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NASA NTRS2008

Building on 50 Years of Systems Engineering Experience for a New Era of Space Exploration

Over the past 50 years, the National Aeronautics and Space Administration (NASA) has delivered space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides the United States (US) capability for both crew and heavy cargo to low-Earth orbit to construct the International Space Station, before the Shuttle is retired in 2010. In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The goals for this new system include increased safety and reliability coupled with lower operations costs that promote sustainable space exploration for decades to come. The Ares I will loft the Orion crew exploration vehicle, while the heavy-lift Ares V will carry the Altair lunar lander, as well as the equipment and supplies needed to construct a lunar outpost for a new generation of human and robotic space pioneers. NASA's Marshall Space Flight Center manages the Shuttle's propulsion elements and is managing the design and development of the Ares rockets, along with a host of other engineering assignments in the field of scientific space exploration. Specifically, the Marshall Center's Engineering Directorate houses the skilled workforce and unique facilities needed to build capable systems upon the foundation laid by the Mercury, Gemini, Apollo, and Shuttle programs. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level testing activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity and to validate computer modeling and simulation, as well as the main propulsion test article analysis to be conducted in the Static Test Stand. Ultimately, fielding a robust space transportation solution that will carry international explorers and essential payloads will pave the way for a new era of scientific discovery now dawning beyond planet Earth.

Dumbacher, Daniel L.↗

NASA NTRS2009

Ares V: New Opportunities for Scientific Payloads

What if scientists and payload planners had access to three to five times the volume and five to nine times the mass provided by today's launch vehicles? This simple question can lead to numerous exciting possibilities, all involving NASA's new Ares V cargo launch vehicle now on the drawing board. Multiple scientific fields and payload designers have that opportunity with the Ares V cargo launch vehicle, being developed at NASA as the heavy-lift component of the U.S. Space Exploration Policy. When the Ares V begins flying late next decade, its capabilities will significantly exceed the 1960s-era Saturn V or the current Space Shuttle, while it benefits from their engineering, manufacturing, and infrastructure heritage. It will send more crew and cargo to more places on the lunar surface than Apollo and provide ongoing support to a permanent lunar outpost. Moreover, it will restore a strategic heavy-lift U.S. asset, which can support human and robotic exploration and scientific ventures for decades to come. Assessment of astronomy payload requirements since Spring 2008 has indicated that Ares V has the potential to support a range of payloads and missions. Some of these missions were impossible in the absence of Ares V's capabilities. Collaborative design/architecture inputs, exchanges, and analyses have already begun between scientists and payload developers. A 2008 study by a National Research Council (NRC) panel, as well as analyses presented by astronomers and planetary scientists at two weekend conferences in 2008, support the position that Ares V has benefit to a broad range of planetary and astronomy missions. This early dialogue with Ares V engineers is permitting the greatest opportunity for payload/transportation/mission synergy and the least financial impact to Ares V development. In addition, independent analyses suggest that Ares V has the opportunity to enable more cost-effective mission design.

Creech, Steve↗

NASA NTRS2009

Developments to Increase the Performance, Operational Versatility and Automation of a Lunar Surface Manipulation System

The objective of this paper is to describe and summarize the results of the development efforts for the Lunar Surface Manipulation System (LSMS) with respect to increasing the performance, operational versatility, and automation. Three primary areas of development are covered, including; the expansion of the operational envelope and versatility of the current LSMS test-bed, the design of a second generation LSMS, and the development of automation and remote control capability. The first generation LSMS, which has been designed, built, and tested both in lab and field settings, is shown to have increased range of motion and operational versatility. Features such as fork lift mode, side grappling of payloads, digging and positioning of lunar regolith, and a variety of special end effectors are described. LSMS operational viability depends on bei nagble to reposition its base from an initial position on the lander to a mobility chassis or fixed locations around the lunar outpost. Preliminary concepts are presented for the second generation LSMS design, which will perform this self-offload capability. Incorporating design improvements, the second generation will have longer reach and three times the payload capability, yet it will have approximately equivalent mass to the first generation. Lastly, this paper covers improvements being made to the control system of the LSMS test-bed, which is currently operated using joint velocity control with visual cues. These improvements include joint angle sensors, inverse kinematics, and automated controls.

Dorsey, John T.↗

NASA NTRS2009

The Lunar Mapping and Modeling Project

The Lunar Mapping and Modeling Project (LMMP) has been created to manage the development of a suite of lunar mapping and modeling products that support the Constellation Program (CxP) and other lunar exploration activities, including the planning, design, development, test and operations associated with lunar sortie missions, crewed and robotic operations on the surface, and the establishment of a lunar outpost. The information provided through LMMP will assist CxP in: planning tasks in the areas of landing site evaluation and selection, design and placement of landers and other stationary assets, design of rovers and other mobile assets, developing terrain-relative navigation (TRN) capabilities, and assessment and planning of science traverses.

Noble, Sarah K.↗

NASA NTRS2009

Exploration Life Support Critical Questions for Future Human Space Missions

Exploration Life Support (ELS) is a project under NASA s Exploration Technology Development Program. The ELS Project plans, coordinates and implements the development of advanced life support technologies for human exploration missions in space. Recent work has focused on closed loop atmosphere and water systems for a lunar outpost, including habitats and pressurized rovers. But, what are the critical questions facing life support system developers for these and other future human missions? This paper explores those questions and discusses how progress in the development of ELS technologies can help answer them. The ELS Project includes Atmosphere Revitalization Systems (ARS), Water Recovery Systems (WRS), Waste Management Systems (WMS), Habitation Engineering, Systems Integration, Modeling and Analysis (SIMA), and Validation and Testing, which includes the sub-elements Flight Experiments and Integrated Testing. Systems engineering analysis by ELS seeks to optimize the overall mission architecture by considering all the internal and external interfaces of the life support system and the potential for reduction or reuse of commodities. In particular, various sources and sinks of water and oxygen are considered along with the implications on loop closure and the resulting launch mass requirements.

Ewert, Michael K.↗

NASA NTRS2009

Developing Sustainable Spacecraft Water Management Systems

It is well recognized that water handling systems used in a spacecraft are prone to failure caused by biofouling and mineral scaling, which can clog mechanical systems and degrade the performance of capillary-based technologies. Long duration spaceflight applications, such as extended stays at a Lunar Outpost or during a Mars transit mission, will increasingly benefit from hardware that is generally more robust and operationally sustainable overtime. This paper presents potential design and testing considerations for improving the reliability of water handling technologies for exploration spacecraft. Our application of interest is to devise a spacecraft wastewater management system wherein fouling can be accommodated by design attributes of the management hardware, rather than implementing some means of preventing its occurrence.

Thomas, Evan A.↗

NASA NTRS2009

Cascade Distillation Subsystem Development: Early Results From the Exploration Life Support Distillation Technology Comparison Test

In 2009, the Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell International, Torrance, CA) was assessed in the National Aeronautics and Space Administration (NASA) Exploration Life Support (ELS) distillation comparison test. The purpose of the test was to collect data to support down-selection and development of a primary distillation technology for application in a lunar outpost water recovery system. The CDS portion of the comparison test was conducted between May 6 and August 19, 2009. The system was challenged with two pretreated test solutions, each intended to represent a feasible wastewater generated in a surface habitat. The 30-day equivalent wastewater loading volume for a crew of four was processed for each wastewater solution. Test Solution 1 consisted of a mixed stream containing human-generated urine and humidity condensate. Test Solution 2 contained the addition of human-generated hygiene wastewater to the solution 1 waste stream components. Approximately 1500 kg of total wastewater was processed through the CDS during testing. Respective recoveries per solution were 93.4 +/- 0.7 and 90.3 +/- 0.5%. The average specific energy of the system was calculated to be less than 130 W-hr/kg. The following paper provides detailed information and data on the performance of the CDS as challenged per the ELS distillation comparison test.

Callahan, Michael R.↗

NASA NTRS2009

Thermal Interface Evaluation of Heat Transfer from a Pumped Loop to Titanium-Water Thermosyphons

Titanium-water thermosyphons are being considered for use in the heat rejection system for lunar outpost fission surface power. Key to their use is heat transfer between a closed loop heat source and the heat pipe evaporators. This work describes laboratory testing of several interfaces that were evaluated for their thermal performance characteristics, in the temperature range of 350 to 400 K, utilizing a water closed loop heat source and multiple thermosyphon evaporator geometries. A gas gap calorimeter was used to measure heat flow at steady state. Thermocouples in the closed loop heat source and on the evaporator were used to measure thermal conductance. The interfaces were in two generic categories, those immersed in the water closed loop heat source and those clamped to the water closed loop heat source with differing thermal conductive agents. In general, immersed evaporators showed better overall performance than their clamped counterparts. Selected clamped evaporator geometries offered promise.

Jaworske, Donald A.↗

NASA NTRS2010

Cascade Distillation Subsystem Development: Early Results from the Exploration Life Support Distillation Technology Comparison Test

In 2009, the Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell International, Torrance, California) was assessed in the National Aeronautics and Space Administration (NASA) Exploration Life Support (ELS) distillation comparison test. The purpose of the test was to collect data to support down-selection and development of a primary distillation technology for application in a lunar outpost water recovery system. The CDS portion of the comparison test was conducted between May 6 and August 19, 2009. The system was challenged with two pretreated test solutions, each intended to represent a feasible wastewater generated in a surface habitat. The 30-day equivalent wastewater loading volume for a crew of four was intended to be processed for each wastewater solution. Test Solution 1 consisted of a mixed stream containing human-generated urine and humidity condensate. Test Solution 2 contained the addition of human-generated hygiene wastewater to the solution 1 waste stream components. Approximately 1500 kg of total wastewater was processed through the CDS during testing. Respective recoveries per solution were 93.4 +/- 0.7 and 90.3 +/- 0.5 percent. The average specific energy of the system during testing was calculated to be less than 120 W-hr/kg. The following paper provides detailed information and data on the performance of the CDS as challenged per the ELS distillation comparison test.

Callahan, Michael R.↗

NASA NTRS2010

Microwave Plasma Hydrogen Recovery System

A microwave plasma reactor was developed for the recovery of hydrogen contained within waste methane produced by Carbon Dioxide Reduction Assembly (CRA), which reclaims oxygen from CO2. Since half of the H2 reductant used by the CRA is lost as CH4, the ability to reclaim this valuable resource will simplify supply logistics for longterm manned missions. Microwave plasmas provide an extreme thermal environment within a very small and precisely controlled region of space, resulting in very high energy densities at low overall power, and thus can drive high-temperature reactions using equipment that is smaller, lighter, and less power-consuming than traditional fixed-bed and fluidized-bed catalytic reactors. The high energy density provides an economical means to conduct endothermic reactions that become thermodynamically favorable only at very high temperatures. Microwave plasma methods were developed for the effective recovery of H2 using two primary reaction schemes: (1) methane pyrolysis to H2 and solid-phase carbon, and (2) methane oligomerization to H2 and acetylene. While the carbon problem is substantially reduced using plasma methods, it is not completely eliminated. For this reason, advanced methods were developed to promote CH4 oligomerization, which recovers a maximum of 75 percent of the H2 content of methane in a single reactor pass, and virtually eliminates the carbon problem. These methods were embodied in a prototype H2 recovery system capable of sustained high-efficiency operation. NASA can incorporate the innovation into flight hardware systems for deployment in support of future long-duration exploration objectives such as a Space Station retrofit, Lunar outpost, Mars transit, or Mars base. The primary application will be for the recovery of hydrogen lost in the Sabatier process for CO2 reduction to produce water in Exploration Life Support systems. Secondarily, this process may also be used in conjunction with a Sabatier reactor employed to stockpile life-support oxygen as well as propellant and fuel production from Martian atmospheric CO2

Atwater, James↗

NASA NTRS2011

Energy Storage Project

NASA's Exploration Technology Development Program funded the Energy Storage Project to develop battery and fuel cell technology to meet the expected energy storage needs of the Constellation Program for human exploration. Technology needs were determined by architecture studies and risk assessments conducted by the Constellation Program, focused on a mission for a long-duration lunar outpost. Critical energy storage needs were identified as batteries for EVA suits, surface mobility systems, and a lander ascent stage; fuel cells for the lander and mobility systems; and a regenerative fuel cell for surface power. To address these needs, the Energy Storage Project developed advanced lithium-ion battery technology, targeting cell-level safety and very high specific energy and energy density. Key accomplishments include the development of silicon composite anodes, lithiated-mixed-metal-oxide cathodes, low-flammability electrolytes, and cell-incorporated safety devices that promise to substantially improve battery performance while providing a high level of safety. The project also developed "non-flow-through" proton-exchange-membrane fuel cell stacks. The primary advantage of this technology set is the reduction of ancillary parts in the balance-of-plant--fewer pumps, separators and related components should result in fewer failure modes and hence a higher probability of achieving very reliable operation, and reduced parasitic power losses enable smaller reactant tanks and therefore systems with lower mass and volume. Key accomplishments include the fabrication and testing of several robust, small-scale nonflow-through fuel cell stacks that have demonstrated proof-of-concept. This report summarizes the project s goals, objectives, technical accomplishments, and risk assessments. A bibliography spanning the life of the project is also included.

Mercer, Carolyn R.↗

NASA NTRS2008

Material Damage from Impacts of Lunar Soil Particles Ejected by the Rocket Exhaust of Landing Spacecraft

This paper details the experimentation of lunar stimulant sandblasting. This was done to understand the damage that landing spacecraft on the moon will have to a permanent lunar outpost. The sandblasting was done with JSC-1A onto glass coupons. Correlations between the velocity and the damage done to the glass were not found. Reasons for this and future analyses are discussed.

Wittbrodt, Audelia C.↗

NASA NTRS2011

Lunar Surface Systems Supportability Technology Development Roadmap

The Lunar Surface Systems Supportability Technology Development Roadmap is a guide for developing the technologies needed to enable the supportable, sustainable, and affordable exploration of the Moon and other destinations beyond Earth. Supportability is defined in terms of space maintenance, repair, and related logistics. This report considers the supportability lessons learned from NASA and the Department of Defense. Lunar Outpost supportability needs are summarized, and a supportability technology strategy is established to make the transition from high logistics dependence to logistics independence. This strategy will enable flight crews to act effectively to respond to problems and exploit opportunities in an environment of extreme resource scarcity and isolation. The supportability roadmap defines the general technology selection criteria. Technologies are organized into three categories: diagnostics, test, and verification; maintenance and repair; and scavenge and recycle. Furthermore, "embedded technologies" and "process technologies" are used to designate distinct technology types with different development cycles. The roadmap examines the current technology readiness level and lays out a four-phase incremental development schedule with selection decision gates. The supportability technology roadmap is intended to develop technologies with the widest possible capability and utility while minimizing the impact on crew time and training and remaining within the time and cost constraints of the program.

Oeftering, Richard C.↗

NASA NTRS2012

Concepts for a Shroud or Propellant Tank Derived Deep Space Habitat

Long duration human spaceflight missions beyond Low Earth Orbit will require much larger spacecraft than capsules such as the Russian Soyuz or American Orion Multi-Purpose Crew Vehicle. A concept spacecraft under development is the Deep Space Habitat, with volumes approaching that of space stations such as Skylab, Mir, and the International Space Station. This paper explores several concepts for Deep Space Habitats constructed from a launch vehicle shroud or propellant tank. It also recommends future research using mockups and prototypes to validate the size and crew station capabilities of such a habitat. Keywords: Exploration, space station, lunar outpost, NEA, habitat, long duration, deep space habitat, shroud, propellant tank.

Howard, Robert L.↗

NASA NTRS2012

Contaminant Removal from Oxygen Production Systems for In Situ Resource Utilization

The In Situ Resource Utilization (ISRU) project has been developing technologies to produce oxygen from lunar regolith to provide consumables to a lunar outpost. The processes developed reduce metal oxides in the regolith to produce water, which is then electrolyzed to produce oxygen. Hydrochloic and hydrofluoric acids are byproducts of the reduction processes, as halide minerals are also reduced at oxide reduction conditions. Because of the stringent water quality requirements for electrolysis, there is a need for a contaminant removal process. The Contaminant Removal from Oxygen Production Systems (CROPS) team has been developing a separation process to remove these contaminants in the gas and liquid phase that eliminates the need for consumables. CROPS has been using Nafion, a highly water selective polymeric proton exchange membrane, to recover pure water from the contaminated solution. Membrane thickness, product stream flow rate, and acid solution temperature and concentration were varied with the goal of maximizing water permeation and acid rejection. The results show that water permeation increases with increasing solution temperature and product stream flow rate, while acid rejection increases with decreasing solution temperature and concentration. Thinner membranes allowed for higher water flux and acid rejection than thicker ones. These results were used in the development of the hardware built for the most recent Mars ISRU demonstration project.

Anthony, Stephen M.↗

NASA NTRS2012

Return to the Moon: NASA's LCROSS AND LRO Missions

NASA s goals include objectives for robotic and human spaceflight: a) Implement a sustained and affordable human and robotic program to explore the solar system and beyond; b) Extend human presence across the solar system, starting with a human return to the Moon by the year 2020, in preparation for human exploration of Mars and other destinations; c) A lunar outpost is envisioned. Site Considerations: 1) General accessibility of landing site (orbital mechanics) 2) Landing site safety 3) Mobility 4) Mars analog 5) Power 6) Communications 7) Geologic diversity 8) ISRU considerations

Morales, Lester↗

NASA NTRS2008

Production of Methane and Water from Crew Plastic Waste

Recycling is a technology that will be key to creating a self sustaining lunar outpost. The plastics used for food packaging provide a source of material that could be recycled to produce water and methane. The recycling of these plastics will require some additional resources that will affect the initial estimate of starting materials that will have to be transported from earth, mainly oxygen, energy and mass. These requirements will vary depending on the recycling conditions. The degredation products of these plastics will vary under different atmospheric conditions. An estimate of the the production rate of methane and water using typical ISRU processes along with the plastic recycling will be presented.

Captain, Janine↗

NASA NTRS2008

Lunar Water Resource Demonstration

In cooperation with the Canadian Space Agency, the Northern Centre for Advanced Technology, Inc., the Carnegie-Mellon University, JPL, and NEPTEC, NASA has undertaken the In-Situ Resource Utilization (ISRU) project called RESOLVE. This project is a ground demonstration of a system that would be sent to explore permanently shadowed polar lunar craters, drill into the regolith, determine what volatiles are present, and quantify them in addition to recovering oxygen by hydrogen reduction. The Lunar Prospector has determined these craters contain enhanced hydrogen concentrations averaging about 0.1%. If the hydrogen is in the form of water, the water concentration would be around 1%, which would translate into billions of tons of water on the Moon, a tremendous resource. The Lunar Water Resource Demonstration (LWRD) is a part of RESOLVE designed to capture lunar water and hydrogen and quantify them as a backup to gas chromatography analysis. This presentation will briefly review the design of LWRD and some of the results of testing the subsystem. RESOLVE is to be integrated with the Scarab rover from CMIJ and the whole system demonstrated on Mauna Kea on Hawaii in November 2008. The implications of lunar water for Mars exploration are two-fold: 1) RESOLVE and LWRD could be used in a similar fashion on Mars to locate and quantify water resources, and 2) electrolysis of lunar water could provide large amounts of liquid oxygen in LEO, leading to lower costs for travel to Mars, in addition to being very useful at lunar outposts.

Muscatello, Anthony C.↗