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Materials processing in space - An overview of studies in the U.S.A.

The paper reviews the evolution of the U.S. Materials Processing In Space Program, current materials processing in space program, and future programs. The discussion covers a summary of significant findings from previous flight experiments, a current assessment of the attractive areas for future experimentation, and a synopsis of the experiments accepted for future Space Processing Application Rocket (SPAR) and Spacelab flights. The ultimate goal is to develop a viable commercial interest in using space (1) to perform research for improving industrial technology or developing new products; (2) to prepare research quantities of material to serve as paradigms for comparing current earth-based technologies; (3) to manufacture limited quantities of a unique product to test market potential, or to fulfill a limited but compelling need; and (4) to produce materials in space of adequate quantity and value to be economically self-sufficient.

Naumann, R. J.↗

TRUSS: An intelligent design system for aircraft wings

Competitive leadership in the international marketplace, superiority in national defense, excellence in productivity, and safety of both private and public systems are all national defense goals which are dependent on superior engineering design. In recent years, it has become more evident that early design decisions are critical, and when only based on performance often result in products which are too expensive, hard to manufacture, or unsupportable. Better use of computer-aided design tools and information-based technologies is required to produce better quality United States products. A program is outlined here to explore the use of knowledge based expert systems coupled with numerical optimization, database management techniques, and designer interface methods in a networked design environment to improve and assess design changes due to changing emphasis or requirements. The initial structural design of a tiltrotor aircraft wing is used as a representative example to demonstrate the approach being followed.

Bates, Preston R.↗

Unattended network operations technology assessment study. Technical support for defining advanced satellite systems concepts

The results are summarized of an unattended network operations technology assessment study for the Space Exploration Initiative (SEI). The scope of the work included: (1) identified possible enhancements due to the proposed Mars communications network; (2) identified network operations on Mars; (3) performed a technology assessment of possible supporting technologies based on current and future approaches to network operations; and (4) developed a plan for the testing and development of these technologies. The most important results obtained are as follows: (1) addition of a third Mars Relay Satellite (MRS) and MRS cross link capabilities will enhance the network's fault tolerance capabilities through improved connectivity; (2) network functions can be divided into the six basic ISO network functional groups; (3) distributed artificial intelligence technologies will augment more traditional network management technologies to form the technological infrastructure of a virtually unattended network; and (4) a great effort is required to bring the current network technology levels for manned space communications up to the level needed for an automated fault tolerance Mars communications network.

Price, Kent M.↗

Configurable technology development for reusable control and monitor ground systems

The control monitor unit (CMU) uses configurable software technology for real-time mission command and control, telemetry processing, simulation, data acquisition, data archiving, and ground operations automation. The base technology is currently planned for the following control and monitor systems: portable Space Station checkout systems; ecological life support systems; Space Station logistics carrier system; and the ground system of the Delta Clipper (SX-2) in the Single-Stage Rocket Technology program. The CMU makes extensive use of commercial technology to increase capability and reduce development and life-cycle costs. The concepts and technology are being developed by McDonnell Douglas Space and Defense Systems for the Real-Time Systems Laboratory at NASA's Kennedy Space Center under the Payload Ground Operations Contract. A second function of the Real-Time Systems Laboratory is development and utilization of advanced software development practices.

Uhrlaub, David R.↗

The Teaching of Anthropogenic Climate Change and Earth Science via Technology-Enabled Inquiry Education

A gap has existed between the tools and processes of scientists working on anthropogenic global climate change (AGCC) and the technologies and curricula available to educators teaching the subject through student inquiry. Designing realistic scientific inquiry into AGCC poses a challenge because research on it relies on complex computer models, globally distributed data sets, and complex laboratory and data collection procedures. Here we examine efforts by the scientific community and educational researchers to design new curricula and technology that close this gap and impart robust AGCC and Earth Science understanding. We find technology-based teaching shows promise in promoting robust AGCC understandings if associated curricula address mitigating factors such as time constraints in incorporating technology and the need to support teachers implementing AGCC and Earth Science inquiry. We recommend the scientific community continue to collaborate with educational researchers to focus on developing those inquiry technologies and curricula that use realistic scientific processes from AGCC research and/or the methods for determining how human society should respond to global change.

technology↗

Fluid Flow Nozzle Energy Harvesters

Power generation schemes that could be used downhole in an oil well to produce about 1 Watt average power with long-life (decades) are actively being developed. A variety of proposed energy harvesting schemes could be used to extract energy from this environment but each of these has their own limitations that limit their practical use. Since vibrating piezoelectric structures are solid state and can be driven below their fatigue limit, harvesters based on these structures are capable of operating for very long lifetimes (decades); thereby, possibly overcoming a principle limitation of existing technology based on rotating turbo-machinery. An initial survey identified that spline nozzle configurations can be used to excite a vibrating piezoelectric structure in such a way as to convert the abundant flow energy into useful amounts of electrical power. This paper presents current flow energy harvesting designs and experimental results of specific spline nozzle/ bimorph design configurations which have generated suitable power per nozzle at or above well production analogous flow rates. Theoretical models for non-dimensional analysis and constitutive electromechanical model are also presented in this paper to optimize the flow harvesting system.

bimorph↗

Solar Energy Technical Publications Catalog: Solar Thermal Technology

The research and development described in these documents was conducted within the U.S . Department of Energy's (DOE) Solar Thermal Technology Program. The goal of this program is to advance the engineering and scientific understanding of solar thermal technology and to establish the technology base from which private industry can develop solar thermal power production options for introduction into the competitive energy market. Solar thermal technology concentrates the solar flux using tracking mirrors or lenses onto a receiver where the solar energy is absorbed as heat and converted into electricity or incorporated into products as process heat. The two primary solar thermal technologies, central receivers and distributed receivers, employ various point and line-focus optics to concentrate sunlight. Current central receiver systems use fields of heliostats (two-axis tracking mirrors) to focus the sun's radiant energy onto a single, tower- mounted receiver. Point focus concentrators up to 17 meters in diameter track the sun in two axes and use parabolic dish mirrors or Fresnel lenses to focus radiant energy onto a receiver. Troughs and bowls are line-focus tracking reflectors that concentrate sunlight onto receiver tubes along their focal lines. Concentrating collector modules can be used alone or in a multimodule system. The concentrated radiant energy absorbed by the solar thermal receiver is transported to the conversion process by a circulating work fluid. Receiver temperatures range from l00 degrees C in low-temperature troughs to over 1500 degrees C in dish and central receiver systems. The Solar Thermal Technology Program is directing efforts to advance and improve each system concept through solar thermal materials, components, and subsystems research and development and by testing and evaluation. These efforts are carried out with the technical direction of DOE and its network of field laboratories that works with private industry. Together they have established a comprehensive, goal-directed program to improve performance and provide technically proven options for eventual incorporation into the nation's energy supply. To successfully contribute to an adequate energy supply at reasonable cost, solar thermal energy must be economically competitive with a variety of other energy sources. The Solar Thermal Technology Program has developed components and system-level performance targets as quantitative program goals. These targets are used in planning research and development activities, measuring progress, assessing alternative technology options, and developing optimal components. These targets are pursued vigorously to ensure a successful program. This catalog represents part of an effort to provide information on publications about solar thermal research and development activities conducted by DOE's laboratories. Publications listed include technical and research reports and special publications. The following national laboratories are represented in this edition: Sandia National Laboratories, Solar Energy Research Institute, Jet Propulsion Laboratory. This catalog is a product of the DOE Solar Technical Information Program, which is dedicated to providing information to scientific and industrial users in ways most convenient and useful to them. This catalog focuses on solar thermal technologies, and its purpose is to keep the scientific and industrial communities informed of the latest developments in federally sponsored research in this technology.

140000* -- Solar Energy↗

Multijunction Solar Cell Development and Production at Spectrolab

Development of multijunction space solar cells is much like that for any high technology product. New products face two major pressures from the market: improving performance while maintaining heritage. This duality of purpose is not new and has been represented since ancient times by the Roman god Janus.[1] This deity was typically represented as two faces on a single head: one facing forward and the other to the rear. The image of Janus has been used as symbolism for many combined forces of dual purpose, such as the balance in life between beginnings and endings, or between art and science. For our purposes, Janus represents our design philosophy balance between looking to the future for improvement while simultaneously blending past heritage. In the space photovoltaics industry there are good reasons for both purposes. Looking to the past, a product must have a space flight heritage to gain widespread use. The main reason being that this is an unforgiving business. Spacecraft are expensive to build, launch and operate. Typically once a satellite is launched, in-field service for a power systems problem is near impossible.[2Balanced with this is looking forward. New missions typically require more power than previous programs or attempt new objectives such as a new orbit. And there is always the cost pressure for both the satellite itself as well as the launch costs. Both of which push solar technology to improve power density at a lower cost. The consequence of this balance in a high-risk environment is that space PV develops as a series of infrequent large technology steps or generational changes interspersed with more frequent small technology steps or evolutionary changes. Figure 1 gives a bit of clarification on this point. It depicts the historical progress in space solar cells tracked by efficiency against first launch date for most major products introduced by Spectrolab. The first generation is the Si-based technology reaching a peak values near 15% AM0 (herein denoted for max. power, AM0, 1.353 W/cm2, 28 C). The GaAs single junction device generation supplanted this technology with first flight of GaAs on GaAs substrate in 1982.[3] More recently this generation has been supplanted by the multijunction solar cell GaInP/GaAs/Ge generation. The first launch of a commercial satellite powered by multijunction technology was in 1997 (Hughes HS 601HP) using solar arrays based on Spectrolab s dual junction (DJ) cells. The cells at that time were an impressive 21.5% efficient at beginning-of-life (BOL).[4] Eight years later, the multijunction device has evolved through several versions. The incorporation of an active Ge subcell formed the Triple Junction (TJ) product line at 25.1% efficient, on orbit since November 2001. The evolution of the TJ into the Improved Triple Junction (ITJ) at 26.8% efficient has been on orbit since June of 2002.[5]

Fetzer, Chris↗

Series Bosch System Development

State-of-the-art (SOA) carbon dioxide (CO2) reduction technology for the International Space Station produces methane as a byproduct. This methane is subsequently vented overboard. The associated loss of hydrogen ultimately reduces the mass of oxygen that can be recovered from CO2 in a closed-loop life support system. As an alternative to SOA CO2 reduction technology, NASA is exploring a Series-Bosch system capable of reducing CO2 with hydrogen to form water and solid carbon. This results in 100% theoretical recovery of oxygen from metabolic CO2. In the past, Bosch-based technology did not trade favorably against SOA technology due to a high power demand, low reaction efficiencies, concerns with carbon containment, and large resupply requirements necessary to replace expended catalyst cartridges. An alternative approach to Bosch technology, labeled "Series-Bosch," employs a new system design with optimized multi-stage reactors and a membrane-based separation and recycle capability. Multi-physics modeling of the first stage reactor, along with chemical process modeling of the integrated system, has resulted in a design with potential to trade significantly better than previous Bosch technology. The modeling process and resulting system architecture selection are discussed.

Abney, Morgan B.↗

A historical overview of tiltrotor aeroelastic research at Langley Research Center

The Bell/Boeing V-22 Osprey which is being developed for the U.S. Military is a tiltrotor aircraft combining the versatility of a helicopter with the range and speed of a turboprop airplane. The V-22 represents a tiltrotor lineage which goes back over forty years, during which time contributions to the technology base needed for its development were made by both government and industry. NASA Langley Research Center has made substantial contributions to tiltrotor technology in several areas, in particular in the area of aeroelasticity. The purpose of this talk is to present a summary of the tiltrotor aeroelastic research conducted at Langley which has contributed to that technology.

Kvaternik, Raymond G.↗

Monolithically Integrated SiGe/Si PIN-HBT Front-End Transimpedance Photoreceivers

The demand for monolithically integrated photoreceivers based on Si-based technology keeps increasing as low cost and high reliability products are required for the expanding commercial market. Higher speed and wider operating frequency range are expected when SiGe/Si heterojunction is introduced to the circuit design. In this paper, a monolithic SiGe/Si PIN-HBT front-end transimpedance photoreceiver is demonstrated for the first time. For this purpose, mesa-type SiGe/Si PIN-HBT technology was developed. Fabricated HBTs exhibit f(sub max) of 34 GHz with DC gain of 25. SiGe/Si PIN photodiodes, which share base and collector layers of HBTs, demonstrate responsivity of 0.3 A/W at lambda=850 nm and bandwidth of 450 MHz. Based on these devices, single- and dual-feedback transimpedance amplifiers were fabricated and they exhibited the bandwidth of 3.2 GHz and 3.3 GHz with the transimpedance gain of 45.2 dB(Omega) and 47.4 dB(Omega) respectively. Monolithically integrated single-feedback PIN-HBT photoreceivers were implemented and the bandwidth was measured to be approx. 0.5 GHz, which is limited by the bandwidth of PIN photodiodes.

Rieh, J.-S.↗

Packages of Distributed Energy Technologies Demonstrating Demand Flexibility at Community Scale

The combination of increased electric load growth across all sectors, deferred electrical infrastructure investment, and other factors resulting in variable electric power supply, has created technical challenges to maintaining a resilient and reliable grid. Many federal, regional, and local efforts are in play to modernize the electric grid, including advancing building technologies and distributed energy resources (DERs) that are utilizing smarter controls to become responsive to both occupant and grid needs. This report reviews ten pilot projects demonstrating how groups of buildings combined with behind-the-meter (BTM) DERs such as electric vehicle (EV) charging, battery storage, flexible HVAC and domestic hot water systems, and photovoltaic systems can reliably and cost effectively provide grid services. Each of the ten pilot projects aim to deliver both energy efficiency and demand flexibility (DF) while supporting load growth. The ten demonstration teams are piloting flexible DER packages across diverse communities of residential and commercial buildings to address a variety of regional grid needs. The outcomes of these pilot projects will be used to inform future scaling through utility program development. This paper characterizes the ten teams, showcasing the decision-making process used by each group to develop their packages (Section 2), the grid services they plan to deliver (Section 3), the types of DER packages selected for deployment within building sectors (Section 4) and trends between building sector, DER types, and grid services In order to achieve community scale benefits, the pilot projects must utilize aggregated control mechanisms for coordinating buildings and DERs together. Several types of coordinated control architectures have evolved amongst the teams, influenced by use type, existing market conditions, and integration type. Three coordinated controls architectures have been characterized, highlighting their use cases, benefits, challenges, and tradeoffs in their design. These insights can aid utilities, control vendors, and developers in scaling community-level energy systems (Paul, 2024). Ultimately, the technology packages selected by the ten teams will be coordinated to provide power system services, also known as grid services. Insights from these demonstrations will be useful for grid operators, regulators, aggregators and other stakeholders as they look to deploy demand flexible resources as grid services in the future. The grid services that each team is targeting for demonstration are described in Section 3 and Section 4. Methods for evaluating the grid services have been described in the paper Metrics for Evaluating Grid Service Provision from Communities of Grid-interactive and Efficient Buildings and other DER (MacDonald, 2023). To identify technology packages for demonstration, Section 2 shows that project teams used a range of analysis approaches, including building energy modeling, AMI data analysis, cost-benefit frameworks, and utility pilot data. Some teams emphasized technical modeling to quantify grid impacts and demand reduction potential, while others prioritized economic evaluations, stakeholder input, or exploratory pilots to inform deployment decisions. This diversity reflects the need to tailor selection methods to project goals, available data, and organizational context. Section 5 discusses trends between the DER technologies deployed and the grid service provisions from each team. Residential buildings (multifamily and single family) lean towards technologies that enhance energy efficiency (e.g. weatherization upgrades, smart thermostats) and onsite power generation integration (e.g. solar PV). Commercial building demonstrations prioritize technologies that ensure operational reliability (e.g. battery storage) and centralized energy management systems and optimization solutions. Teams that are deploying controllable storage-based technologies are more likely to provide grid services that require a near real-time response. Teams incorporating load shifting technologies like smart thermostats with HEMs are likely to include energy markets participation and customer bill management offerings. Campus demonstrations are adopting diverse sets of DERs to emphasize renewable generation, paired with centralized control. This section also describes technologies that were considered during project planning but ultimately excluded from final deployment. These demonstrations reveal that effective DER package design should be tailored to building type, customer segment, and construction vintage. Multifamily buildings benefit from centralized HVAC upgrades and supervisory controls, while single-family homes are well-suited for individualized technologies like solar, storage, and smart home energy monitors. Commercial and campus settings prioritize EMIS integration and load optimization. New construction enables cost-effective integration of DER-ready infrastructure, whereas retrofits require deployments aligned with owner and tenant value streams. For utility program planners, early coordination with developers and building owners, paired with segmented and modular program offerings, can improve adoption, scalability, and grid impact.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Design and Fabrication of the ISTAR Direct-Connect Combustor Experiment at the NASA Hypersonic Tunnel Facility

The Integrated Systems Test of an Airbreathing Rocket (ISTAR) project was a flight demonstration project initiated to advance the state of the art in Rocket Based Combined Cycle (RBCC) propulsion development. The primary objective of the ISTAR project was to develop a reusable air breathing vehicle and enabling technologies. This concept incorporated a RBCC propulsion system to enable the vehicle to be air dropped at Mach 0.7 and accelerated up to Mach 7 flight culminating in a demonstration of hydrocarbon scramjet operation. A series of component experiments was planned to reduce the level of risk and to advance the technology base. This paper summarizes the status of a full scale direct connect combustor experiment with heated endothermic hydrocarbon fuels. This is the first use of the NASA GRC Hypersonic Tunnel facility to support a direct-connect test. The technical and mechanical challenges involved with adapting this facility, previously used only in the free-jet configuration, for use in direct connect mode will be also described.

Lee, Jin-Ho↗

Lunar RFC Reliability Testing for Assured Mission Success

NASA's Constellation program has selected the closed cycle hydrogen oxygen Polymer Electrolyte Membrane (PEM) regenerative Fuel Cell (RFC) as its baseline solar energy storage system for the lunar outpost and manned rover vehicles. Since the outpost and manned rovers are "human-rated", these energy storage systems will have to be of proven reliability exceeding 99 percent over the length of the mission. Because of the low (TRL=5) development state of the closed cycle hydrogen oxygen PEM RFC at present, and because there is no equivalent technology base in the commercial sector from which to draw or infer reliability information from, NASA will have to spend significant resources developing this technology from TRL 5 to TRL 9, and will have to embark upon an ambitious reliability development program to make this technology ready for a manned mission. Because NASA would be the first user of this new technology, NASA will likely have to bear all the costs associated with its development. When well-known reliability estimation techniques are applied to the hydrogen oxygen RFC to determine the amount of testing that will be required to assure RFC unit reliability over life of the mission, the analysis indicates the reliability testing phase by itself will take at least 2 yr, and could take up to 6 yr depending on the number of QA units that are built and tested and the individual unit reliability that is desired. The cost and schedule impacts of reliability development need to be considered in NASA's Exploration Technology Development Program (ETDP) plans, since life cycle testing to build meaningful reliability data is the only way to assure "return to the moon, this time to stay, then on to Mars" mission success.

Bents, David J.↗

Lunar Regenerative Fuel Cell (RFC) Reliability Testing for Assured Mission Success

NASA's Constellation program has selected the closed cycle hydrogen oxygen Polymer Electrolyte Membrane (PEM) Regenerative Fuel Cell (RFC) as its baseline solar energy storage system for the lunar outpost and manned rover vehicles. Since the outpost and manned rovers are "human-rated," these energy storage systems will have to be of proven reliability exceeding 99 percent over the length of the mission. Because of the low (TRL=5) development state of the closed cycle hydrogen oxygen PEM RFC at present, and because there is no equivalent technology base in the commercial sector from which to draw or infer reliability information from, NASA will have to spend significant resources developing this technology from TRL 5 to TRL 9, and will have to embark upon an ambitious reliability development program to make this technology ready for a manned mission. Because NASA would be the first user of this new technology, NASA will likely have to bear all the costs associated with its development.When well-known reliability estimation techniques are applied to the hydrogen oxygen RFC to determine the amount of testing that will be required to assure RFC unit reliability over life of the mission, the analysis indicates the reliability testing phase by itself will take at least 2 yr, and could take up to 6 yr depending on the number of QA units that are built and tested and the individual unit reliability that is desired. The cost and schedule impacts of reliability development need to be considered in NASA's Exploration Technology Development Program (ETDP) plans, since life cycle testing to build meaningful reliability data is the only way to assure "return to the moon, this time to stay, then on to Mars" mission success.

Bents, David J.↗

Application of Multihop Relay for Performance Enhancement of AeroMACS Networks

A new transmission technology, based on IEEE 802.16-2009 (WiMAX), is currently being developed for airport surface communications. A C-band spectrum allocation at 5091-5150 MHz has been created by ITU to carry this application. The proposed technology, known as AeroMACS, will be used to support fixed and mobile ground to ground applications and services. This article proposes and demonstrates that IEEE 802.16j-amendment-based WiMAX is most feasible for AeroMACS applications. This amendment introduces multihop relay as an optional deployment that may be used to provide additional coverage and/or enhance the capacity of the network. Particular airport surface radio coverage situations for which IEEE 802.16-2009-WiMAX provides resolutions that are inefficient, costly, or excessively power consuming are discussed. In all these cases, it is argued that 16j technology offers a much better alternative. A major concern about deployment of AeroMACS is interference to co-allocated applications such as the Mobile Satellite Service (MSS) feeder link. Our initial simulation results suggest that no additional interference to MSS feeder link is caused by deployment of IEEE 802.16j-based AeroMACS.

Kamali, Behnam↗

Novel High Resolution High Temperature In-Line Sensors for Steel Manufacturing

To support efficiency, productivity, yield improvements, and future industry 4.0 and SMART manufacturing objectives for a competitive and prosperous steel industry, this program has embarked on an effort to develop, demonstrate and deploy several novel sensing technologies based on fiber optics for use in production steel facilities. Over the duration of this program, our team has successfully demonstrated three of these technologies: (1) near continuous Rayliegh Scattering optical frequency domain reflectometry (OFDR) sensing with single mode silica fibers for temperature sensing to 700 C, (2) semi-distributed fiber Bragg grating (FBG) sensing with multimode sapphire fibers for temperature sensing to >1600 C, and (3) remote in-situ Raman analysis for slag and flux chemistry analysis at steelmaking temperatures >1550 C. Each of these sensor and interrogation systems was developed, refined, and tested in our labs at Missouri S&T and then successfully deployed at SSAB’s production facilities at two sites, one in Montpelier, IA and one in Mobile, AL.

36 MATERIALS SCIENCE↗

Rendezvous, proximity operations and capture quality function deployment report

Rendezvous, Proximity Operations, and Capture (RPOC) is a missions operations area which is extremely important to present and future space initiatives and must be well planned and coordinated. To support this, a study team was formed to identify a specific plan of action using the Quality Function Deployment (QFD) process. This team was composed of members from a wide spectrum of engineering and operations organizations which are involved in the RPOC technology area. The key to this study's success is an understanding of the needs of potential programmatic customers and the technology base available for system implementation. To this end, the study team conducted interviews with a variety of near term and future programmatic customers and technology development sponsors. The QFD activity led to a thorough understanding of the needs of these customers in the RPOC area, as well as the relative importance of these needs.

Lamkin, Stephen L.↗