficiency work. Along with a related financed project type, these deals resulted in $4.2 billion of project investment in the five years ending in 2016, a pace that has even accelerated since.Measurement and verification (M&V) on the projects is the key to assuring savings realization and persistence. Perceived as a weakness or burdensome added cost in the early years of the program, M&V has become a strength. All energy conservation measures (ECMs) have some form of measurement – defined as a measured baseline establishment followed by at least one measurement of the main energy-saving parameter for a given ECM taken in the performance period. The government’s in-house energy consulting office, the Federal Energy Management Program (FEMP), now recommends measurement of these “Option A” M&V ECMs throughout the contract term, usually annually. Moreover, a significantly higher percentage of projects are now characterized by more ambitious M&V, including Option B (all parameter measurement) for most generation (including renewable) and some efficiency measures, and more frequent Option C (whole facility utility bill analysis) for “deep retrofit” projects with multiple, interactive ECMs. Coincident with this progress in M&V has been a much greater embracing of ESPC by the federal agencies, resulting in the enormous rate of projects now executed. This paper traces the evolution of M&V in federal ESPC and argues that the heightened credibility of the estimated (and guaranteed) savings has contributed significantly to the procurement vehicle’s long-term viability. This focus on savings integrity via M&V has been learned over two decades for U.S. federal ESPC, but countries with developing ESPC markets would be wise to emphasize it as their markets emerge, allowing them to avoid some of the “growing pains” experienced in the U.S.

Coleman, Philip↗

DOE OSTI2025

Grid Communications: Digital Assurance and Supply Chain Challenges and Emerging Regulation Session Two

The TADA Grid Communications Workshops are designed to strengthen cybersecurity and digital assurance across the energy sector by focusing on secure deployment and management of grid communications technologies. These workshops bring together state energy offices, utilities, and technology suppliers to explore the intersection of communications infrastructure, supply chain risks, and emerging regulatory requirements. Participants will apply Cyber-Informed Engineering (CIE) principles to reduce risks in communications systems, engage with INL’s procurement guidance, and explore future tools. Through scenario-based exercises and peer exchange, attendees will develop risk-based security strategies and actionable compliance roadmaps tailored to their grid communications projects. The workshops also help participants navigate evolving regulatory frameworks such as FEOC rules in the OBBB, NERC CIP-013, and NDAA 2024, while identifying compliance gaps in mixed-technology environments. A key outcome is the formation of a practitioner network with ongoing access to INL expertise and resources, fostering long-term resilience in the digital energy ecosystem. This is Session 2 of 3 (Full Version).

29 - ENERGY PLANNING, POLICY AND ECONOMY↗

DOE OSTI2025

Grid Communications: Cybersecurity and Supply Chain Challenges and Emerging Regulation Session Three

29 - ENERGY PLANNING, POLICY AND ECONOMY↗

DOE OSTI2025

Grid Communications Supply Chain & Emerging Regulation Challenges Session 1

29 - ENERGY PLANNING, POLICY AND ECONOMY↗

NASA NTRS2022

Fission Surface Power Project (FSP) TDM Annual Review

This is a power point document to be presented at NASA HQ on March 3, 2022 for the Technology Demonstration Mission program and the management of STMD. It summarizes the activities over the last year of the Fission Surface Power (FSP) project. FSP is a project with the main goal of developing a nuclear reactor for operation on the Moon.

Nuclear↗

NASA NTRS1977

The 26-meter S-X Conversion Project

The 26-meter S-X conversion project provides for the conversion of an existing 26-meter S-band subnet to a 34-meter S- and X-band subnet. The subnet chosen for conversion consists of the following stations: DSS 12 near Barstow, DSS 44 in Australia, and DSS 62 in Spain. The main subsystems effected by this project are the antenna mechanical, antenna microwave, and receiver-exciter. In addition to these, there are many project-related electronic equipments that have been added to the existing station equipment. The major subsystems are essentially through the design stage with the antenna mechanical subsystem completed through detail design with procurement in process.

Lobb, V. B.↗

NASA NTRS1989

Large screen display for the Mission Control Center

The Mission Control Center (MCC), located at the Johnson Space Center near Houston, Texas, is the primary point of control and monitoring for National Space Transportation System (NSTS) flight activities. NSTS flight managers monitor and command spacecraft from one of two Flight Control Rooms (FCR). Each FCR is equipped with five large screen displays for group dissemination of spacecraft system status and vehicle position relative to Earth geography. The primary or center screen display is ten feet in height and twenty feet in width. The secondary or side screens are seven and one-hald feet high and ten feet wide. The center screen projection system is exhibiting high maintenance costs and is considered to be in wear-out phase. The replacement of the large center screen displays at the MCC is complicated by the unique requirements of the Flight Controller user. These requirements demand a very high performance, multiple color projection system capable of the display of high resolution text, graphics and images produced in near real time. The current system to be replaced, the replacement system requirements, the efforts necessary to procure the major element of this system (the projector) for the government, and how the new capabilities are to be integrated into the existing MCC operational configuration are discussed.

Skudlarek, Martin J.↗

NASA NTRS1999

NASA Historical Data Book: NASA Launch Systems, Space Transportation, Human Spaceflight and Space Science, 1979-1988 - Volume 5

In 1973, NASA published the first volume of the NASA Historical Data Book, a hefty tome containing mostly tabular data on the resources of the space agency between 1958 and 1968. There, broken into detailed tables, were the facts and figures associated with the budget, facilities, procurement, installations, and personnel of NASA during that formative decade. In 1988, NASA reissued that first volume of the data book and added two additional volumes on the agency's programs and projects, one each for 1958-1968 and 1969-1978. NASA published a fourth volume in 1994 that addressed NASA resources for the period between 1969 and 1978. This fifth volume of the NASA Historical Data Book is a continuation of those earlier efforts. This fundamental reference tool presents information, much of it statistical, documenting the development of four critical areas of NASA responsibility for the period between 1979 and 1988. This volume includes detailed information on the development and operation of launch systems, space transportation, human spaceflight, and space science during this era. As such, it contains in-depth statistical information about the early Space Shuttle program through the return to flight in 1988, the early efforts to build a space station, the development of new launch systems, and the launching of seventeen space science missions. A companion volume will appear late in 1999, documenting the space applications, support operations, aeronautics, and resources aspects of NASA during the period between 1979 and 1988. NASA began its operations as the nation's civilian space agency in 1958 following the passage of the National Aeronautics and Space Act. It succeeded the National Advisory Committee for Aeronautics (NACA). The new organization was charged with preserving the role of the United States "as a leader in aeronautical and space science and technology" and in its application, with expanding our knowledge of the Earth's atmosphere and space, and with exploring flight both within and outside the atmosphere. By the 1980s, NASA had established itself as an agency with considerable achievements on record. The decade was marked by the inauguration of the Space Shuttle flights and haunted by the 1986 Challenger accident that temporarily halted the program. The agency also enjoyed the strong support of President Ronald Reagan, who enthusiastically announced the start of both the Space Station program and the National Aerospace Plane program.

Rumerman, Judy A.↗

NASA NTRS2018

A Flexible Control Center Architecture for Support of Diverse Spaceflight Missions

The Ames Multi-Mission Operations Center (MMOC) enables and supports flight and science operations for Ames' spaceflight missions. The MMOC is composed of the facilities, networks, information technology equipment, software, and system administration services needed by flight projects to effectively and efficiently perform all mission functions, including planning, scheduling, command, telemetry processing, and science analysis. The MMOC's ready-to-use services reduce start-up time, shorten procurement and provisioning and allow mission planning efforts to focus more on science and less on infrastructure. The architecture of the MMOC was designed from the start for flexibility, so that it can readily support multiple missions of greatly varying size and complexity while simultaneously keeping costs low.

Differding, Joan C.↗

NASA NTRS1999

Assurance of COTS Boards for Space Flight

Space Flight hardware and software designers are increasingly turning to Commercial-Off-the-Shelf (COTS) products in hopes of meeting the demands imposed on them by projects with short development cycle times. The Technology Validation Assurance (TVA) team at NASA GSFC has embarked on applying a method for inserting COTS hardware into the Spartan 251 spacecraft. This method includes Procurement, Characterization, Ruggedization/Remediation and Verification Testing process steps which are intended to increase the user's confidence in the hardware's ability to function in the intended application for the required duration. As this method is refined with use, it has the potential for becoming a benchmark for industry-wide use of COTS in high reliability systems.

Plante Jeannette↗

NASA NTRS1998

Assurance of COTS Boards for Space Flight

Space Flight hardware and software designers are increasingly turning to Commercial-Off-the-Shelf (COTS) products in hopes of meeting the demands imposed on them by projects with short development cycle times. The Technology Validation Assurance (TVA) team at NASA GSFC has embarked on applying a method for inserting COTS hardware into the Spartan 251 spacecraft. This method includes Procurement, Characterization, Ruggedization/Remediation and Verification Testing process steps which are intended to increase the uses confidence in the hardware's ability to function in the intended application for the required duration. As this method is refined with use, it has the potential for becoming a benchmark for industry-wide use of COTS in high reliability systems.

Plante, Jeannette↗

DOE OSTI2023

Experience from the US contribution to HL-LHC: Nb3Sn focusing quadrupoles and SRF crab cavities

The Interaction Regions (IR) of many colliders benefit from the application of leading-edge technologies to ensure the highest possible luminosity delivered to the experiments. Leading-edge low-beta focusing magnets and crab cavities to handle individual bunches are critically important to increase the instantaneous and integrated luminosity in future Colliders.The High-Luminosity LHC Upgrade, HL-LHC, with Nb3Sn Magnets (called MQXF) and Superconducting Radio Frequency (SRF) crab cavities (of two types, called DQW and RFD) is a world-wide collaborative project under construction in this decade to utilize the solutions mentioned above as key ingredients to increase tenfold the integrated luminosity delivered to the CMS and ATLAS experiments in the next decade. The HL-LHC AUP is the US effort to contribute approximately 50% of the low-beta focusing magnets and crab cavities for the HL-LHC.In this contribution we present the valuable lessons learned by the US efforts in the procurement, construction, and testing phases of the Nb3Sn focusing magnets and SRF crab cavities. We will report on the experience gathered by HL-LHC AUP in the production of the first half of deliverables (magnets MQXFA03 to MQXFA13). We will also report on the test of the first cryoassemblies and the status of the cavities’ development, production and testing.Both the technical and project management lessons-learned will inform applications of these technologies to future colliders and projects.

43 PARTICLE ACCELERATORS↗