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NASA NTRS2003

The NASA Astrobiology Institute: early history and organization

The NASA Astrobiology Institute (NAI) was established as a means to advance the field of astrobiology by providing a multidisciplinary, multi-institution, science-directed program, executed by universities, research institutes, and NASA and other government laboratories. The scientific community and NASA defined the science content at several workshops as summarized in the NASA Astrobiology Roadmap. Teams were chosen nationwide, following the recommendations of external review groups, and the research program began in 1998. There are now 16 national Teams and five international affiliated and associated astrobiology institutions. The NAI has attracted an outstanding group of scientific groups and individuals. The Institute facilitates the involvement of the scientists in its scientific and management vision. Its goal is to support basic research and allow the scientists the freedom to select their projects and alter them as indicated by new research. Additional missions include the education of the public, the involvement of students who will be the astrobiologists of future generations, and the development of a culture of collaboration in NAI, a "virtual institute," spread across many sites nationally and internationally.

United States National Aeronautics and Space Admin↗
NASA NTRS1997

Thermal-Structures and Materials Testing Laboratory

Since its inception and successful implementation in 1997 at James Madison University, the Thermal Structures and Materials Testing Laboratory (T-SaMTL) funded by the NASA Langley Research Center is evolving into one of the University's premier and exemplary efforts to increase minority representation in the sciences and mathematics. Serving ten (10) students and faculty directly and almost fifty (50) students indirectly, T-SAMTL, through its recruitment efforts, workshops, mentoring program, tutorial services and its research and computational laboratories has marked the completion of the first year with support from NASA totaling $ 100,000. Beginning as an innovative academic research and mentoring program for underrepresented minority science and mathematics students, the program now boasts a constituency which consists of 50% graduating seniors in the spring of 1998 with 50% planning to go to graduate school. The program's intent is to increase the number of underrepresented minorities who receive doctoral degrees in the sciences by initiating an academically enriched research program aimed at strengthening the academic and self actualization skills of undergraduate students with the potential to pursue doctoral study in the sciences. The program provides financial assistance, academic enrichment, and professional and personal development support for minority students who demonstrate the potential and strong desire to pursue careers in the sciences and mathematics. James Madison University was awarded the first $100,000, in April 1997, by The NASA Langley Research Center for establishment and support of its Thermal Structures and Materials Testing

Teate, Anthony A.↗
NASA NTRS2000

Partners in Freedom: Contributions of the Langley Research Center to U.S. Military Aircraft of the 1990's

Established in 1917 as the nation#s first civil aeronautics research laboratory under the National Advisory Commit-tee for Aeronautics (NACA), Langley was a small laboratory that solved the problems of flight for military and civil aviation. Throughout history, Langley has maintained a working partnership with the Department of Defense, U.S. industry, universities, and other government agencies to support the defense of the nation with research. During World War II, Langley directed virtually all of its workforce and facilities to research for military aircraft. Following the war, a balanced program of military and civil projects was undertaken. In some instances Langley research from one aircraft program helped solve a problem in another. At the conclusion of some programs, Langley obtained the research models for additional tests to learn more about previously unknown phenomena. The data also proved useful in later developmental programs. Many of the military aircraft in the U.S. inventory as of late 1999 were over 20 years old. Langley activities that contributed to the development of some of these aircraft began over 50 years prior. This publication documents the role, from early concept stages to problem solving for fleet aircraft, that Langley played in the military aircraft fleet of the United States for the 1990's.

Chambers, Joseph R.↗
NASA NTRS2002

Combustion Sensors: Gas Turbine Applications

This report documents efforts to survey the current research directions in sensor technology for gas turbine systems. The work is driven by the current and future requirements on system performance and optimization. Accurate real time measurements of velocities, pressure, temperatures, and species concentrations will be required for objectives such as combustion instability attenuation, pollutant reduction, engine health management, exhaust profile control via active control, etc. Changing combustor conditions - engine aging, flow path slagging, or rapid maneuvering - will require adaptive responses; the effectiveness of such will be only as good as the dynamic information available for processing. All of these issues point toward the importance of continued sensor development. For adequate control of the combustion process, sensor data must include information about the above mentioned quantities along with equivalence ratios and radical concentrations, and also include both temporal and spatial velocity resolution. Ultimately these devices must transfer from the laboratory to field installations, and thus must become low weight and cost, reliable and maintainable. A primary conclusion from this study is that the optics-based sensor science will be the primary diagnostic in future gas turbine technologies.

Human, Mel↗
NASA NTRS1986

Overview of the 1986 free-piston Stirling activities at NASA Lewis Research Center

An overview of the NASA Lewis Research Center's free-piston Stirling engine research is presented, including efforts to improve and advance its design for use in specific space power applications. These efforts are a part of the SP-100 program being conducted to support the Department of Defense (DOD), Department of Energy (DOE) and NASA. Such efforts include: (1) the testing and improvement of 25 kWe Stirling Space Power Demonstrator Engine (SPDE); (2) the preliminary design of 25 kWe single-cylinder Experimental stirling Space Engine (ESSE); and, (3) a study to determine the feasibility of scaling a single-cylinder free-piston Stirling engine/linear alternator to 150 kWe. Other NASA Lewis free-piston Stirling engine activities will be described, directed toward the advancement of general free-piston Stirling engine technology and its application in specific terrestrial applications. One such effort, supported by DOE/Oak Ridge National Laboratory (DRNL), is the development of a free-piston Stirling engine which produces hydraulic power. Finally, a terrestrial solar application involving a conceptual design of a 25 kWe Solar Advanced Stirling Conversion System (ASCS) capable of delivering power to an electric utility grid will be discussed. The latter work is supported by DOE/Sandia National Laboratory (SNLA).

Alger, Donald L.↗
NASA NTRS2003

Integration of NASA Research into Undergraduate Education in Math, Science, Engineering and Technology at North Carolina A&T State University

The NASA PAIR program incorporated the NASA-Sponsored research into the undergraduate environment at North Carolina Agricultural and Technical State University. This program is designed to significantly improve undergraduate education in the areas of mathematics, science, engineering, and technology (MSET) by directly benefiting from the experiences of NASA field centers, affiliated industrial partners and academic institutions. The three basic goals of the program were enhancing core courses in MSET curriculum, upgrading core-engineering laboratories to compliment upgraded MSET curriculum, and conduct research training for undergraduates in MSET disciplines through a sophomore shadow program and through Research Experience for Undergraduates (REU) programs. Since the inception of the program nine courses have been modified to include NASA related topics and research. These courses have impacted over 900 students in the first three years of the program. The Electrical Engineering circuit's lab is completely re-equipped to include Computer controlled and data acquisition equipment. The Physics lab is upgraded to implement better sensory data acquisition to enhance students understanding of course concepts. In addition a new instrumentation laboratory in the department of Mechanical Engineering is developed. Research training for A&T students was conducted through four different programs: Apprentice program, Developers program, Sophomore Shadow program and Independent Research program. These programs provided opportunities for an average of forty students per semester.

Monroe, Joseph↗
NASA NTRS2003

Packaging Technology Designed, Fabricated, and Assembled for High-Temperature SiC Microsystems

A series of ceramic substrates and thick-film metalization-based prototype microsystem packages designed for silicon carbide (SiC) high-temperature microsystems have been developed for operation in 500 C harsh environments. These prototype packages were designed, fabricated, and assembled at the NASA Glenn Research Center. Both the electrical interconnection system and the die-attach scheme for this packaging system have been tested extensively at high temperatures. Printed circuit boards used to interconnect these chip-level packages and passive components also are being fabricated and tested. NASA space and aeronautical missions need harsh-environment, especially high-temperature, operable microsystems for probing the inner solar planets and for in situ monitoring and control of next-generation aeronautical engines. Various SiC high-temperature-operable microelectromechanical system (MEMS) sensors, actuators, and electronics have been demonstrated at temperatures as high as 600 C, but most of these devices were demonstrated only in the laboratory environment partially because systematic packaging technology for supporting these devices at temperatures of 500 C and beyond was not available. Thus, the development of a systematic high-temperature packaging technology is essential for both in situ testing and the commercialization of high-temperature SiC MEMS. Researchers at Glenn developed new prototype packages for high-temperature microsystems using ceramic substrates (aluminum nitride and 96- and 90-wt% aluminum oxides) and gold (Au) thick-film metalization. Packaging components, which include a thick-film metalization-based wirebond interconnection system and a low-electrical-resistance SiC die-attachment scheme, have been tested at temperatures up to 500 C. The interconnection system composed of Au thick-film printed wire and 1-mil Au wire bond was tested in 500 C oxidizing air with and without 50-mA direct current for over 5000 hr. The Au thick-film metalization-based wirebond electrical interconnection system was also tested in an extremely dynamic thermal environment to assess thermal reliability. The I-V curve1 of a SiC high-temperature diode was measured in oxidizing air at 500 C for 1000 hr to electrically test the Au thick-film material-based die-attach assembly.

Chen, Liang-Yu↗
NASA NTRS2008

Simulation of the Impact of New Air-Based Ocean Surface Wind Measurements on H*Wind Analyses

The H'Wind analysis, a product of the Hurricane Research Division of NOAA's Atlantic Oceanographic and Meteorological Laboratory, brings together wind measurements from a variety of observation platforms into an objective analysis of the distribution of wind speeds in a tropical cyclone. This product is designed to improve understanding of the extent and strength of the wind field, and to improve the assessment of hurricane intensity. See http://www.aoml.noaa.gov/hrd/data sub/wind.html. The Hurricane Imaging Radiometer (HIRad) is a new airborne microwave remote sensor for hurricane observations that is currently under development by NASA Marshall Space Flight Center, NOAA Hurricane Research Division, the University of Central Florida and the University of Michigan. HIRad is being designed to enhance the real-time airborne ocean surface winds observation capabilities of NOAA and USAF Weather Squadron hurricane hunter aircraft using the operational airborne Stepped Frequency Microwave Radiometer (SFMR). Unlike SFMR, which measures wind speed and rain rate along the ground track directly beneath the aircraft, HIRad will provide images of the surface wind and rain field over a wide swath (approx. 3 x the aircraft altitude). The instrument is described in a paper presented to the Hurricanes and Tropical Meteorology Symposium. The present paper describes a set of Observing System Simulation Experiments (OSSEs) in which measurements from the new instrument as well as those from existing instruments (air, surface, and space-based) are simulated from the output of a numerical model from the University of Miami and those results are used to construct H*Wind analyses. Evaluations will be presented on the impact of the HIRad instrument on H'Wind analyses, both in terms of adding it to the full suite of current measurements, as well as using it to replace instrument(s) that may not be functioning at the future tame the HIRad instrument is implemented.

Miller, Timothy↗
NASA NTRS2008

Simulation of the Impact of New Ocean Surface Wind Measurements on H*Wind Analyses

The H*Wind analysis, a product of the Hurricane Research Division of NOAA's Atlantic Oceanographic and Meteorological Laboratory, brings together wind measurements from a variety of observation platforms into an objective analysis of the distribution of surface wind speeds in a tropical cyclone. This product is designed to improve understanding of the extent and strength of the wind field, and to improve the assessment of hurricane intensity. See http://www.aoml.noaa.gov/hrd/data sub/wind.html. The Hurricane Imaging Radiometer (HIRAD) is a new passive microwave remote sensor for hurricane observations that is currently under development by NASA Marshall Space Flight Center, NOAA Hurricane Research Division, the University of Central Florida and the University of Michigan. HIRAD is being designed to enhance the current real-time airborne ocean surface winds observation capabilities of NOAA and USAF Weather Squadron hurricane hunter aircraft using the operational airbome Stepped Frequency Microwave Radiometer (SFMR). Unlike SFMR, which measures wind speed and rain rate along the ground track directly beneath the aircraft, HIRAD will provide images of the surface wind and rain field over a wide swath (approximately 3 x the aircraft altitude, or approximately 2 km from space). The instrument is described in a separate paper presented at this conference. The present paper describes a set of Observing System Simulation Experiments (OSSEs) in which measurements from the new instrument as well as those from existing instruments (air, surface, and space-based) are simulated from the output of a numerical model from the University of Miami, and those results are used to construct H*Wind analyses. Evaluations will be presented on the relative impact of HIRAD and other instruments on H*Wind analyses, including the use of HIRAD from 2 aircraft altitudes and from a space-based platform.

Miller, Timothy↗
NASA NTRS1989

Global backscatter assessment

The focus of this effort is the development of a global-scale model of aerosol backscatter for laser atmospheric wind sounder (LAWS) design and performance studies. Background parameters are derived from aerosol data sets with global-scale spatial and/or temporal coverage, using objective statistical decomposition and/or a priori stratification based on supplementary data. Backscatter coefficients at the LAWS design wavelength are derived from background aerosol physical, chemical, and optical data, or from direct backscatter measurements at other wavelengths, using background conversion factors. Direct measurements of aerosol backscatter at 10.6 microns from the Royal Signals and Radar Establishment (RSRE) and the Wave Propagation Laboratory (WPL) were selected. The RSRE backscatter data processing code were optimized under low backscatter conditions, performed detailed analyses of collocated intercomparisons between the two lidars, and assisted in the analysis of the long-term backscatter climatologies from the two lidars. Timely presentation of global backscattering experiment (GLOBE) research results to the global geophysical community is required.

Bowdle, David A.↗
NASA NTRS2019

Small Stirling Technology Exploration Power for Future Space Science Missions

High efficiency dynamic Radioisotope Power Systems (RPS) could be mission enabling for low power space applications such as small probes, landers rovers, and communication repeaters. These applications would contain science instruments and be distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Small RPS could be used to provide power for sensing radiation, temperature, pressure, seismic activity, and other measurements of interest to planetary scientists. Small RPS would use fractional versions of the General Purpose Heat Source (GPHS) or Light Weight Radioisotope Heater Units (LWRHU), to heat power conversion technologies. Dynamic power systems are capable of three to four times higher conversion efficiency compared to static power conversion technologies, and would provide an equal amount of power using less fuel or more power using an equal amount of fuel. Providing spacecraft with more power could decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. NASA Glenn Research Center (GRC) is developing a low power dynamic RPS that would convert heat from multiple LWRHU to one watt of usable direct current electric power for spacecraft instrumentation and communication. The power system could be used to charge batteries or capacitors for higher power burst usage. The initial design, called Small Stirling Technology Exploration Power (smallSTEP), is around 3 kg, 11 cm diameter X 32 cm long, and converts 8 watts of heat to one watt of electricity using a Stirling convertor. This low power conversion system represents a new class of RPS with power levels two orders of magnitude lower than prototypes currently being developed for space applications under NASA contracts. Development of the 1-watt RPS includes maturation of convertor and controller designs, performance evaluation of an evacuated metal foil insulation, and development of system interfaces. Initial demonstration of the subsystems has been completed in a laboratory environment and a higher fidelity system is being pursued for demonstration in relevant environments for use on small spacecraft needed to carry out future space science missions.

Wilson, Scott↗
NASA NTRS1984

Research directions and progress in SERI advanced high efficiency concepts program

Novel solar cell designs and materials with the objective of achieving the maximum attainable photovoltaic conversion efficiencies are researched. Laboratory demonstrations of solar cells of greater than 30% efficiency under concentrated sunlight and thin film solar cells with one sun efficiencies of 17 to 20% are sought. These demonstrations are necessary intermediate steps towards the realization of very high efficiency, multi-bandgap, thin-film solar cells. Conversion efficiencies above 30% could be achieved by a cascade multijunction cell consisting of a high bandgap (1.7 eV) cell coupled optically and electrically on top of a lower bandgap (1.1 eV) cell. Recent improvements in peak currents of this interconnect are quite promising. However, this cell structure poses difficult problems for materials fabrication as a result of the combined requirements of choice of bandgaps, low defect density material, and high doping densities. Recent improvements in the quality of materials and newly proposed cell structures which may simplify fabrication are significant steps in the development of the multijunction concentrator solar cell.

Benner, J. P.↗
NASA NTRS1976

Earth-atmosphere system and surface reflectivities in arid regions from Landsat MSS data

Previously developed programs for computing atmospheric transmission and scattering of the solar radiation are used to compute the ratios of the earth-atmosphere system (space) directional reflectivities in the nadir direction to the surface Lambertian reflectivity, for the four bands of the Landsat multispectral scanner (MSS). These ratios are presented as graphs for two water vapor levels, as a function of the surface reflectivity, for various sun elevation angles. Space directional reflectivities in the vertical direction are reported for selected arid regions in Asia, Africa, and Central America from the spectral radiance levels measured by the Landsat MSS. From these space reflectivities, surface reflectivities are computed applying the pertinent graphs. These surface reflectivities are used to estimate the surface albedo for the entire solar spectrum. The estimated albedos are in the range 0.34-0.52, higher than the values reported by most previous researchers from space measurements, but are consistent with laboratory and in situ measurements.

Otterman, J.↗
NASA NTRS1992

Utilization of Space Station Freedom for technology research

Space Station Freedom presents a unique opportunity for technology developers to conduct research in the space environment. Research can be conducted in the pressurized volume of the Space Station's laboratories or attached to the Space Station truss in the vacuum of space. Technology developers, represented by the Office of Aeronautics and Space Technology (OAST), will have 12 percent of the available Space Station resources (volume, power, data, crew, etc.) to use for their research. Most technologies can benefit from research on Space Station Freedom and all these technologies are represented in the OAST proposed traffic model. This traffic model consists of experiments that have been proposed by technology developers but not necessarily selected for flight. Experiments to be flown in space will be selected through an Announcement of Opportunity (A.O.) process. The A.O. is expected to be released in August, 1992. Experiments will generally fall into one of the 3 following categories: (1) Individual technology experiments; (2) Instrumented Space Station; and (3) Guest investigator program. The individual technology experiments are those that do not instrument the Space Station nor directly relate to the development of technologies for evolution of Space Station or development of advanced space platforms. The Instrumented Space Station category is similar to the Orbiter Experiments Program and allows the technology developer to instrument subsystems on the Station or develop instrumentation packages that measure products or processes of the Space Station for the advancement of space platform technologies. The guest investigator program allows the user to request data from Space Station or other experiments for independent research. When developing an experiment, a developer should consider all the resources and infrastructure that Space Station Freedom can provide and take advantage of these to the maximum extent possible. Things like environment, accommodations, carriers, and integration should all be taken into account. In developing experiments at Langley Research Center, an iterative approach is proving useful. This approach uses Space Station utilization and subsystem experts to advise and critique experiment designs to take advantage of everything the Space Station has to offer. Also, solid object modeling and animation computer tools are used to fully visualize the experiment and its processes. This process is very useful for attached payloads and allows problems to be detected early in the experiment design phase.

Avery, Don E.↗
NASA NTRS1996

A Digital Control Algorithm for Magnetic Suspension Systems

An ongoing program exists to investigate and develop magnetic suspension technologies and modelling techniques at NASA Langley Research Center. Presently, there is a laboratory-scale large air-gap suspension system capable of five degree-of-freedom (DOF) control that is operational and a six DOF system that is under development. Those systems levitate a cylindrical element containing a permanent magnet core above a planar array of electromagnets, which are used for levitation and control purposes. In order to evaluate various control approaches with those systems, the Generic Real-Time State-Space Controller (GRTSSC) software package was developed. That control software package allows the user to implement multiple control methods and allows for varied input/output commands. The development of the control algorithm is presented. The desired functionality of the software is discussed, including the ability to inject noise on sensor inputs and/or actuator outputs. Various limitations, common issues, and trade-offs are discussed including data format precision; the drawbacks of using either Direct Memory Access (DMA), interrupts, or program control techniques for data acquisition; and platform dependent concerns related to the portability of the software, such as memory addressing formats. Efforts to minimize overall controller loop-rate and a comparison of achievable controller sample rates are discussed. The implementation of a modular code structure is presented. The format for the controller input data file and the noise information file is presented. Controller input vector information is available for post-processing by mathematical analysis software such as MATLAB1.

Britton, Thomas C.↗
NASA NTRS1992

Introduction to Space Station Freedom

NASA field centers and contractors are organized to develop 'work packages' for Space Station Freedom. Marshall Space Flight Center and Boeing are building the U.S. laboratory and habitation modules, nodes, and environmental control and life support system; Johnson Space Center and McDonnell Douglas are responsible for truss structure, data management, propulsion systems, thermal control, and communications and guidance; Lewis Research Center and Rocketdyne are developing the power system. The Canadian Space Agency (CSA) is contributing a Mobile Servicing Center, Special Dextrous Manipulator, and Mobile Servicing Center Maintenance Depot. The National Space Development Agency of Japan (NASDA) is contributing a Japanese Experiment Module (JEM), which includes a pressurized module, logistics module, and exposed experiment facility. The European Space Agency (ESA) is contributing the Columbus laboratory module. NASA ground facilities, now in various stages of development to support Space Station Freedom, include: Marshall Space Flight Center's Payload Operations Integration Center and Payload Training Complex (Alabama), Johnson Space Center's Space Station Control Center and Space Station Training Facility (Texas), Lewis Research Center's Power System Facility (Ohio), and Kennedy Space Center's Space Station Processing Facility (Florida). Budget appropriations impact the development of the Space Station. In Fiscal Year 1988, Congress appropriated only half of the funds that NASA requested for the space station program ($393 million vs. $767 million). In FY 89, NASA sought $967 million for the program, and Congress appropriated $900 million. NASA's FY 90 request was $2.05 billion compared to an appropriation of $1.75 billion; the FY 91 request was $2.45 billion, and the appropriation was $1.9 billion. After NASA restructured the Space Station Freedom program in response to directions from Congress, the agency's full budget request of $2.029 billion for Space Station Freedom in FY 92 was appropriated. For FY 93, NASA is seeking $2.25 billion for the program; the planned budget for FY 94 is $2.5 billion. Further alterations to the hardware configuration for Freedom would be a serious setback; NASA intends 'to stick with the current baseline' and continue planning for utilization.

Kohrs, Richard↗
NASA NTRS2000

Beyond Coordination: Joint Planning and Program Execution. The IHPRPT Materials Working Group

"Partnership is more than just coordination," stated then-Commander of the Air Force Research Laboratory (AFRL), Major General Dick Paul (USAF-Ret), at this year's National Space and Missile Materials Symposium. His comment referred to the example of the joint planning and program execution provided by the Integrated High Payoff Rocket Propulsion Technology (IHPRPT) Materials Working Group (IMWG). Most people agree that fiscal pressures imposed by shrinking budgets have made it extremely difficult to build upon our existing technical capabilities. In times of sufficient budgets, building advanced systems poses no major difficulties. However, with today's budgets, realizing enhanced capabilities and developing advanced systems often comes at an unaffordable cost. Overcoming this problem represents both a challenge and an opportunity to develop new business practices that allow us to develop advanced technologies within the restrictions imposed by current funding levels. Coordination of technology developments between different government agencies and organizations is a valuable tool for technology transfer. However, rarely do the newly developed technologies have direct applicability to other ongoing programs. Technology requirements are typically determined up-front during the program planning stage so that schedule risk can be minimized. The problem with this process is that the costs associated with the technology development are often borne by a single program. Additionally, the potential exists for duplication of technical effort. Changing this paradigm is a difficult process but one that can be extremely worthwhile should the right opportunity arise. The IMWG is one such example where NASA, the DoD, and industry have developed joint requirements that are intended to satisfy multiple program needs. More than mere coordination, the organizations comprising the group come together as partners, sharing information and resources, proceeding from a joint roadmap.

Stropki, Michael A.↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗