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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2026

Community Solar Project Models: An Introduction to Basic Financial and Administrative Relationships [Slides]

This resource is a collection of visual aids and descriptions to help explain the basic financial and administrative relationships underpinning common community solar project models. The graphics in this resource depict the flow of electricity from generation to consumption and the financial exchanges between the community solar project owner, subscribers, and distribution utility. Community solar models vary based on ownership (e.g., third party, utility), customer type (e.g., multifamily, single-household), and solar array location (e.g., on-site, off-site).

14 SOLAR ENERGY↗

DOE OSTI2026

Dataset 2: A National Dataset on Human Choices in Pooled Rideshare, 2022

Dataset 2: A National Dataset on Human Choices in Pooled Rideshare, 2022. Dataset Description: Pooled Rideshare Acceptance Survey - Phase 2 (2022, N = 2,884). This dataset captures responses from a nationally representative sample of 2,884 adults across the United States to understand choice behaviors between personal and pooled rideshare services. The primary objective of this research is to investigate choice behaviors in rideshare services and provide insights that inform service design, policymaking, and transportation planning, with the aim of encouraging pooled rideshare adoption and enhancing transportation network energy efficiency. Data was collected via an online survey administered through a national panel provider. Participants ranged in age from 18 to 94 years, and representation from all U.S. regions. The survey was designed with a focus on investigating the stated-preference between personal and pooled rideshare services. Each participant responded to 20 stated-preference questions, where they were presented with a hypothesized situation to choose between a personal rideshare option and a pooled rideshare option to complete a trip. The sociodemographic information and attitudes towards factors of pooled rideshare acceptance were also collected to support the comprehensive investigation of participants’ rideshare choice behaviors. - Phase_2_Final - Each row represents an individual respondent, and each column corresponds to a variable such as stated-preference scenario attributes, stated-preference scenario responses, attitudes toward specific service features, and sociodemographic data. The data is available in both .CSV and .SAV formats. - Phase_2_Final_MapFile - The accompanying data dictionary explains all variable labels, response scales, and codes. An .XLSX format of the full survey instrument is included to support interpretation and reuse of the dataset.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2008

The Planning and Implementation of Test Facility Improvements

As engineering programs develop, and product testing begins, ideas for process improvement soon become obvious. Engineers envision new holding and handling fixtures. Additional custom-made support equipment may be needed. Perhaps modifications to the building or modifications to facility hardware are the order of the day. This is where a flexible creative test organization is needed. We need not be content with the status quo. All of these desired test innovations can make the difficult easy and improve the work flow. At times, implementing these new ideas demands more time or specialized expertise than test team members have. Through the coordinated use of labor resources, the needed improvements can still be made and in a timely fashion that supports program schedules. This presentation provides practical advice and a method whereby test personnel can creatively develop facility improvements and manage them from start to finish. You can control just how much time you invest and what part of your concepts you will personally design. By wisely defining the requirements and presenting them to the appropriate help sources (vendors, contractors, coworkers, and support departments), you can get the help you need to bring the improvements you have conceived, into fruition. Aspects of this presentation include defining requirements for test facility improvements, choosing labor resources, writing a statement of work, determining cost and benefits, securing department approval, coordinating procurement, managing the project, and training the end users. The process of successfully implementing test facility improvements is thoroughly explained. It has been tried, proven and improved over nearly 25 years of use. Whether considering a $50 improvement or a $50 million dollar improvement, this discussion will provide helpful pointers. Examples of improvements made through this process and their illustration will be included.

Oberlander, Larry↗

NASA NTRS1999

Cosmic Journeys. To the Edge of Gravity, Space and Time: Structure and Evolution of the Universe Roadmap: 2003-2023

The Roadmap for the Structure and Evolution of the Universe (SEU) Theme embraces three fundamental, scientific quests: (1) To explain structure in the Universe and forecast our cosmic destiny, (2) To explore the cycles of matter and energy in the evolving Universe, (3) To examine the ultimate limits of gravity and energy in the Universe. We develop these quests into six focused research campaigns: (1) Identify dark matter and learn how it shapes galaxies and systems of galaxies, (2) Explore where and when the chemical elements were made (3) Understand the cycles in which matter, energy, and magnetic field are exchanged between stars and the gas between stars, (4) Discover how gas flows in disks and how cosmic jets are formed, (5) Identify the sources of gamma-ray bursts and high-energy cosmic rays, (6) Measure how strong gravity operates near black holes and how it affects the early Universe. These campaigns lead to a portfolio of future major missions of great scientific interest and popular appeal, strongly endorsed by the scientific community. Many have undergone significant initial study. Some are in a state of readiness that make them ideal candidates for the present Office of Space Science Strategic Plan; others may well feature in the next Plan. Each provides a golden scientific opportunity to advance our understanding of the Universe. We have identified three top-priority near-term science objectives together with missions to accomplish these goals. The three problems span a diverse range of subdisciplines, of observational technique, of timescales, and of cost, and are thus complementary, forming a coherent core program for the SEU theme in the 2003-2007 timeframe.These are : (1) Obtain precise measures of the chemical composition and physical conditions in objects ranging from the closest stars to the most distant quasars, (2) Utilize gravitational radiation as a probe of supermassive blackholes throughout the universe, (3) determine the nature of the highest energy cosmic rays. We also describe a small number of exciting missions which are strong candidates for new start status in the midterm, 2008-2013, pending technology development. These missions tackle fundamental problems through the entire electromagnetic spectrum, from the radio through gamma rays, and in many cases develop fascinating technologies with applicability not only elsewhere in NASA but outside of space science as well. Finally, we describe a set of "vision missions," which stretch our scientific imagination and set technology challenges for our field.

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NASA NTRS2002

An End-to-End Architecture for Science Goal Driven Observing

New observatories will have greater on-board storage capacity and on-board processing capabilities. The new bottleneck will be download capacity. The cost of downlink time and limitations of bandwidth will end the era where all exposure data is downloaded and all data processing is performed on the ground. In addition, observing campaigns involving inherently variable targets will need scheduling flexibility to focus observing time and data download on exposures that are scientifically interesting. The ability to quickly recognize and react to such events by re-prioritizing the observing schedule will be an essential characteristic for maximizing scientific returns. It will also be a step towards increasing spacecraft autonomy, a major goal of NASA's strategic plan. The science goal monitoring (SGM) system is a proof-of-concept effort to address these challenges. We are developing an interactive distributed system that will use on-board processing and storage combined with event-driven interfaces with ground-based processing and operations, to enable fast re-prioritization of observing schedules, and to minimize time spent on non-optimized observations. SGM is initially aimed towards time-tagged observing modes used frequently in spectroscopic studies of varying targets. In particular, the SGM is collaborating with the proposed MIDEX-class mission Kronos team. The variable targets that Kronos seeks to study make an adaptive system such as SGM particularly valuable for achieving mission goals. However, the architecture and interfaces will also be designed for easy adaptability to other observing platforms, including ground-based systems and to work with different scheduling and pipeline processing systems. This talk will focus on our strategy for developing SGM and the technical challenges that we have encountered. We will discuss the SGM architecture as it applies to the Kronos mission and explain how it is scalable to other missions.

Jones, Jeremy↗

NASA NTRS1998

Propulsion System for Very High Altitude Subsonic Unmanned Aircraft

This paper explains why a spark ignited gasoline engine, intake pressurized with three cascaded stages of turbocharging, was selected to power NASA's contemplated next generation of high altitude atmospheric science aircraft. Beginning with the most urgent science needs (the atmospheric sampling mission) and tracing through the mission requirements which dictate the unique flight regime in which this aircraft has to operate (subsonic flight at greater then 80 kft) we briefly explore the physical problems and constraints, the available technology options and the cost drivers associated with developing a viable propulsion system for this highly specialized aircraft. The paper presents the two available options (the turbojet and the turbocharged spark ignited engine) which are discussed and compared in the context of the flight regime. We then show how the unique nature of the sampling mission, coupled with the economic considerations pursuant to aero engine development, point to the spark ignited engine as the only cost effective solution available. Surprisingly, this solution compares favorably with the turbojet in the flight regime of interest. Finally, some remarks are made about NASA's present state of development, and future plans to flight demonstrate the three stage turbocharged powerplant.

Bents, David J.↗

NASA NTRS1997

The Evolving Universe: Structure and Evolution of the Universe Roadmap 2000-2020

The Roadmap for the Structure and Evolution of the Universe (SEU) theme embraces three fundamental, scientific quests: (1) To explain structure in the Universe and forecast our cosmic destiny. (2) To explore the cycles of matter and energy in the evolving Universe. (3) To examine the ultimate limits of gravity and energy in the Universe. These quests are developed into six, focused research campaigns addressing the objectives of one or more quests: Identify dark matter and learn how it shapes galaxies and systems of galaxies; Find out where and when the chemical elements were made; Understand the cycles in which matter, energy, and magnetic field are exchanged between stars and the gas between stars; Discover how gas flows in disks and how cosmic jets are formed; Identify the sources of gamma-ray bursts and high-energy cosmic rays; and Measure how strong gravity operates near black holes and how it affects the early Universe. These campaigns lead to a portfolio of future major missions of strong scientific and popular appeal, strongly endorsed by the scientific community and which has undergone significant initial study. Some of these missions are in a state of readiness that makes ideal candidates for the present Office of Space Science Strategic Plan; others may well feature in the next Strategic Plan. Each provides a golden scientific opportunity to advance our understanding of the Universe. Our highest priority science objectives are addressed by five Observatory Class Missions, unranked by science, but in approximate order of readiness: A high-energy gamma-ray facility that will observe relativistic jets and study the sources of cosmic gamma ray bursts; An ultra-sensitive X-ray telescope, optimized for spectroscopy, to examine the hot gas linked with clusters of galaxies, the disks around black holes, and supernova explosions; A large, radio telescope in deep space to map central regions of distant quasars and perform astrometric investigations; An orbiting gravitational coalescing, massive black holes and test how gravity waves distort spacetime; A pair of Earth-orbiting, optical telescopes that will detect flashes of light produced when ultra high-energy cosmic rays impact the upper atmosphere so as to determine their arrival directions and energies. A new program for supporting pertinent international collaboration is strongly endorsed and maintaining a strong Explorer program is important. The flexibility to exploit exceptional opportunities, such as attaching payloads to space station, should also be acquired. A strong technology development program must be initiated now to enable this mission set.

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NASA NTRS1989

Microgravity combustion science: A program overview

The promise of microgravity combustion research is introduced by way of a brief survey of results, the available set of reduced gravity facilities, and plans for experimental capabilities in the Space Station era. The study of fundamental combustion processes in a microgravity environment is a relatively new scientific endeavor. A few simple, precursor experiments were conducted in the early 1970's. Today the advent of the U.S. space shuttle and the anticipation of the Space Station Freedom provide for scientists and engineers a special opportunity, in the form of long duration microgravity laboratories, and need, in the form of spacecraft fire safety and a variety of terrestrial applications, to pursue fresh insight into the basic physics of combustion. The microgravity environment enables a new range of experiments to be performed since buoyancy-induced flows are nearly eliminated, normally obscured forces and flows may be isolated, gravitational settling or sedimentation is nearly eliminated, and larger time or length scales in experiments become permissible. The range of experiments completed to date was not broad, but is growing. Unexpected phenomena have been observed often in microgravity combustion experiments, raising questions about the degree of accuracy and completion of our classical understanding and our ability to estimate spacecraft fire hazards. Because of the field's relative immaturity, instrumentation has been restricted primarily to high-speed photography. To better explain these findings, more sophisticated diagnostic instrumentation, similar to that evolving in terrestrial laboratories, is being developed for use on Space Station Freedom and, along the way, in existing microgravity facilities.

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NASA NTRS2017

The Evolution of the Orbiting Sample Container for a Future Mars Sample Return

Although NASA has no specific plans at this time to return samples from Mars, the Program Formulation Office of the Mars Exploration Program sponsors ongoing mission concept studies, systems analyses, and technology investments which explore different strategies for the potential return of samples from Mars, consistent with the charter of the program and stated priorities of the science community. A critical component of such a campaign would be an Orbiting Sample container (OS), which would contain the Mars samples to be returned to Earth. This paper discusses the most recent efforts by the JPL’s Mars Formulation Office to mature an OS design planned for use on a potential Mars Sample Return (MSR) mission. Similar to the “Decadal Study Architecture” [1], the current MSR architecture envisions as a three-mission campaign with each mission serving a critical role towards returning Martian rock and atmospheric samples back to Earth. An OS would be a central piece of hardware in the proposed MSR architecture due to its interfaces to all the three missions of the potential campaign. Additionally, numerous stakeholders and subsystems such as science and planetary protection impose challenging requirements on the OS’s functions and capabilities. As a result, designing an OS that meets all the requirements is challenging and quite complex. The story of the OS’s evolution from black box concept thru to the current-and-still-maturing baseline design is the focus of this paper. From the OS’s launch off Earth aboard a Sample Retrieval Lander (SRL) through to return to Earth, the design and functional requirements generated by and for each stage of the OS’s mission are discussed. Then, with an understanding of what the OS would be required to do, a mapping of the main requirements to the design features of the current OS concept is explained. Many tests and analyses have been conducted to support and validate the current OS design. Results from test and analysis in the areas of aerothermal, impact dynamics, optical tracking, and radio electromagnetics are presented.

Spencer, David↗

NASA NTRS2000

The DYNAMO Orbiter Project: High Resolution Mapping of Gravity/Magnetic Fields and In Situ Investigation of Mars Atmospheric Escape

Dynamo is a small Mars orbiter planned to be launched in 2005 or 2007, in the frame of the NASA/CNES Mars exploration program. It is aimed at improving gravity and magnetic field resolution, in order to better understand the magnetic, geologic and thermal history of Mars, and at characterizing current atmospheric escape, which is still poorly constrained. These objectives are achieved by using a low periapsis orbit, similar to the one used by the Mars Global Surveyor spacecraft during its aerobraking phases. The proposed periapsis altitude for Dynamo of 120-130 km, coupled with the global distribution of periapses to be obtained during one Martian year of operation, through about 5000 low passes, will produce a magnetic/gravity field data set with approximately five times the spatial resolution of MGS. Low periapsis provides a unique opportunity to investigate the chemical and dynamical properties of the deep ionosphere, thermosphere, and the interaction between the atmosphere and the solar wind, therefore atmospheric escape, which may have played a crucial role in removing atmosphere, and water, from the planet. There is much room for debate on the importance of current atmosphere escape processes in the evolution of the Martian atmosphere, as early "exotic" processes including hydrodynamic escape and impact erosion are traditionally invoked to explain the apparent sparse inventory of present-day volatiles. Yet, the combination of low surface gravity and the absence of a substantial internally generated magnetic field have undeniable effects on what we observe today. In addition to the current losses in the forms of Jeans and photochemical escape of neutrals, there are solar wind interaction-related erosion mechanisms because the upper atmosphere is directly exposed to the solar wind. The solar wind related loss rates, while now comparable to those of a modest comet, nonetheless occur continuously, with the intriguing possibility of important cumulative and/or enhanced effects over the several billion years of the solar system's life. If the detailed history of the Martian internal field could be traced back, and the current escape processes could be understood well enough to model the expected stronger losses under early Sun conditions, one could go a long way toward constraining this part of the mysterious history of Mars' atmosphere.

Smrekar, S.↗

NASA NTRS2004

Small Aircraft Transportation System Concept and Technologies

This paper summarizes both the vision and the early public-private collaborative research for the Small Aircraft Transportation System (SATS). The paper outlines an operational definition of SATS, describes how SATS conceptually differs from current air transportation capabilities, introduces four SATS operating capabilities, and explains the relation between the SATS operating capabilities and the potential for expanded air mobility. The SATS technology roadmap encompasses on-demand, widely distributed, point-to-point air mobility, through hired-pilot modes in the nearer-term, and through self-operated user modes in the farther-term. The nearer-term concept is based on aircraft and airspace technologies being developed to make the use of smaller, more widely distributed community reliever and general aviation airports and their runways more useful in more weather conditions, in commercial hired-pilot service modes. The farther-term vision is based on technical concepts that could be developed to simplify or automate many of the operational functions in the aircraft and the airspace for meeting future public transportation needs, in personally operated modes. NASA technology strategies form a roadmap between the nearer-term concept and the farther-term vision. This paper outlines a roadmap for scalable, on-demand, distributed air mobility technologies for vehicle and airspace systems. The audiences for the paper include General Aviation manufacturers, small aircraft transportation service providers, the flight training industry, airport and transportation authorities at the Federal, state and local levels, and organizations involved in planning for future National Airspace System advancements.

Small aircraft transportation system↗

NASA NTRS1991

Use of satellite data and modeling to assess the influence of stratospheric processes on the troposphere

Over the past forty years, numerous linear stability studies have been performed in order to explain the origin and structure of observed waves in the atmosphere. Of these studies, only a small fraction have considered the stability of time-dependent, zonally varying flow or the influence of radiative-photochemical feedbacks on the stability of zonally uniform flow. The stability of such flows is described, and these flows may yield important information concerning the origin, structure, and transient time scales of free waves in the atmosphere. During the period 1990 to 1991, a beta-plane model that couples radiative transfer, ozone advection, and ozone photochemistry with the quasigeostrophic dynamical circulation was developed in order to study the diabatic effects of Newtonian cooling and ozone-dynamics interaction on the linear stability of free planetary waves in the atmosphere. The stability of a basic state consisting of a westward-moving wave and a zonal mean jet was examined using a linearized, nondivergent barotropic model on sphere. The sensitivity of the stability of the flow to the strength and structure of the zonal jet was emphasized. The current research is focused on the following problems: (1) examination of the finite amplitude interactions among radiation, ozone, and dynamics; and (2) examination of the role of seasonal forcing in short-term climate variability. The plans for next year are presented.

Nathan, Terrence↗

NASA NTRS1997

Physical Structure of Four Symbiotic Binaries

Disk accretion powers many astronomical objects, including pre-main sequence stars, interacting binary systems, and active galactic nuclei. Unfortunately, models developed to explain the behavior of disks and their surroundings - boundary layers, jets, and winds - lack much predictive power, because the physical mechanism driving disk evolution - the viscosity - is not understood. Observations of many types of accreting systems are needed to constrain the basic physics of disks and provide input for improved models. Symbiotic stars are an attractive laboratory for studying physical phenomena associated with disk accretion. These long period binaries (P(sub orb) approx. 2-3 yr) contain an evolved red giant star, a hot companion, and an ionized nebula. The secondary star usually is a white dwarf accreting material from the wind of its red giant companion. A good example of this type of symbiotic is BF Cygni: our analysis shows that disk accretion powers the nuclear burning shell of the hot white dwarf and also manages to eject material perpendicular to the orbital plane (Mikolajewska, Kenyon, and Mikolajewski 1989). The hot components in other symbiotic binaries appear powered by tidal overflow from a very evolved red giant companion. We recently completed a study of CI Cygni and demonstrated that the accreting secondary is a solar-type main sequence star, rather than a white dwarf (Kenyon et aL 1991). This project continued our study of symbiotic binary systems. Our general plan was to combine archival ultraviolet and optical spectrophotometry with high quality optical radial velocity observations to determine the variation of line and continuum sources as functions of orbital phase. We were very successful in generating orbital solutions and phasing UV+optical spectra for five systems: AG Dra, V443 Her, RW Hya, AG Peg, and AX Per. Summaries of our main results for these systems appear below. A second goal of our project was to consider general models for the outbursts of symbiotic stars, with an emphasis on understanding the differences between disk-driven and nuclear-powered eruptions.

Kenyon, Scott J.↗

NASA NTRS2021

A variable magnetic disc wind in the black hole X-ray binary GRS 1915+105?

Context. GRS 1915+105 being one of the brightest transient black hole binaries (BHBs) in the X-rays offers a unique testbed for the study of the connection between accretion and ejection mechanisms in BHBs. In particular, this source can be used to study the accretion disc wind and its dependence on the state changes in BHBs. Aims. Our aim is to investigate the origin and geometry of the accretion disc wind in GRS 1915+105. This study will provide a basis for planning future observations with the X-ray Imaging Spectroscopy Mission (XRISM), and may also provide important parameters for estimating the polarimetric signal with the upcoming Imaging X-ray Polarimetry Explorer (IXPE). Methods. We analysed the spectra of GRS 1915+105 in the soft ϕ and hard χ classes using the high-resolution spectroscopy offered by Chandra HETGS. In the soft state, we find a series of wind absorption lines that follow a non-linear dependence of velocity width, velocity shift, and equivalent width with respect to ionisation, indicating a multiple component or stratified outflow. In the hard state we find only a faint Fe XXVI absorption line. We model the absorption lines in both the states using a dedicated magneto-hydrodynamic (MHD) wind model to investigate a magnetic origin of the wind and to probe the cause of variability in the observed line flux between the two states. Conclusions. The MHD disc wind model provides a good fit for both states, indicating the possibility of a magnetic origin of the wind. The multiple ionisation components of the wind are well characterised as a stratification of the same magnetic outflow. We find that the observed variability in the line flux between soft and hard states cannot be explained by photo-ionisation alone but is most likely due to a large (three orders of magnitude) increase in the wind density. We find the mass outflow rate of the wind to be comparable to the accretion rate, suggesting an intimate link between accretion and ejection processes that lead to state changes in BHBs.

A. Ratheesh↗

DOE OSTI2026

Frequency Control and Dynamics (Part 1) [Slides]

This presentation provides an introductory overview of system dynamics and frequency control in electric power systems, with a focus on concepts relevant to small and interconnected grids such as those in Malawi. It explains foundational principles of AC system frequency, the relationship between generation-demand balance and frequency deviations, and the operational limits of generators and end-use equipment. The deck discusses frequency stability within broader system stability classifications and illustrates how inertia and turbine-governor dynamics shape system response to disturbances. It then outlines the tiered approach to frequency control - primary, secondary, and tertiary - detailing the roles, characteristics, timescales, and response mechanisms of each. Special emphasis is placed on hydro and thermal unit behavior, area control error (ACE), automatic generation control (AGC), and the operational implications of interconnecting small systems with larger grids. The material was developed to support Malawi's electricity sector and the establishment of the Southern Africa Battery Energy Storage Center of Excellence (SABESS CoE).

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Frequency Control and Dynamics (Part 2) [Slides]

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2005

Models for Water Isotopes Constrained with Data from Crystal Face

During the year covered by this proposal we conducted work on several different topics, as reflected by our publications listed below. One major activity was to work with a group of about 10 scientists from around the country to prepare a science-planning document (Tropical Composition, Cloud and Climate Coupling Experiment (TC4)) that outlined the rationale, locations, strategy to accomplish the goals, and possible payloads for a set of three tropical missions. We also prepared background materials for various NRAs being prepared at NASA Headquarters for missions in Costa Rica, Darwin and Guam. Unfortunately budgetary constraints prevented these missions from moving forward. In conjunction with the group NASA Ames we built a new numerical model for deep convection and have applied that model to simulate the CRYSTAL isotope data. Our goal in particular has been to better understanding how convection distributes water vapor isotopes. CRYSTAL observations of water isotopes are very different from those suggested by previous workers who assumed the isotopes would obey Rayleigh fractionation. The water isotope study has several implications. First it is a check on the realism of the deep convection model. Second, the isotopes are a measure of the precipitation removal in the atmosphere. Hence they provide a constraint on a parameter that is difficult to otherwise measure. Finally it has been suggested that isotopes may be the key to unraveling the water transport into the stratosphere and upper troposphere. Such transport is critical both for the radiation balance and for stratospheric chemistry. Ours is the first model that is able to treat this transport. Our initial results are now in press in Geophys. Res. Lett. Essentially we are able to explain the vertical profiles of isotopes in the tropical tropopause transition layer. We are also able to account for stratospheric humidity ana isotope abundances with this model. The data suggest that isotopes do not provide a clear constraint on the mechanism by which water enters the stratosphere- whether by convection, or by slow ascent. Our work is relevant for the water isotope comparison experiments recently done by NASA. We are conducting numerical experiments related to this project to help understand that data.

Toon, Owen B.↗

NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗