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This report summarizes the results of the program conducted by Ultramet under SBIR Phase 2 Contract NAS3-25418. The objective of this program was to develop lightweight materials and processes for advanced high accuracy Space Solar Concentrators using rigidized foam for the substrate structure with an integral optical surface.
Engineers at the NASA Dryden Flight Research Facility (NASA-Dryden) have conducted two flight research programs with lightweight, low-power miniaturized instrumentation systems built around commercial data loggers. One program quantified the performance of a radio-controlled model airplane. The other program was a laminar boundary-layer transition experiment on a manned sailplane. NASA-Dryden personnel's flight experience with the miniaturized instrumentation systems used on these two programs is reported. The data loggers, the sensors, and the hardware and software developed to complete the systems are described. How the systems were used is described and the challenges encountered to make them work are covered. Examples of raw data and derived results are shown as well. Finally, future plans for these systems are discussed. For some flight research applications where miniaturized instrumentation is a requirement, the authors conclude that commercially available data loggers and sensors are viable alternatives. In fact, the data loggers and sensors make it possible to gather research-quality data in a timely and cost-effective manner.
The Taurus Lightweight Manned Spacecraft (LMS) was developed by students of the University of Maryland's Aerospace Engineering course in Space Vehicle Design. That course required students to design an Alternative Manned Spacecraft (AMS) to augment or replace the Space Transportation System and meet the following design requirements: (1) launch on the Taurus Booster being developed by Orbital Sciences Corporation; (2) 99.9 percent assured crew survival rate; (3) technology cutoff date of 1 Jan. 1991; (4) compatibility with current space administration infrastructure; and (5) first flight by May 1995. The Taurus LMS design meets the above requirements and represents an initial step toward larger and more complex spacecraft. The Taurus LMS has a very limited application when compared to the space shuttle, but it demonstrates that the U.S. can have a safe, reliable, and low-cost space system. The Taurus LMS is a short mission duration spacecraft designed to place one man into low Earth orbit (LEO). The driving factor for this design was the low payload carrying capabilities of the Taurus Booster - 1300 kg to a 300-km orbit. The Taurus LMS design is divided into six major design sections. The Human Factors section deals with the problems of life support and spacecraft cooling. The Propulsion section contains the Abort System, the Orbital Maneuvering System (OMS), the Reaction Control System (RCS), and Power Generation. The thermal protection systems and spacecraft structure are contained in the Structures section. The Avionics section includes Navigation, Attitude Determination, Data Processing, Communication systems, and Sensors. The Mission Analysis section was responsible for ground processing and spacecraft astrodynamics. The Systems Integration Section pulled the above sections together into one spacecraft, and addressed costing and reliability.
Engineers at the NASA Dryden Flight Research Facility (NASA-Dryden) have conducted two flight research programs with lightweight, low-power miniaturized instrumentation systems built around commercial data loggers. One program quantified the performance of a radio-controlled model airplane. The other program was a laminar boundary-layer transition experiment on a manned sailplane. The purpose of this paper is to report NASA-Dryden personnel's flight experience with the miniaturized instrumentation systems used on these two programs. The paper will describe the data loggers, the sensors, and the hardware and software developed to complete the systems. The paper also describes how the systems were used and covers the challenges encountered to make them work. Examples of raw data and derived results will be shown as well. Finally, future plans for these systems will be discussed.
A critical technology area for lightweight SiC-based telescope systems is the structural integrity and thermal stability over spaceborne environmental launch and thermal operating conditions. Note, it is highly desirable to have an inherently athermal design of both SiC mirrors and structure. SSG has developed an 8 inch diameter SiC telescope system for brassboard level optical and thermal testing. The brassboard telescope has demonstrated less than 0.2 waves P-V in the visible wavefront change over +50 C to -200 C temperature range. SSG has also fabricated a SiC truss structural assembly and successfully qualified this hardware at environmental levels greater than 3 times higher than normal Delta, Titan, and ARIES launch loads. SSG is currently developing two SiC telescopes; an 20 cm diameter off-axis 3 mirror re-imaging and a 60 cm aperture on-axis 3 mirror re-imager. Both hardware developments will be tested to flight level environmental, optical, and thermal specifications.
The flexible parallel link mechanism is designed for increased rigidity to sustain the buckling when it carries a heavy payload. Compared to a one link flexible manipulator, a two link flexible manipulator, especially the flexible parallel mechanism, has more complicated characteristics in dynamics and control. The objective of this research is the theoretical analysis and the experimental verification of dynamics and control of a two link flexible manipulator with a flexible parallel link mechanism. Nonlinear equations of motion of the lightweight manipulator are derived by the Lagrangian method in symbolic form to better understand the structure of the dynamic model. A manipulator with a flexible parallel link mechanism is a constrained dynamic system whose equations are sensitive to numerical integration error. This constrained system is solved using singular value decomposition of the constraint Jacobian matrix. The discrepancies between the analytical model and the experiment are explained using a simplified and a detailed finite element model. The step response of the analytical model and the TREETOPS model match each other well. The nonlinear dynamics is studied using a sinusoidal excitation. The actuator dynamic effect on a flexible robot was investigated. The effects are explained by the root loci and the Bode plot theoretically and experimentally. For the base performance for the advanced control scheme, a simple decoupled feedback scheme is applied.
This report discusses application of a new lightweight carbon-carbon (C-C) space radiator technology developed under the NASA Civil-Space Technology Initiative (CSTI) High Capacity Power Program to a 20 kWe lunar based power system. This system comprises a nuclear (SP-100 derivative) heat source, a Closed Brayton Cycle (CBC) power conversion unit with heat rejection by means of a plane radiator. The new radiator concept is based on a C-C composite heat pipe with integrally woven fins and a thin walled metallic liner for containment of the working fluid. Using measured areal specific mass values (1.5 kg/m2) for flat plate radiators, comparative CBC power system mass and performance calculations show significant advantages if conventional heat pipes for space radiators are replaced by the new C-C heat pipe technology.
Lightweight ceramic ablators (LCA's) were recently developed at Ames to investigate the use of low density fibrous substrates and organic resins as high temperature, high strength ablative heat shields. Unlike the traditional ablators, LCA's use porous ceramic/carbon fiber matrices as substrates for structural support, and polymeric resins as fillers. Several substrates and resins were selected for the initial studies, and the best performing candidates were further characterized. Three arcjet tests were conducted to determine the LCA's thermal performance and ablation characteristics in a high enthalpy, hypersonic flow environment. Mass loss and recession measurements were obtained for each sample at post test, and the recession rates were determined from high speed motion films. Surface temperatures were also obtained from optical pyrometers.
An experiment conducted in the framework of a NASA In-Space Technology Experiments Program based on a concept of inflatable deployable structures is described. The concept utilizes very low inflation pressure to maintain the required geometry on orbit and gravity-induced deflection of the structure precludes any meaningful ground-based demonstrations of functions performance. The experiment is aimed at validating and characterizing the mechanical functional performance of a 14-m-diameter inflatable deployable reflector antenna structure in the orbital operational environment. Results of the experiment are expected to significantly reduce the user risk associated with using large space-deployable antennas by demonstrating the functional performance of a concept that meets the criteria for low-cost, lightweight, and highly reliable space-deployable structures.
The objective of this task is to develop the fluted core flexible blankets, also referred to as the Tailorable Advanced Blanket Insulation (TABI), to a technology readiness level (TRL) of 6. This task is one of the six tasks under TA 3, Lightweight Durable TPS study, of the Single Stage to Orbit (SSTO) program. The purpose of this task is to develop a durable and low maintenance flexible TPS blanket material to be implemented on the SSTO vehicle.
This report discusses development and proof-of-concept testing of a new lightweight carbon-carbon (C-C) space radiator heat pipe, carried out under the NASA Civil Space Technology Initiative (CSTI) High Capacity Power Program. The prototype heat pipe, equipped with a niobium-zirconium foil liner, was filled with potassium working fluid and tested for 11 hours, including startup from ambient temperature with the working fluid initially in the frozen state to near 700 K condenser temperature. Steady-state heat pipe input power during testing was facility limited to about 300 watts. Post test inspection showed the heat pipe to be in excellent condition after eight thermal cycles from ambient to steady-state operating temperature. Utilization of other liner materials and working fluids would greatly extend the spectrum of service temperatures for this technology, with potential applications ranging from small spacecraft heat rejection to aircraft and terrestrial uses.
Because the 2195 aluminum-lithium material of the super lightweight external tank (SLWT ET) has a lower toughness than the 2219 aluminum used in previous ET's, careful attention must be paid to stress concentrations. This report details the analysis performed on some of the stress concentrations in the orthogrid panels of the liquid hydrogen tank.
Engineers at the NASA Dryden Flight Research Facility (NASA-Dryden) have conducted two flight research programs with lightweight, low-power miniaturized instrumentation systems built around commercial data loggers. One program quantified the performance of a radio-controlled model airplane. The other program was a laminar boundary-layer transition experiment on a manned sailplane. The purpose of this article is to report NASA-Dryden personnel's flight experience with the miniaturized instrumentation systems used on these two programs. This article will describe the data loggers, the sensors, and the hardware and software developed to complete the systems. It also describes how the systems were used and covers the challenges encountered to make them work. Examples of raw data and derived results will be shown as well. For some flight research applications where miniaturized instrumentation is a requirement, the authors conclude that commercially available data loggers and sensors are viable alternatives. In fact, the data loggers and sensors make it possible to gather research-quality data in a timely and cost-effective manner.
Lightweight, flexible sheets containing arrays of stacked solar photovoltaic cells developed to supply electric power aboard spacecraft. Solar batteries satisfying stringent requirements for operation in outer space also adaptable to terrestrial environment. Attractive for use as long-lived, portable photovoltaic power sources. Cells based on amorphous silicon which offers potential for order-of-magnitude increases in power per unit weight, power per unit volume, and endurance in presence of ionizing radiation.
Report presents results of study for proposed lightweight composite material alternative to present semimonocoque aluminum intertank structure for advanced launch vehicles. Proposed structure integrated assembly of sandwich panels made of laminated epoxy-matrix/carbon-fiber skins, and aluminum honeycomb core.
Lightweight cathodes for rechargeable nickel-based electrochemical cells undergoing development. In cathodes, mats of nickel fibers are substrates providing structural support of, and electrical contact with, active cathode material. Offers specific energies greater than sintered nickel plaque cathodes. Electrodes used in rechargeable batteries for applications in which weight major concern, including laptop computers, cellular phones, flashlights, soldiers' backpacks, and electric vehicles.
This paper describes the design, development, and qualification of a new lightweight and compact Antenna Pointing Mechanism (APM). The APM was specially designed to meet the stringent mass, envelope, and environmental requirements of OFFEQ experimental satellite. During the development phase, some problems were encountered with the brushless DC motors, slip ring contact resistance, and bearing drag torque. All of these problems were resolved, and two APM units have been operating successfully in orbit since April, 1995.
The cancellation of the Advanced Solid Rocket Booster Project and the earth-to-orbit payload requirements for the Space Station dictated that the National Aeronautics and Space Administration (NASA) look at performance enhancements from all Space Transportation System (STS) elements (Orbiter Project, Space Shuttle Main Engine Project, External Tank Project, Solid Rocket Motor Project, & Solid Rocket Booster Project). The manifest for launching of Space Station components indicated that an additional 12-13000 pound lift capability was required on 10 missions and 15-20,000 pound additional lift capability is required on two missions. Trade studies conducted by all STS elements indicate that by deleting the parachute Recovery System (and associated hardware) from the Solid Rocket Boosters (SRBS) and going to a lightweight External Tank (ET) the 20,000 pound additional lift capability can be realized for the two missions. The deletion of the parachute Recovery System means the loss of four SRBs and this option is two expensive (loss of reusable hardware) to be used on the other 10 Space Station missions. Accordingly, each STS element looked at potential methods of weight savings, increased performance, etc. As the SRB and ET projects are non-propulsive (i.e. does not have launch thrust elements) their only contribution to overall payload enhancement can be achieved by the saving of weight while maintaining adequate safety factors and margins. The enhancement factor for the SRB project is 1:10. That is for each 10 pounds saved on the two SRBS; approximately 1 additional pound of payload in the orbiter bay can be placed into orbit. The SRB project decided early that the SRB recovery system was a prime candidate for weight reduction as it was designed in the early 1970s and weight optimization had never been a primary criteria.