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Materials and structures for hypersonic vehicles

The development of low-density materials with higher strength and stiffness, and more efficient engine and airframe structures is considered enabling technology for reusable hypersonic vehicles. Advanced structural concepts are required for minimum weight hot structures that will be fully reusable. Key design drivers are maximum heating rate, duration of heating, total heat load, flight envelope and type of propulsion system, mission life requirements, and containment of liquid hydrogen. For hot-structures applications in the range from 600-1800°F, advanced alloys of titanium, titanium and nickel aluminides, and metal-matrix composites are leading candidates because of their high specific properties. For temperatures in excess of 2000°F carbon-carbon and ceramic-matrix composites are the most structurally efficient materials. This paper addresses the technology issues for light weight hot structures, gives brief assessments of the state of the art, presents selected highlights of current research, and identifies areas requiring additional development.

Hypersonic Vehicles↗

Materials and structures for hypersonic vehicles

The development of low-density materials with higher strength and stiffness, and more efficient engine and airframe structures is considered enabling technology for reusable hypersonic vehicles. Advanced structural concepts are required for minimum weight hot structures that will be fully reusable. Key design drivers are maximum heating rate, duration of heating, total heat load, flight envelope and type of propulsion system, mission life requirements, and containment of liquid hydrogen. For hot-structures applications in the range from 600-1800°F, advanced alloys of titanium, titanium and nickel aluminides, and metal-matrix composites are leading candidates because of their high specific properties. For temperatures in excess of 2000°F carbon-carbon and ceramic-matrix composites are the most structurally efficient materials. This paper addresses the technology issues for light weight hot structures, gives brief assessments of the state of the art, presents selected highlights of current research, and identifies areas requiring additional development.

Hypersonic Vehicles↗

Near Earth Asteroid Scout Solar Sail Engineering Development Unit Test Suite

The Near Earth Asteroid (NEA) Scout project is a 6U reconnaissance mission to investigate a near Earth asteroid utilizing an 86m(sub 2) solar sail as the primary propulsion system. This will be the largest solar sail NASA has launched to date. NEA Scout is currently manifested on the maiden voyage of the Space Launch System in 2018. In development of the solar sail subsystem, design challenges were identified and investigated for packaging within a 6U form factor and deployment in cis-lunar space. Analysis was able to capture understanding of thermal, stress, and dynamics of the stowed system as well as mature an integrated sail membrane model for deployed flight dynamics. Full scale system testing on the ground is the optimal way to demonstrate system robustness, repeatability, and overall performance on a compressed flight schedule. To physically test the system, the team developed a flight sized engineering development unit with design features as close to flight as possible. The test suite included ascent vent, random vibration, functional deployments, thermal vacuum, and full sail deployments. All of these tests contributed towards development of the final flight unit. This paper will address several of the design challenges and lessons learned from the NEA Scout solar sail subsystem engineering development unit. Testing on the component level all the way to the integrated subsystem level. From optical properties of the sail material to fold and spooling the single sail, the team has developed a robust deployment system for the solar sail. The team completed several deployments of the sail system in preparation for flight at half scale (4m) and full scale (6.8m): boom only, half scale sail deployment, and full scale sail deployment. This paper will also address expected and received test results from ascent vent, random vibration, and deployment tests.

Lockett, Tiffany Russell↗

Recent bed rest results and countermeasure development at NASA

Bedrest studies of normal subjects provide opportunities to understand physiologic responses to supine posture and inactivity. Furthermore, head-down tilt has been a valuable procedure to investigate adaptation to microgravity and development of countermeasures to maintain the health and well-being of humans during space-flight. Recent bedrest experiments at NASA have ranged in duration from a few hours to 17 weeks. Acute studies of 6 degrees head-down tilt indicate that elevation of capillary blood pressure from 28 to 34 mm Hg and increased capillary perfusion in tissues of the head cause facial and intracranial edema. Intracranial pressure increases from 2 to 17 mm Hg going from upright posture to 6 degrees head-down tilt. Microvessels of the head have a low capacity to constrict and diminish local perfusion. Elevation of blood and tissue fluid pressures/flow in the head may also explain the higher headward bone density associated with long-term head-down tilt. These mechanistic studies of head-down tilt, along with a better understanding of the relative stresses involved with upright posture and lower body negative pressure, have facilitated development of suitable physiologic countermeasures to maintain astronaut health during microgravity. Presently no exercise hardware is available to provide a blood pressure gradient from head to feet in space. However, recent studies in our laboratory suggest that treadmill exercise using a graded lower-body compression suit and 100 mmHg lower body negative pressure provides equivalent or greater physiologic stress than similar upright exercise on Earth. Therefore, exercise within a lower body negative pressure chamber may provide a cost-effective and simple countermeasure to maintain the cardiovascular and neuro-musculoskeletal systems of astronauts during long-duration flight.

manned↗

Nutritional Status Assessment (SMO 016E)

It has not been possible to assess nutritional status of crew members on the ISS during flight because blood and urine could not be collected during ISS missions. Postflight observations of alterations in nutritional status for several nutrients are troubling, and we require the ability to monitor the status of these nutrients during flight to determine if there is a specific impetus or timeframe for these changes. In addition to the monitoring of crew nutritional status during flight, in-flight sample collection would allow better assessment of countermeasure effectiveness. SMO 016E is also designed to expand the current medical requirement for nutritional assessment (MR016L) to include additional normative markers for assessing crew health and countermeasure effectiveness. Additional markers of bone metabolism will be measured to better monitor bone health and the effectiveness of countermeasures to prevent bone resorption. New markers of oxidative damage will be measured to better assess the type of oxidative insults that occur during space flight. The array of nutritional assessment parameters will be expanded to include parameters that will allow us to better understand changes in folate and vitamin B6 status, and related cardiovascular risk factors during and after flight. Additionally, stress hormones and hormones that affect bone and muscle metabolism will also be measured. This additional assessment will allow us to better monitor the health of crew members and make more accurate recommendations for their rehabilitation. Several nutritional assessment parameters are altered at landing, but it is not known how long these changes persist. We extended the current protocol to include an additional postflight blood and urine sample collection 30 days after landing. Data are being collected before, during, and after flight. These data will provide a complete survey of how nutritional status and related systems are affected by space flight. Analyzing the data will help us to define nutritional requirements for long-duration missions. This expanded set of measurements will also aid in the identification of nutritional countermeasures to counteract, for example, the deleterious effects of microgravity on bone and muscle and the effects of space radiation.

Smith, S. M.↗

RGB Imaging as a Tool to Monitor Indoor Crop Plant Production

Future crop production in space will require robust monitoring technologies that can optimize crop yield, reduce waste, and generate data for an automated plant growth design. Imaging has been suggested as a tool for measuring plant health, yet imaging systems for indoor crops have not been tested in spaceflight. Fortunately, RGB images of crop plants growing inside the Advanced Plant Habitat (APH) aboard the ISS have already been captured. In ground-based studies, the Kennedy Space Center (NASA, KSC) is collaborating with the United States Department of Agriculture (USDA ARS) to develop an imaging system for monitoring indoor crop plant health. In one study, we applied a drought stress to ‘Dragoon’ lettuce plants over a period of 14 days and captured RGB images in 24 h increments. Images were analyzed, and by applying a difference index, the images were able to be used to detect the drought stress in lettuce. This difference index was then applied to RGB images collected inside the APH ground unit for a pre-flight experiment growing ‘Outredgous’ lettuce under different substrate moisture conditions, and results showed that the RGB camera was capable of detecting drought stress inside the spaceflight plant growth hardware. These results suggest that RGB cameras already deployed to space may offer valuable information for monitoring plant production in extraterrestrial environments. This research was supported by NASA’s space biology program.

Rachel Tucker↗

Rescue Shuttle Flight Re-Entry: Controlling Astronaut Thermal Exposure

A rescue mission for the STS-125 Hubble Telescope Repair Mission requires reentry from space with 11 crew members aboard, exceeding past cabin thermal load experience and risking crew thermal stress potentially causing cognitive performance and physiological decrements. The space shuttle crew cabin air revitalization system (ARS) was designed to support a nominal crew complement of 4 to 7 crew and 10 persons in emergencies, all in a shirt-sleeve environment. Subsequent to the addition of full pressure suits with individual cooling units, the ARS cannot maintain a stable temperature in the crew cabin during reentry thermal loads. Bulk cabin thermal models, used for rescue mission planning and analysis of crew cabin air, were unable to accurately represent crew workstation values of air flow, carbon dioxide, and heat content for the middeck. Crew temperature models suggested significantly elevated core temperatures. Planning for an STS-400 potential rescue of seven stranded crew utilized computational fluid dynamics (CFD) models to demonstrate inhomogeneous cabin thermal properties and improve analysis compared to bulk models. In the absence of monitoring of crew temperature, heart rate, metabolic rate and incomplete engineering data on the performance of the integrated cooling garment/cooling unit (ICG/CU) at cabin temperatures above 75 degrees F, related systems & models were reevaluated and tests conducted with humans in the loop. Changes to the cabin ventilation, ICU placement, crew reentry suit-donning procedures, Orbiter Program wave-off policy and post-landing power down and crew extraction were adopted. A second CFD and core temperature model incorporated the proposed changes and confirmed satisfactory cabin temperature, improved air distribution, and estimated core temperatures within safe limits. CONCLUSIONS: These changes in equipment, in-flight and post-landing procedures, and policy were implemented for the STS-400 rescue shuttle & will be implemented in any future rescue flights from the International Space Station of stranded shuttle crews.

Gillis, David B.↗

Cardiovascular responses to repetitive exposure to hyper- and hypogravity states produced by parabolic flight

Physiologic changes to repetitive hyper- and hypogravity stresses occurring during eight to ten parabolas on NASA's KC-135 aircraft were studied. Hemodynamic responses in 11 subjects in 4 different postures (supine, standing, sitting, and semisupine Space Shuttle launch position) were determined using noninvasive impedance cardiography. Five seconds of heart rate, cardiac index, thoracic fluid index, stroke index, ejection velocity index, and ventricular ejection time data were averaged during four different gravity (g) states: 1.3g (before parabola onset); 1.9g (parabola entry); 0g (parabola peak); and 1.7g (parabola exit) for each subject. The standing position was associated with the largest changes in the cardiovascular response to hypo- and hypergravity. The thoracic fluid index did not indicate a headward redistribution during transition from a simulated launch position to weightlessness. Analysis of the eight to ten parabolas revealed that, in general, values obtained at 1.8g differed from 1.6g, 0g differed from 1.6 and 1.3g, and 1.6g differed from 1.3g. The factors of gravity, thoracic fluid index, and cardiac index exhibited significant differences that were most likely to occur between parabola 1 versus parabolas 6, 7, and 8, and parabola 2 versus parabolas 4 through 8. Only the parameter of thoracic fluid index exhibited significance for parabolas 3 versus parabolas 6 and 7.

Space Flight↗

Human Ecology in Space Flight, Volume I

Human ecology in space flight - cabin atmosphere, biological chemical regenerative systems, gravity and acceleration, and space radiation

SPACE CABIN ATMOSPHERE↗

Psychological considerations in future space missions

Issues affecting human psychological adjustments to long space missions are discussed. Noting that the Shuttle flight crewmembers will not have extensive flight qualification requirements, the effects of a more heterogeneous crew mixture than in early space flights is considered to create possibilities of social conflicts. Routine space flight will decrease the novelty of a formerly unique experience, and the necessity of providing personal space or other mechanisms for coping with crowded, permanently occupied space habitats is stressed. Women are noted to display more permeable personal space requirements. The desirability of planning leisure activities is reviewed, and psychological test results for female and male characteristics are cited to show that individuals with high scores in both traditionally male and female attributes are most capable of effective goal-oriented behavior and interpersonal relationships. Finally, it is shown that competitiveness is negatively correlated with the success of collaborative work and the social climate of an environment.

Helmreich, R. L.↗

Vectran Fiber Time-Dependent Behavior and Additional Static Loading Properties

Vectran HS appears from literature and testing to date to be an ideal upgrade from Kevlar braided cords for many long-term, static-loading applications such as tie-downs on solar arrays. Vectran is a liquid crystalline polymer and exhibits excellent tensile properties. The material has been touted as a zero creep product. Testing discussed in this report does not support this statement, though the creep is on the order of four times slower than with similar Kevlar 49 products. Previous work with Kevlar and new analysis of Vectran testing has led to a simple predictive model for Vectran at ambient conditions. The mean coefficient of thermal expansion (negative in this case) is similar to Kevlar 49, but is not linear. A positive transition in the curve occurs near 100 C. Out-gassing tests show that the material performs well within parameters for most space flight applications. Vectran also offers increased abrasion resistance, minimal moisture regain, and similar UV degradation. The effects of material construction appear to have a dramatic effect in stress relaxation for braided Vectran. To achieve the improved relaxation rate, upgrades must also examine alternate construction or preconditioning methods. This report recommends Vectran HS as a greatly improved replacement material for applications where time-dependent relaxation is a major factor.

Fette, Russell B.↗

Altered Innate and Lymphocytic Immunity in Murine Splenocytes Following Short-Duration Spaceflight

Immune dysregulation has been demonstrated following spaceflight of varying durations and limited in-flight studies indicate this phenomenon may persist during spaceflight. Causes may include microgravity, physiological stress, isolation, confinement and disrupted circadian rhythms. To further investigate the mechanisms associated with flight-associated immune changes, murine splenocytes immune parameters were assessed following 14 day space flight on Space Shuttle mission STS-135.

Crucian, Brian E.↗

Energy Beam Highways Through the Skies

The emergence of Energy Beam Flight Transportation Systems could dramatically change the way we travel in the 21st Century. A framework for formulating 'Highways of Light' and the top level architectures that invoke radically new Space Power Grid infrastructure, are introduced. Basically, such flight systems, hereafter called Lightcraft, would employ off-board energy beam sources (either laser or microwave) to energize on-board dependent 'motors' -- instead of the traditional autonomous 'engines' with their on-board energy sources (e.g., chemical fuels). Extreme reductions in vehicle dry mass appear feasible with the use of off-board power and a high degree of on-board artificial intelligence. Such vehicles may no longer need airports for refueling (since they require no propellant), and could possibly pick up travelers at their homes -- before motoring over to one of many local boost stations, for the flight out. With off-board power, hyper-energetic acceleration performance and boost-glide trajectories become feasible. Hypersonic MS airbreathing propulsion can enable boosts up to twice escape velocity, which will cut trip times to the moon down to 5.5 hours. The predominant technological, environmental and social factors that will result from such transportation systems will be stressed. This presentation first introduces the remote source siting options for the space power system infrastructure, and then provides three representative laser/microwave Lightcraft options (derived from historical Case Studies): i.e., 'Acorn', 'Toy Top', and 'Disc.' Next the gamut of combined-cycle engine options developed for these Lightcraft are examined -- to illuminate the 'emerging technologies' that must be harnessed to produce flight hardware. Needed proof-of concept experiments are identified, along with the Macro-Level Issues that can springboard these revolutionary concepts into hardware reality.

Myrabo, Leik N.↗

An Analytical Tool for Fracture Control

The structural integrity of critical NASA space flight hardware is ensured through a damage tolerance program which is dictated in the fracture control requirements. The goal of a fracture control program is to ensure proper material selection and control, control of working stress levels, use of fracture resistant design concepts, manufacturing process control, and the use of qualified inspection procedures. The damage tolerance philosophy assumes that all components contain initial defects and the damage accumulation process is thus entirely crack propagation. The service capability of fracture critical components is determined by analysis and/or test. A large percentage of NASA fracture critical hardware is certified by analysis only and it is therefore imperative that the analysis code utilized contain the latest state of the art technology. Not all space contractors and vendors are able to develop and maintain an analysis code which meets this requirement. A response to this need has been fulfilled by the development of the NASA/FLAGRO (NASGRO) fracture mechanics code here at the Johnson Space Center. The NASGRO code is based primarily in Linear Elastic Fracture Mechanics (LEFM) and is continually updated to meet to needs of the user community. Development assistance comes from other NASA centers as well as the European Space Agency (ESA). The code currently has a vast materials data file (over 350 different entries) which defines the material strength, fracture toughness, crack growth rate, and crack growth threshold. The code also allows for user defined inputs of data from other sources. The code also provides a large library of stress intensity factor solutions for numerous geometries and loading conditions.

Patin, Raymond M.↗

Treatment of Transient Pressure Events in Space Flight Pressurized Systems

The general physics of pressure transients, sources of pressure transients, and major factors influencing pressure transients are addressed. Mitigation strategies that aid in reducing the magnitude of pressure transients are discussed. Methods to characterize pressure transients and their effects on the structure are presented. Case studies illustrate the structural analysis methodology used to predict the structural dynamic response. The structural verification process involves formulating acceptance and qualification programs, which requires knowledge of the stress state. The maximum expected operating pressure (MEOP) is established such that the maximum stress produced by static pressure is equivalent to the maximum stress at the same critical location produced by the combined effect of steady state pressure and the magnitude of the pressure transient. A roadmap on how to treat transient pressures in the structural verification process of spaceflight pressurized systems (e.g., valves, lines, pressure vessels, pressurized structures) is presented.

Transient Pressure Events↗

Description, validation, and modification of the Guyton model for space-flight applications. Part A. Guyton model of circulatory, fluid and electrolyte control. Part B. Modification of the Guyton model for circulatory, fluid and electrolyte control

The mathematical model that has been a cornerstone for the systems analysis of space-flight physiological studies is the Guyton model describing circulatory, fluid and electrolyte regulation. The model and the modifications that are made to permit simulation and analysis of the stress of weightlessness are described.

Leonard, J. I.↗

Materials Control for Aerospace Applications

The distant future of mankind and the ultimate survivability of the human race, as it is known today, will depend on mans' ability to break earthly bonds and establish new territorial positions throughout the universe. Man must therefore be positioned to not only travel to, but also, to readily adapt to numerous and varying environments. For this mass migration across the galaxies nothing is as import to the human race as is NASA's future missions into Low Earth Orbit (LEO), to the moon, and/or Mars. These missions will form the building blocks to eternity for mankind. From these missions, NASA will develop the foundations for these building blocks based on sound engineering and scientific principles, both known and yet to be discovered. The integrity of the program will lead to development, tracking and control of the most basic elements of hardware production: That being development and control of applications of space flight materials. Choosing the right material for design purposes involves many considerations, such as governmental regulations associated with manufacturing operations, both safety of usage and of manufacturing, general material usage requirements, material longevity and performance requirements, material interfacing compatibility and material usage environments. Material performance is subject to environmental considerations in as much as a given material may perform exceptionally well at standard temperatures and pressures while performing poorly under non-standard conditions. These concerns may be found true for materials relative to the extreme temperatures and vacuum gradients of high altitude usage. The only way to assure that flight worthy materials are used in design is through testing. However, as with all testing, it requires both time on schedule and cost to the operation. One alternative to this high cost testing approach is to rely on a materials control system established by NASA. The NASA community relies on the MAPTIS materials control system founded at MSFC and supported by the other NASA Centers. This system is a data bank of all materials used in space flight operations. These materials are rated for several characteristics that are common concerns in high altitude or deep space usage: Odor, off gassing, material fluid compatibility, toxicity, corrosion susceptibility, stress corrosion susceptibility, etc.

Ferguson, Michael↗