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Advanced Ceramic Matrix Composites: Science and Technology of Materials, Design, Applications, Performance and Integration

Overview of NASA Transformational Tools and Technologies Project's 2700F CMC/EBC Technology Challenge J. Hurst, NASA (National Aeronautics and Space Administration, Glenn Research Center, Cleveland, OH USA Key Words: ceramic matrix composites (CMCs), SiC/SiC composites, environmental barrier coatings (EBCs), CMC modeling, simulated engine testing As advanced gas turbine engine designs continue to move toward both higher operating temperatures and increased pressures, materials capable of functioning under these extreme conditions are being sought by both government and industry. As part of its mission, the NASA's Transformational Tools and Technologies Project, under the auspices of NASA's Aeronautics Research Mission Directorate, has been pursuing a five year Technology Challenge problem. This challenge problem has sought to develop high temperature materials for turbine engines that enable a 6% reduction in fuel burn for commercial aircraft, compared to current SOA materials. Specifically this is accomplished by the development and demonstration of a ceramic matrix composite (CMC) and environmental barrier coating (EBC) system capable of sustained performance at temperature of 2700F. The NASA Glenn Research Center has continued its two decade long interest in CMC/EBCs technology by pursuing this 2700F performance goal. This ambitious effort included an array of vendors, universities and engine companies. Included in this challenge was fiber development, fiber architecture considerations, ceramic matrix composition, environmental barrier compositions and processing routes as well as test development. Evaluation of the CMC/EBC materials included a variety of testing, from coupon testing for strength and creep resistance, to testing aimed at determining material behavior under more engine-like conditions. The development and validation of thermomechanical models and computational tools for design, analysis, and life prediction, have been an important part of this effort as well. Simulated engine testing of vane subcomponents by P&W was the final step following years of development. In addition to achieving the temperature goals and enhanced durability performance of the Tech Challenge, an additional goal achieved by this work was reaching a Technology Readiness Level of 5 for the 3-D CMC/EBC system. As this five year Technical Challenge comes to a conclusion, future development interests in environmental barrier coatings and environmental modeling are discussed.

SiC/SiC composites↗

Advanced tow placement of composite fuselage structure

The Hercules NASA ACT program was established to demonstrate and validate the low cost potential of the automated tow placement process for fabrication of aircraft primary structures. The program is currently being conducted as a cooperative program in collaboration with the Boeing ATCAS Program. The Hercules advanced tow placement process has been in development since 1982 and was developed specifically for composite aircraft structures. The second generation machine, now in operation at Hercules, is a production-ready machine that uses a low cost prepreg tow material form to produce structures with laminate properties equivalent to prepreg tape layup. Current program activities are focused on demonstration of the automated tow placement process for fabrication of subsonic transport aircraft fuselage crown quadrants. We are working with Boeing Commercial Aircraft and Douglas Aircraft during this phase of the program. The Douglas demonstration panels has co-cured skin/stringers, and the Boeing demonstration panel is an intricately bonded part with co-cured skin/stringers and co-bonded frames. Other aircraft structures that were evaluated for the automated tow placement process include engine nacelle components, fuselage pressure bulkheads, and fuselage tail cones. Because of the cylindrical shape of these structures, multiple parts can be fabricated on one two placement tool, thus reducing the cost per pound of the finished part.

Anderson, Robert L.↗

Progress on LISA Colloid Microthruster Technology Development

Colloid microthrusters have been operated successfully in flight, providing drag-free and precision control for spacecraft that can be used for future applications such as gravity wave and exoplanet observatories. The Space Technology 7 Disturbance Reduction System (ST7- DRS) technology demonstration payload included eight Busek Colloid Micro-Newton Thrusters (CMNTs) as part of the Laser Interferometer Space Antenna (LISA) Pathfinder mission that launched in December of 2015. The CMNTs provided full attitude and precision drag-free control of the spacecraft with <10 nm/√Hz stability along the most sensitive axis during commissioning, nominal, and extended mission phases through April of 2017. Performance requirements (≤0.1 μN/√Hz) were met and models were validated based on on- orbit measurements of test mass motion and actuation during the 60-day nominal and 30-day extended missions. In 2018, the European Space Agency (ESA) selected LISA to be the agency’s next “large-class” mission, currently in Phase A, with a launch scheduled for 2034 and a 12.5-year duration, including the transfer (1.5 years), commissioning (1 year), nominal (4 or 6 years), and extended (6 or 4 years) phases of the mission, which sets the lifetime and consumables requirement. NASA is considering a significant contribution of hardware to the ESA-led mission, potentially including colloid microthrusters. In preparation, NASA is developing five technologies to TRL 5 and 6, including the colloid microthrusters, to be ready for infusion into LISA by the mission adoption review (MAR), currently scheduled for 2024. While ST7-DRS effectively brought the CMNTs to TRL 7, additional lower-TRL flow control components must be developed for full redundancy, reducing the system-level TRL back to 4. Key to the future of the colloid microthruster technology will be to use lessons learned and keep as much of the heritage from the ST7 design as possible while updating the system to support redundancy and lifetime requirements of a flagship-class mission. This paper describes the technology plan and progress to reach TRL 6 by the MAR, focusing on near- term plans to reach TRL 5 by the end of March 2022 for the LISA Colloid Microthrusters (CMTs). Work includes requirements development and sizing studies, breadboard and brassboard hardware developments at Busek, including relevant lifetime and environment testing, and lifetime modeling, verification and validation efforts at JPL, UCLA, and UCI.

Gamero-Castaño, Manuel↗

SeaWiFS technical report series. Volume 15: The simulated SesWiFS data set, version 2

This document describes the second version of the simulated SeaWiFS data set. A realistic simulated data set is essential for mission readiness preparations and can potentially assist in all phases of ground support for a future mission. The second version improves on the first version primarily through additional realism and complexity. This version incorporates a representation of virtually every aspect of the flight mission. Thus, it provides a high-fidelity data set for testing several aspects of the ground system, including data acquisition, data processing, data transfers, calibration and validation, quality control, and mission operations. The data set is constructed for a seven-day period, 25-31 March 1994. Specific features of the data set include Global Area coverage (GAC), recorded Local Area Coverage (LAC), and realtime High Resolution Picture Transmission (HRPT) data for the seven-day period. A realistic orbit, which is propagated using a Brouwer-Lyddane model with drag, is used to simulate orbit positions. The simulated data corresponds to the command schedule based on the orbit for this seven-day period. It includes total (at-satellite) radiances not only for ocean, but for land, clouds, and ice. The simulation also utilizes a high-resolution land-sea mask. It includes the April 1993 SeaWiFS spectral responses and sensor saturation responses. The simulation is formatted according to July 1993 onboard data structures, which include corresponding telemetry (instrument and spacecraft) data. The methods are described and some examples of the output are given. The instrument response functions made available in April 1993 have been used to produce the Version 2 simulated data. These response functions will change as part of the sensor improvements initiated in July-August 1993.

Hooker, Stanford B.↗

NEXT Single String Integration Test Results

As a critical part of NASA's Evolutionary Xenon Thruster (NEXT) test validation process, a single string integration test was performed on the NEXT ion propulsion system. The objectives of this test were to verify that an integrated system of major NEXT ion propulsion system elements meets project requirements, to demonstrate that the integrated system is functional across the entire power processor and xenon propellant management system input ranges, and to demonstrate to potential users that the NEXT propulsion system is ready for transition to flight. Propulsion system elements included in this system integration test were an engineering model ion thruster, an engineering model propellant management system, an engineering model power processor unit, and a digital control interface unit simulator that acted as a test console. Project requirements that were verified during this system integration test included individual element requirements ; integrated system requirements, and fault handling. This paper will present the results of these tests, which include: integrated ion propulsion system demonstrations of performance, functionality and fault handling; a thruster re-performance acceptance test to establish baseline performance: a risk-reduction PMS-thruster integration test: and propellant management system calibration checks.

Soulas, George C.↗

Stirling Power Conversion for Lunar Applications

NASA is developing Stirling power convertors for use in nuclear power systems that would provide electricity to users on the lunar surface. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced dynamic convertor technologies that would increase the efficiency beyond the heritage systems for missions to the Moon and other solar system bodies of interest. Development efforts have focus on Stirling and Brayton designs that meet reliability and robustness requirements for operation in the lunar environment. GRC is also maturing low power convertors in the range of 1-40 watts to power micro-spacecraft or a network of distributed probes and include basic demonstration of in-house designs for convertors and controllers. In addition to RPS applications, conceptual fission systems have been demonstrated using Stirling convertors in multiple electrically heated tests and one test heated by a nuclear reactor. The Stirling convertors used in these fission system concepts include 100 We convertors to enable a 1 kWe system, 1 kWe convertors to enable a 10 kWe system, and 6 kWe convertors to enable a 40 kWe system. The maturation of Stirling power convertors for nuclear applications includes verification of performance in relevant environments and validation of the design with a focus on high reliability and robustness. Over 1 million hours of testing has been accumulated on dozens of convertors since 1999 in the Stirling Research Laboratory at the NASA Glenn Research Center located in Cleveland Ohio, where the longest running convertor is the work record holder at 137,000 hours, or 15.5 years. These maturation efforts have been instrumental in increasing the technology readiness level of Stirling technologies for space applications.

S. Wilson↗

NSTAR Ion Thruster and Breadboard Power Processor Functional Integration Test Results

A 2.3 kW Breadboard Power Processing Unit (BBPPU) was developed as part of the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) Program. The NSTAR program will deliver an electric propulsion system based on a 30 cm xenon ion thruster to the New Millennium (NM) program for use as the primary propulsion system for the initial NM flight. The final development test for the BBPPU, the Functional Integration Test, was carried out to demonstrate all aspects of BBPPU operation with an Engineering Model Thruster. Test objectives included: (1) demonstration and validation of automated thruster start procedures, (2) demonstration of stable closed loop control of the thruster beam current, (3) successful response and recovery to thruster faults, and (4) successful safing of the system during simulated spacecraft faults. These objectives were met over the specified 80-120 VDC input voltage range and 0.5-2.3 output power capability of the BBPPU. Two minor anomalies were noted in discharge and neutralizer keeper current. These anomalies did not affect the stability of the system and were successfully corrected.

Hamley, John A.↗

NASA Space Launch System Prepares for Key Hotfire Test Before Vehicle Integration

NASA this year is working toward the final major integrated hardware and avionics test for its Space Launch System (SLS), the agency’s new super heavy-lift vehicle to send large, strategic payloads to the Moon, Mars and beyond. As the backbone of the Artemis human lunar exploration program, Artemis I SLS operations will then shift to the launch site and integration for the inaugural mission. For this final major test of the first vehicle NASA has built exclusively for deep space exploration since the Saturn V, a NASA/Boeing/Aerojet Rocketdyne team will conduct the final core stage “green run” test at NASA's Stennis Space Center with a dramatic firing of all four core stage engines. This test will validate the operation of the stage structures, main propulsion system, engines, avionics, and software. Following data review, stage inspection, and refurbishment, the stage will be barged to NASA’s Kennedy Space Center to continue integration of the Artemis I launch vehicle. Already underway is assembly of the mission’s five-segment solid rocket boosters. The mission’s upper stage and spacecraft adapters also are staged at the launch site ready for integration. Even as the Artemis I SLS proceeds toward launch later this year, the Artemis II and Artemis III vehicles are coming together, with core stages, engines, boosters, upper stage, and payload accommodations in various stages of manufacturing and/or processing. Planning is also underway for additional core stages and a new, more powerful upper stage that will increase lunar payload mass. SLS is the anchor transportation leg of a plan for sustained human exploration of the Moon, including the first human landing later in the decade. This paper will discuss SLS progress to date and expected 2021 milestones.

Bruce R. Askins↗

Augmented Reality Tool for Operationally Relevant 3D Sensorimotor Assessments

This project will leverage existing capabilities of an augmented reality (AR) sensorimotor assessment tool. Currently, the tool mimics the capabilities of validated 2-dimensional (2D) assessments. While this modality is well-aligned with seated interactions with flight-deck displays, extravehicular activity (EVA) tasks will require full body mobility wherein astronauts reach and bend in a 3-dimensional (3D) space. These types of motions, naturally including head movements, are known to elicit experiences of disorientation. Thus, sensorimotor assessments that include these stimulations and larger movements are important for understanding astronaut readiness prior to initial EVAs. The proposed effort will extend the current 2D eye-hand coordination task in AR to a 3D task designed to evaluate dynamic balance and eye-hand-body coordination. The new module will extend the range of motion and interaction space such that it better aligns with operational task needs for astronaut readiness evaluation.

Sarah Catherine Moudy↗

SIMBIOS Project 1998 Annual Report

The purpose of this series of technical reports is to provide current documentation of the Sensor Intercomparison and Merger for Biological and Interdisciplinary Ocean Studies (SIMBIOS) Project activities, NASA Research Announcement (NRA) research status, satellite data processing, data product validation and field calibration. This documentation is necessary to ensure that critical information is related to the scientific community and NASA management. This critical information includes the technical difficulties and challenges of combining ocean color data from an array of independent satellite systems to form consistent and accurate global bio-optical time series products. This technical report is not meant to substitute for scientific literature. Instead, it will provide a ready and responsive vehicle for the multitude of technical reports issues by an operational project.

McClain, Charles R.↗

Vacuum Deployment and Testing of a 4-Quadrant Scalable Inflatable Solar Sail System

Solar sails reflect photons streaming from the sun and transfer momentum to the sail. The thrust, though small, is continuous and acts for the life of the mission without the need for propellant. Recent advances in materials and ultra-low mass gossamer structures have enabled a host of useful missions utilizing solar sail propulsion. The team of L'Garde, Jet Propulsion Laboratories, Ball Aerospace, and Langley Research Center, under the direction of the NASA In-Space Propulsion office, has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. The baseline design currently in development and testing was optimized around the 1 AU solar sentinel mission. Featuring inflatably deployed sub-T(sub g), rigidized beam components, the 10,000 sq m sail and support structure weighs only 47.5 kg, including margin, yielding an areal density of 4.8 g/sq m. Striped sail architecture, net/membrane sail design, and L'Garde's conical boom deployment technique allows scalability without high mass penalties. This same structural concept can be scaled to meet and exceed the requirements of a number of other useful NASA missions. This paper discusses the interim accomplishments of phase 3 of a 3-phase NASA program to advance the technology readiness level (TRL) of the solar sail system from 3 toward a technology readiness level of 6 in 2005. Under earlier phases of the program many test articles have been fabricated and tested successfully. Most notably an unprecedented 4-quadrant 10 m solar sail ground test article was fabricated, subjected to launch environment tests, and was successfully deployed under simulated space conditions at NASA Plum Brook s 30m vacuum facility. Phase 2 of the program has seen much development and testing of this design validating assumptions, mass estimates, and predicted mission scalability. Under Phase 3 a much larger 20 m square test article including subscale vane has been fabricated and tested. A 20 m system ambient deployment has been successfully conducted after enduring Delta-2 launch environment testing. The program will culminate in a vacuum deployment of a 20 m subscale test article at the NASA Glenn s Plum Brook 30 m vacuum test facility to bring the TRL level as close to 6 as possible in 1 g. This focused program will pave the way for a flight experiment of this highly efficient space propulsion technology.

Lichodziejewski, David↗

Airport Noise Tech Challenge Overview

The Supersonics Project, operating under NASA Aeronautics Mission Directorate#s Fundamental Aero Program, has been organized around the Technical Challenges that have historically precluded commercial supersonic flight. One of these Challenges is making aircraft that are capable of such high aerodynamic performance quiet enough around airports that they will not be objectionable. It is recognized that a successful civilian supersonic aircraft will be a system where many new technologies will come together, and for this to happen not only will new low noise propulsion concepts be required, but new engineering tools that predict the noise of the aircraft as these technologies are combined and compromised with the rest of the aircraft design. These are the two main objectives of the Airport Noise Tech Challenge. " ! As a Project in the Fundamental Aero Program, we work at a relatively low level of technology readiness. However, we have high level milestones which force us to integrate our efforts to impact systems-level activities. To keep the low-level work tied to delivering engineering tools and low-noise concepts, we have structured our milestones around development of the concepts and organized our activities around developing and applying our engineering tools to these concepts. The final deliverables in these milestones are noise prediction modules validated against the best embodiment of each concept. These will then be used in cross-disciplinary exercises to demonstrate the viability of aircraft designs to meet all the Technical Challenges. Some of the concepts being developed are shown: Fan Flow Diverters, Multi-jet Shielding, High-Aspect Ratio Embedded Nozzles, Plasma Actuated Instability Manipulation, Highly Variable Cycle Mixer- Ejectors, and Inverted Velocity Profiles. These concepts are being developed for reduced jet noise along with the design tools which describe how they perform when used in various aircraft configurations. Several key upcoming events are highlighted, including tests of the Highly Variable Cycle Mixer-Ejectors, and Inverted Velocity Profiles. Other key events are milestones to be delivered within the next calendar year.

Bridges, James↗

SIMBIOS Project 1999 Annual Report

The purpose of this technical memorandum is to provide current documentation of the Sensor Intercomparison and Merger for Biological and Interdisciplinary Oceanic Studies (SIMBIOS) Project activities, NASA Research Announcement (NRA) research status, satellite data processing, data product validation, and field calibration. This documentation is necessary to ensure that critical information is related to the scientific community and NASA management. This critical information includes the technical difficulties and challenges of combining ocean color data from an array of independent satellite systems to form consistent and accurate global bio-optical time series products. This technical report is not meant as a substitute for scientific literature. Instead, it will provide a ready and responsive vehicle for the multitude of technical reports issued by an operational project.

McClain, Charles R.↗

Bioavailability and Pharmacodynamics of Promethazine in Human Subjects

The acute effects of exposure to microgravity include the development of space motion sickness, which usually requires therapeutic intervention. The current drug of choice, promethazine (PMZ), is available to astronauts in three different dosage forms during space flight; its side effects include nausea, dizziness, sedation and impaired psychomotor performance. This ground-based study is designed to validate flight-suitable methods for pharmacodynamic evaluation of PMZ and to estimate bioavailability and pharmacodynamics of PMZ. Experimental design consists of intramuscular administration of three doses of PMZ (12.5,25 and 50 mg) and placebo in a randomized double blind fashion to human subjects and collecting blood, urine and saliva samples for 72 h. Subjects also complete cognitive performance test batteries, WinSCAT (Windows based Space Cognitive Assessment Test) and ARES (ANAM Readiness Evaluation System). Preliminary results indicate a significant relationship (p=9.88e-05) between circulating PMZ levels and cognitive performance parameters. Time to accurately complete memory tasks increases significantly with concentrations; higher concentrations also increase response time and decrease accuracy of substitution and matching tasks. AUC and half-life estimates for PMZ ranged between 0.12 and 1.7 mg.h/L and 15 and 50 h, respectively. These preliminary results indicate that PMZ may exhibit dose-dependent pharmacokinetics in humans; also, WinSCAT and ARES are sensitive for pharmacodynamic assessment of PMZ, and may be applicable for assessing the pharmacodynamics of other neurocognitive drugs.

Boyd, J. L.↗

Pharmacodynamics of Promethazine in Human Subjects

Promethazine (PMZ) is the drug of choice for the treatment of symptoms associated with space motion sickness in astronauts. Side effects of PMZ include sedation, dizziness and cognitive performance impairment. In this study, we examined pharmacodynamics (PD) in human subjects and validated methods for evaluating cognitive performance effects of medications in space. METHODS: PMZ (12.5,25, and 50 mg) or placebo was administered by IM injection to human subjects in a randomized double-blind treatment design. Samples and data were collected for 72 h post dose. PD evaluation was performed using a battery of performance tests administered using WinSCAT (Windows based Space Cognitive Assessment Test) on a laptop computer, and ARES (ANAM Readiness Evaluation System) on a PDA, plasma concentrations of PMZ were measured using a LC-MS method. RESULTS: Results indicate a linear correlation between PMZ concentration and cognitive performance parameters (p<0.01). Test accuracy decreased and test completion time and response time increased significantly with increasing plasma PMZ concentration. CONCLUSIONS: These results suggest a concentration dependent decrement in cognitive performance associated with PMZ. WinSCAT and ARES are sensitive tools for the assessment PMZ PD and may be applicable for such evaluations with other neurocognitive drugs.

Gatlin, K. T.↗

Leveraging Commercial Software Defined Radio for Low Cost Deep Space Testing

In a typical space mission development life cycle, there is a stage where the spacecraft needs to test against the ground station for interface compatibility to ensure that the spacecraft will be properly tracked after launch. This testing normally requires the spacecraft team to bring their flight equipment to the ground station facility. While recognizing that testing with actual flight or engineering module is the most preferred option because of maximum fidelity, there are occasion when the use of actual flight hardware is a logistically challenge because of spacecraft development. Having another test tool that can emulate the spacecraft signal – by recording the signal transmitted by the spacecraft and regenerate an RF signal for ground system testing - would be very useful. It is even more an attractive option if such spacecraft emulator is inexpensive and highly portable. In this paper, we describe a low-cost, light-weight recorder/playback assembly (RPA) that supports deep space missions testing. The equipment leverages on commercially available software defined radios (SDR) and public-domain software. The RPA has been used to support two missions. One effort is to validate that the Uchinoura 34-m tracking station of the Japanese Aerospace Exploration Agency (JAXA) would be able to track the upcoming NASA Exploration Mission 1 (EM-1) spacecraft, scheduled for launch in 2019. The second effort is to help with the testing and certification of the 21-m antenna ground station at the Morehead State University (MSU) in Kentucky, United States, prior to the time when the Lunar IceCube spacecraft is ready for actual compatibility testing. The RPA also enables students/staff training of the new ground station, using the RPA signal as test input into the system. This low-cost test signal allows the MSU team to save money on not having to develop a full-scale self-generated telemetry test signal source.

White, Leslie↗

Strain Sensor Survey for Parachute Canopy Load Measurements

The parachute failures during the National Aeronautics and Space Administration Low-Density Supersonic Decelerator project revealed many of the complications of using parachutes for atmospheric entry missions and prompted the need for a more in-depth understanding of parachutes. Validation data for point loads on parachute canopies would contribute greatly to this understanding; however, such data does not exist because of a lack in practical sensing technologies capable of measuring the canopy strain. Few commercially available sensing technologies exist that can measure the total strain range of the parachute broadcloth materials, and even fewer can be easily integrated into the canopy. Additionally, many of these options are not at a technology readiness level suitable for flight-testing. This survey presents and compares the latest sensing capabilities that have potential in instrumenting parachute canopies for atmospheric entry and highlights the challenges particular to this application. Each sensor is evaluated for its performance and suitability towards parachute canopy instrumentation. Specifically, sensors are evaluated on their capabilities in measuring maximum strain, strain rate, hysteresis, drift, adherence and integration options, durability, environmental conditions, and technology maturation. Additionally, future work that is needed to assess sensor technologies for this application is provided.

Daniel W. Budolak↗

Joint Lead-Free Solder Test Program for High Reliability Military and Space Applications

Current and future space and defense systems face potential risks from the continued use of tin-lead solder, including: compliance with current environmental regulations, concerns about potential environmental legislation banning lead-containing products, reduced mission readiness, and component obsolescence with lead surface finishes. For example, the United States Environmental Protection Agency (USEPA) has lowered the Toxic Chemical Release reporting threshold for lead to 100 pounds. Overseas, the Waste Electrical and Electronic Equipment (WEEE) and the Restriction on Hazardous Substances (RoHS) Dicctives in Europe and similar mandates in Japan have instilled concern that a legislative body will prohibit the use of lead in aerospace/military electronics soldering. Any potential banning of lead compounds could reduce the supplier base and adversely affect the readiness of missions led by the National Aeronautics and Space Administration (NASA) and the U.S. Department of Defense (DoD). Before considering lead-free electronics for system upgrades or future designs, however, it is important for the DoD and NASA to know whether lead-free solders can meet their systems' requirements. No single lead-free solder is likely to qualify for all defense and space applications. Therefore, it is important to validate alternative solders for discrete applications. As a result of the need for comprehensive test data on the reliability of lead-free solders, a partnership was formed between the DoD, NASA, and several original equipment manufactures (OEMs) to conduct solder-joint reliability (laboratory) testing of three lead-free solder alloys on newly manufactured and reworked circuit cards to generate performance data for high-reliability (IPC Class 3) applications.

Brown, Christina↗