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Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗

Methods for Precision Studies of Neutrino Interactions

Accelerator neutrino oscillation experiments provide a sensitive way to investigatea number of major open questions in neutrino physics. To achieve precision neutrinooscillation measurements, we need a good understanding of key aspects of the experiments,such as the detection technologies used and neutrino interactions at few-GeV energies.The MicroBooNE experiment has advanced the development of technologies for LArTPCs.An ultra-violet laser system was introduced to MicroBooNE in order to measure theelectric field in situ, which plays a central role in the formation of charge and lightsignals in LArTPCs. This thesis describes the setup and operation of the laser system. Ideveloped a general methodology to measure the electric field and the consequent spatialdistortion in LArTPCs, which supports precision measurements in accelerator neutrinooscillation experiments. In MicroBooNE, the measured electric field distortions are upto 15 ± 3 % with respect to the nominal value, and the measured spatial distortions areup to 15 ± 3 cm. The result of the electric field measurement is applied to the detectorsimulation and the event reconstruction, which leads to a better detector characterizationfor neutrino analyses. A significant concern for measurements of neutrino interactions ismodel dependence, as the currently available models are not sufficient for describing thepicture of neutrino interacting at few-GeV energies. In this thesis, I developed a detailedstrategy for a model-independent cross-section measurement at low energy transfers,where the available model predictions do not agree with the inclusive measurementsfrom multiple experiments. A likelihood fit technique for cross-section extraction isrealized in an accelerator neutrino experiment using a LArTPC for the first time. Thetreatment of systematic uncertainties developed in this thesis is generally applicable foranalyses using similar fitting techniques. This neutrino interaction study at low energytransfers provides a probe to the poorly understood region of neutrino cross sections. Themeasurement scheme developed here aims to guide future model-independent cross-sectionmeasurements, particularly for neutrino experiments using LArTPCs.

Chen, Yifan↗

Use of Polarization Lidar for Investigation of Meteorological Formations

This paper presents the results of theoretical and experimental, investigations of depolarization characteristics of different meteorological formations. Experimental investigations are carried out with a monostatic lidar. The ruby laser radiation is polarized in a vertical plane. The radiation reflected is accepted by a lens system of 150 rom in diameter and a viewing angle of 12' and further it is divided by Wollaston prism into the components polarized orthogonally. In this case the principal plane of the prism is exposed parallel with the laser polarization plane. Investigations show the degree of radiation polarization, reflected from water clouds, to be changed within 1/0.7 (seldom up to 0.6) depending on their density. In most cases a signal reflected from the cloud leading edge is polarized completely. The time shift is observed between polarized and crosspolarized components of a Fignal, reflected from a cloud, depending on the density of a meteorological object. While penetrating into the cloud depth a degree of polarization decreases up to 0.8-0.7, and the character of this decrease is different for various types of clouds. For crystal clouds the shift between the components of the reflected signal is not observed and the magnitude of polarization degree amounts to 0.1/0.3 in comparison with water clouds. The polarization degree of radiation reflected by fog is not less than 0.6, and that in the rains of average intensity (about 5 mm/h) is always about 1. The authors have suggested an algorithm of numerical solution of nonstationary transfer equation in the vector form to forecast the influence of multiple scattering effects on polarization characteristics of the lidar light signal. The method of statistical simulation (Monte-Carlo technique) forms the basis of the algorithm. Numerical estimates obtained for a model of stratocumulus at lambda = 0.6943 microns under boundary conditions close to the conditions of natural experiment being discussed proved to be in a good agreement with the results of observation. Specifically, Fig. 1 shows the profiles of polarization (p) versus depth (L) of the following drop formations: fog (curve 1) with horizontal meteorological visibility of 4 km two stratocumulus at a height of 1100 m with the attenuation factors delta = 0.01m(exp -1) (curve 2) and delta = 0.05m(exp -1) (curve 3). Curve 3 shows the results of numerical estimates and the value of their statistical error.

Balin, Yu. S.↗

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗

NASA Technologies that Benefit Society

Applications developed on Earth of technology needed for space flight have produced thousands of spinoffs that contribute to improving national security, the economy, productivity and lifestyle. Over the course of it s history, NASA has nurtured partnerships with the private sector to facilitate the transfer of NASA-developed technology. For every dollar spent on research and development in the space program, it receives back $7 back in the form of corporate and personal income taxes from increased jobs and economic growth. A new technology, known as Liquid-metal alloy, is the result of a project funded by NASA s Jet Propulsion Lab. The unique technology is a blend of titanium, zirconium, nickel, copper and beryllium that achieves a strength greater than titanium. NASA plans to use this metal in the construction of a drill that will help for the search of water beneath the surface of Mars. Many other applications include opportunities in aerospace, defense, military, automotive, medical instrumentation and sporting goods.Developed in the 1980 s, the original Sun Tigers Inc sunlight-filtering lens has withstood the test of time. This technology was first reported in 1987 by NASA s JPL. Two scientists from JPL were later tasked with studying the harmful effects of radiation produced during laser and welding work. They came up with a transparent welding curtain that absorbs, filters and scatters light to maximize protection of human eyes. The two scientists then began doing business as Eagle Eye Optics. Each pair of sunglasses comes complete with ultraviolet protection, dual layer scratch resistant coating, polarized filters for maximum protection against glare and high visual clarity. Sufficient evidence shows that damage to the eye, especially to the retina, starts much earlier than most people realize. Sun filtering sunglasses are important. Winglets seen at the tips of airplane wings are among aviations most visible fuel-saving, performance enhancing technology. Aerodynamics centers on two majors forces-lift and drag. Lift enables the plane to fly and drag is the resistance encountered while moving through the air. The air coming off the end of a standard wing, in a vortex, causes significant drag and turbulence, forcing the spacing between takeoffs. A Langley engineer for NASA published finding in 1976 and verified by test in 1977 that winglets produce a 7 percent increase in lift-drag ratio with a 20 percent decrease in drag. This configuration reduces emissions, allows for greater range and carry more payload and the planes fly more quietly. Winglet technology has saved 2 billion gallons of jet fuel worldwide in 2010. Aerogel represents what technology experts believe to be the best insulation material ever invented. It is very light, flexible and can withstand temperatures of minus 3000 deg F. Aerogel products will be found in everything from clothing, to building insulation to space vehicles. Corpo Nove incorporated the Spaceloft version of the NASA-developed aerogel material into this jacket which was test during an Antarctic expedition.

Griffin, Amanda↗

Biospheric effects of a large extraterrestrial impact: Case study of the cretaceous/tertiary boundary crater

The Chicxulub impact crater, buried in the Yucatan carbonate platform in Mexico, is the site of the impact purported to have caused mass extinctions at the Cretaceous/Tertiary (K/T) boundary. A recently discovered Chicxulub ejecta deposit in Belize contains evidence of carbonate vaporization and precipitation from the vapor plume. Sulfate clasts are almost absent in the Belize ejecta, but are abundant in the coarse ejecta near the crater rim, hwich may reflect the greater abundance of sulfates deep in the target section. The absence of sulfate precipitates in Belize may indicate that most of the vaporized sulfur was deposited in the upper atmosphere. Hydrocode modeling of the impact indicates that between 0.4 to 7.0 x 10(exp 17) g of sulfur were vaporized by the impact in sulfates. Laser experiments indicate that SO2, SO3, and SO4 are produced, and that complex chemical reactions between plume constituents occur during condensation. The sulfur released as SO3 or SO4 converted rapidly into H2HO4 aerosol. A radiative transfer model coupled with a model of coagulation predicts that the aerosol prolonged the initial blackout period caused by impact dust only if it contained impurities. The sulfur released as SO2 converted to aerosol slowly due to the rate limiting oxidation of SO2. Radiative transfer calculations combined with rates of acid production, coagulation, and diffusion indicate that solar transmission was reduced to 10-20 percent of normal for a period of 8-13 years. This reduction produced a climate forcing (cooling) of -300 Wm(exp -2), which far exceeded the +8 Wm(exp -2) greenhouse warming caused by the CO2 released through the vaporization of carbonates, and therefore produced a decade of freezing and near-freezing temperatures. Several decades of moderate warming followed the decade of severe cooling due to the long residence time of CO2. The prolonged impact winter may have been a major cause of the K/T extinctions.

Pope, Kevin O.↗

Magnetized ICF implosions: Scaling of temperature and yield enhancement

This work investigates the impact of an applied magnetic field on the yield and hot-spot temperature of inertial confinement fusion implosions. A scaling of temperature amplification due to magnetization is shown to be in agreement with unperturbed two-dimensional (2D) extended-magnetohydrodynamic simulations. A perfectly spherical hot-spot with an axial magnetic field is predicted to have a maximum temperature amplification of 37%. However, elongation of the hot-spot along field lines raises this value by decreasing the hot-spot surface area along magnetic field lines. A scaling for yield amplification predicts that a magnetic field has the greatest benefit for low-temperature implosions; this is in agreement with simplified 1D simulations, but not 2D simulations where the hot-spot pressure can be significantly reduced by heat-flow anisotropy. Simulations including a P2 drive asymmetry then show that the magnetized yield is a maximum when the capsule drive corrects the hot-spot shape to be round at neutron bang time. An applied magnetic field is also found to be most beneficial for implosions that are more highly perturbed, exceeding the theoretical yield enhancement for symmetric hot-spots. Increasing the magnetic field strength past the value required to magnetize the electrons is beneficial due to the additional suppression of perturbations by magnetic tension.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Time-Resolved Probing of the Iodobenzene C-Band Using XUV-Induced Electron Transfer Dynamics

Time-resolved extreme ultraviolet spectroscopy was used to investigate photodissociation within the iodobenzene C-band. The carbon–iodine bond of iodobenzene was photolyzed at 200 nm, and the ensuing dynamics were probed at 10.3 nm (120 eV) over a 4 ps range. Two product channels were observed and subsequently isolated by using a global fitting method. Their onset times and energetics were assigned to distinct electron transfer dynamics initiated following site-selective ionization of the iodine photoproducts, enabling the electronic states of the phenyl fragments to be identified using a classical over-the-barrier model for electron transfer. In combination with previous theoretical work, this allowed the corresponding neutral photochemistry to be assigned to (1) dissociation via the 7B2, 8A2, and 8B1 states to give ground-state phenyl, Ph(X), and spin–orbit excited iodine and (2) dissociation through the 7A1 and 8B2 states to give excited-state phenyl, Ph(A), and ground-state iodine. The branching ratio was determined to be 87 ± 4% Ph(X) and 13 ± 4% Ph(A). Similarly, the corresponding amount of energy deposited into the internal phenyl modes in these channels was determined to be 44 ± 10 and 65 ± 21%, respectively, and upper bounds to the channel rise times were found to be 114 ± 6 and 310 ± 60 fs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Cloud Thickness from Diffusion of Lidar Pulses in Clouds

Measurements of the distribution of reflected light from a laser beam incident on an aqueous suspension of particles or "cloud" with known thickness and particle size distribution are reported. The distribution is referred to as the "cloud radiative Green's function", G. In the diffusion domain, G is sensitive to cloud thickness, allowing that important quantity to be retrieved. The goal of the laboratory simulation is to provide preliminary estimates of sensitivity of G to cloud thickness,for use in the optimal design of an offbeam Lidar instrument for remote sensing of cloud thickness (THOR, Thickness from Offbeam Returns). These clouds of polystyrene microspheres suspended in water are analogous to real clouds of water droplets suspended in air. The microsphere size distribution is roughly lognormal, from 0.5 microns to 25 microns, similar to real clouds. Density of suspended spheres is adjusted so mean-free-path of visible photons is about 10 cm, approximately 1000 times smaller than in real clouds. The light source is a ND:YAG laser at 530 nm. Detectors are flux and photon-counting Photomultiplier Tube (PMTS), with a glass probe for precise positioning. A Labview 5 VI controls positioning, and data acquisition, via an NI Motion Control board connected to a stepper motor driving an Edmund linear slider, and a 16-channel 16-bit NI-DAQ board. The stepper motor is accurate to 10 microns, and step size is selectable from the VI software. Far from the incident beam, the rate of exponential increase as the direction of the incident beam is approached scales as expected from diffusion theory, linearly with the cloud thickness, and inversely as the square root of the reduced optical thickness, and is independent of particle size. Near the beam the signal begins to increase faster than exponential, due to single and low-order scattering near the backward direction, and here the distribution depends on particle size. Results are being used to verify 3D Monte Carlo radiative transfer simulations, used to estimate signal-to-noise ratios for remotely sensed off beam returns, for both homogeneous and inhomogeneous clouds. Signal-to-noise estimates show that unfiltered observations are straight forward at night, while narrow band pass filters are being studied for day.

Cahalan, Robert F.↗

Solidification cracking of laser melted commercial-purity tungsten

The high melting temperature of tungsten (W) makes it an attractive candidate for energy generation applications; however, its use is limited by its poor ductility at low temperatures. This limitation affects even melt-based additive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB), with as-fabricated pure W exhibiting both longitudinal and transverse cracks. Metallurgical and processing factors that affect these cracks are still being explored. This work utilizes powderless single-tracks on pure W plates made over a range of power and velocity combinations in three unique PBF-LB setups: one with flowing argon, one with continuous vacuum, and an in situ high-speed synchrotron X-ray radiography setup. Each had different oxygen activities in their build environments. Longitudinal cracks with oxides appearing to exude from the crack were found for tracks deposited in a build environment with argon shield gas, while no such cracks were observed for builds conducted in vacuum. A calculation showed that direct oxygen ingress into the melt pool from the build environment is negligible when argon shield gas is present. Thus, incorporation of spatter is a likely mechanism for oxygen ingress into the melt pool. Radiography showed extensive keyholing, spatter generation, and crack formation at keyhole porosity. A heat transfer calculation showed the crack formation time was consistent with cooling below its ductile-to-brittle transition (DBT) temperature. This work identifies solidification cracking as a feasible mechanism in pure W beyond the well-known DBT related cracking.

Materials science↗

The Uranium-Containing and Thorium-Containing Anions Studied by Photoelectron Spectroscopy

An in-depth knowledge of actinide chemistry is fundamental to many aspects of nuclear science and technology, including the synthesis and processing of materials and the remediation of waste disposal sites. Among the actinides, the chemical bonding behaviors of actinium and thorium resemble those of the transition metals; the 5f-electrons of protactinium, uranium, neptunium, and plutonium often play important roles in their bonding; and among the still heavier elements, their bonding tends to mimic the lanthanide elements in terms of electron shielding and their f-electron contributions. Bonding that involves 5f-electrons, however, is especially important, in part because of the significance of uranium and plutonium, but also because these elements are among the few where f-electron participation in bonding is relatively common. This work focused on studying uranium-containing and thorium-containing anions in the gas phase using negative ion photoelectron spectroscopy. Since this technique directly probed valence electrons, it was uniquely positioned to address open questions regarding molecular bonding and electron configurations. A particularly important issue concerned how bonding in actinide-containing molecules was affected by modifications to their actinide atoms’ environment, i.e., due to their interaction with ligands. A closely related question was how actinide atoms’ suborbitals were qualitatively reordered and their energies quantitatively shifted as a result of their ligated environments. These were especially relevant issues in regard to uranium due to it having multiple possible oxidation states (OS) and the potential for 5f electron participation in bonding. The effects of ligands on oxidation states and 5f-orbital energies in uranium bonding was expected to be pronounced. Both ligands and excess electrons were seen as probes of actinide atoms within actinide-containing molecules. Our strategy for advancing knowledge of chemical bonding in the actinide-containing species utilized the synergy between experiments and theory, where in some cases experimental results validated theory and where in others computational results assisted in interpreting experiments. Calculations on actinide systems are terrifically challenging due to large spin-orbit interactions, relativistic effects, and just the sheer number of electrons involved. Even in the simplest species, e.g., U and U2, the most sophisticated, modern calculations carried out by the most experienced theorists often only approximate experimentally-measured values, such as electron affinities. For theory to provide confident predictions that can be used to solve real problems it needed an iterative and ultimately corrective mechanism by which its methods can develop further. Experiments can be used to identify when theory has failed; whereupon the subsequent process of using the experiment-theory interplay can be used to find the cause of the failure. Upon fixing it in one case, different test species can be proposed and studied by the experiment-theory combination to determine whether the problem has been corrected. Thus, experiments not only measure the values of molecular properties, they also provide navigational 3 beacons that keep computations off the reefs in an otherwise dark sea with few reference points. Experimental measurements in the actinide field are not only important, they are in actuality essential to computational progress. While it was not always possible to compare the theoreticallydetermined quantity of interest directly with the same experimentally-measured observable, it was usually possible to compare consequential properties that are both calculable and measurable. In the work completed here electron affinities and electronic state spacings were often sensitive consequential parameters. Reasonable agreement between measured and computational values signaled that a calculation that was very likely to be on-track. We had established collaborative relationships with five computational groups, all of which have expertise in computational actinide chemistry. Their PI’s are L. Cheng, D. Dixon, L. Gagliardi, K. Peterson, and B. Vlaisavljevich. Our close interaction with our theory partners led to us suggesting systems to them and them to us. This reciprocal interaction between our experimental and their computational results was among the most important strengths of this work and was a thread woven throughout. Even though anion photoelectron spectroscopic studies are conducted on anions, much of the information that they provide, pertains to the electronic structure of the neutral counterparts of those anions; among these are electron affinities and electronically excited state spacings. Our experimental tools included several specialized ion sources for forming the anionic species of interest, a mass spectrometer for identifying and mass-selecting them, and an anion photoelectron spectrometer for determining their electron affinities (EA) and characterizing the electronic states of the selected anions’ neutral counterparts. Anion photoelectron spectroscopy is conducted by crossing a mass-selected beam of anions with a fixed-frequency laser beam and energy-analyzing the resultant photodetached electrons. The photodetachment process is governed by the energyconserving relationship: hν = EBE + EKE, where hν is the photon’s energy, EBE is the electron binding (photodetachment transition) energy, and EKE is the electron’s kinetic energy. In our apparatus mass-selection is accomplished via time-of-flight mass spectrometry (TOF-MS), electron energy analysis is achieved with either a magnetic bottle or by velocity mapped imaging. Photodetachment of electrons from anions is implemented via either Nd:YAG or excimer lasers. The photodetachment transition energy, i.e., the EBE, between the ground vibrational and electronic state of an anion and the ground vibrational and electronic state of that anion’s neutral counterpart is the adiabatic electron affinity (EA) of that neutral molecule. Likewise, photodetachment transitions between the ground vibrational and electronic state of an anion and the various electronically-excited states of that anion’s corresponding neutral map the electronic spectrum of that neutral species, i.e., the spectral spacings in the photoelectron spectrum are a mirror image of the neutral’s electronic spectrum. It was, of course, crucial to be able to form the anionic species of interest. There, we had a particularly broad field of anion sources from which to choose. These included several variants of pulsed laser vaporization (LV), laser photoemission, infrared desorption plus photoemission, pulsed arc discharge (PACIS), electrospray ionization (ESI), and Rydberg electron transfer (RET). Each of these anion sources were readily combined with, i.e., connected to, the anion photoelectron spectroscopic portion of our apparatus as described above. Among the sources that utilize lasers, visible light for LV sources as well as IR for desorption sources are provided by Nd:YAG lasers. Ultraviolet photons are provided by both Nd:YAG and excimer lasers, whereas the excitation wavelengths for RET experiments come from two Nd:YAG-pumped dye lasers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Utilizing the ISS Mission as a Testbed to Develop Cognitive Communications Systems

The ISS provides an excellent opportunity for pioneering artificial intelligence software to meet the challenges of real-time communications (comm) link management. This opportunity empowers the ISS Program to forge a testbed for developing cognitive communications systems for the benefit of the ISS mission, manned Low Earth Orbit (LEO) science programs and future planetary exploration programs. In November, 1998, the Flight Operations Directorate (FOD) started the ISS Antenna Manager (IAM) project to develop a single processor supporting multiple comm satellite tracking for two different antenna systems. Further, the processor was developed to be highly adaptable as it supported the ISS mission through all assembly stages. The ISS mission mandated communications specialists with complete knowledge of when the ISS was about to lose or gain comm link service. The current specialty mandated cognizance of large sun-tracking solar arrays and thermal management panels in addition to the highly-dynamic satellite service schedules and rise/set tables. This mission requirement makes the ISS the ideal communications management analogue for future LEO space station and long-duration planetary exploration missions. Future missions, with their precision-pointed, dynamic, laser-based comm links, require complete autonomy for managing high-data rate communications systems. Development of cognitive communications management systems that permit any crew member or payload science specialist, regardless of experience level, to control communications is one of the greater benefits the ISS can offer new space exploration programs. The IAM project met a new mission requirement never previously levied against US space-born communications systems management: process and display the orientation of large solar arrays and thermal control panels based on real-time joint angle telemetry. However, IAM leaves the actual communications availability assessment to human judgment, which introduces unwanted variability because each specialist has a different core of experience with comm link performance. Because the ISS utilizes two different frequency bands, dynamic structure can be occasionally translucent at one frequency while it can completely interdict service at the other frequency. The impact of articulating structure on the comm link can depend on its orientation at the time it impinges on the link. It can become easy for a human specialist to cross-associate experience at one frequency with experience at the other frequency. Additionally, the specialist's experience is incremental, occurring one nine-hour shift at a time. Only the IAM processor experiences the complete 24x7x365 communications link performance for both communications links but, it has no "learning capability." If the IAM processor could be endowed with a cognitive ability to remember past structure-induced comm link outages, based on its knowledge of the ISS position, attitude, communications gear, array joint angles and tracking accuracy, it could convey such experience to the human operator. It could also use its learned communications link behaviors to accurately convey the availability of future communications sessions. Further, the tool could remember how accurately or inaccurately it predicted availability and correct future predictions based on past performance. The IAM tool could learn frequency-specific impacts due to spacecraft structures and pass that information along as "experience." Such development would provide a single artificial intelligence processor that could provide two different experience bases. If it also "knew" the satellite service schedule, it could distinguish structure blockage from schedule or planet blockage and then quickly switch to another satellite. Alternatively, just as a human operator could judge, a cognizant comm system based on the IAM model could "know" that the blockage is not going to last very long and continue tracking a comm satellite, waiting for it to track away from structure. Ultimately, once this capability was fully developed and tested in the Mission Control Center, it could be transferred on-orbit to support development of operations concepts that include more advanced cognitive communications systems. Future applications of this capability are easily foreseen because even more dynamic satellite constellations with more nodes and greater capability are coming. Currently, the ISS fully employs a 300 million bit-per-second (Mbps) return link for harvesting payload science. In the coming eighteen months, it will step up to 600 Mbps. Already there is talk of a 1.2 billion bit-per-second (Gbps) upgrade for the ISS and laser comm links have already been tested from the ISS. Every data rate upgrade mandates more complicated and sensitive communications equipment which implies greater expertise invested in the human operator. Future on-orbit cognizant comm systems will be needed to meet greater performance demands aboard larger, far more complicated spacecraft. In the LEO environment, the old-style one-satellite-per-spacecraft operations concept will give way to a new concept of a single customer spacecraft simultaneously using multiple comm satellites. Much more highly-dynamic manned LEO missions with decades of crew members potentially increase the demand for communications link performance. A cognizant on-board communications system will meet advanced communications demands from future LEO missions and future planetary missions. The ISS has fledgling components of future exploration programs, both LEO and planetary. Further, the Flight Operations Directorate, through the IAM project, has already begun to develop a communications management system that attempts to solve advanced problems ideally represented by dynamic structure impacting scheduled satellite service. With an earnest project to integrate artificial intelligence into the IAM processor, the ISS Program could develop a cognizant communications system that could be adapted and transferred to future on-orbit avionics designs.

Jackson, Dan↗

Utilizing the ISS Mission as a Testbed to Develop Cognitive Communications Systems

The ISS provides an excellent opportunity for pioneering artificial intelligence software to meet the challenges of real-time communications (comm) link management. This opportunity empowers the ISS Program to forge a testbed for developing cognitive communications systems for the benefit of the ISS mission, manned Low Earth Orbit (LEO) science programs and future planetary exploration programs. In November, 1998, the Flight Operations Directorate (FOD) started the ISS Antenna Manager (IAM) project to develop a single processor supporting multiple comm satellite tracking for two different antenna systems. Further, the processor was developed to be highly adaptable as it supported the ISS mission through all assembly stages. The ISS mission mandated communications specialists with complete knowledge of when the ISS was about to lose or gain comm link service. The current specialty mandated cognizance of large sun-tracking solar arrays and thermal management panels in addition to the highly-dynamic satellite service schedules and rise/set tables. This mission requirement makes the ISS the ideal communications management analogue for future LEO space station and long-duration planetary exploration missions. Future missions, with their precision-pointed, dynamic, laser-based comm links, require complete autonomy for managing high-data rate communications systems. Development of cognitive communications management systems that permit any crew member or payload science specialist, regardless of experience level, to control communications is one of the greater benefits the ISS can offer new space exploration programs. The IAM project met a new mission requirement never previously levied against US space-born communications systems management: process and display the orientation of large solar arrays and thermal control panels based on real-time joint angle telemetry. However, IAM leaves the actual communications availability assessment to human judgement, which introduces unwanted variability because each specialist has a different core of experience with comm link performance. Because the ISS utilizes two different frequency bands, dynamic structure can be occasionally translucent at one frequency while it can completely interdict service at the other frequency. The impact of articulating structure on the comm link can depend on its orientation at the time it impinges on the link. It can become easy for a human specialist to cross-associate experience at one frequency with experience at the other frequency. Additionally, the specialist's experience is incremental, occurring one nine-hour shift at a time. Only the IAM processor experiences the complete 24x7x365 communications link performance for both communications links but, it has no "learning capability." If the IAM processor could be endowed with a cognitive ability to remember past structure-induced comm link outages, based on its knowledge of the ISS position, attitude, communications gear, array joint angles and tracking accuracy, it could convey such experience to the human operator. It could also use its learned communications link behaviors to accurately convey the availability of future communications sessions. Further, the tool could remember how accurately or inaccurately it predicted availability and correct future predictions based on past performance. The IAM tool could learn frequency-specific impacts due to spacecraft structures and pass that information along as "experience." Such development would provide a single artificial intelligence processor that could provide two different experience bases. If it also "knew" the satellite service schedule, it could distinguish structure blockage from schedule or planet blockage and then quickly switch to another satellite. Alternatively, just as a human operator could judge, a cognizant comm system based on the IAM model could "know" that the blockage is not going to last very long and continue tracking a comm satellite, waiting for it to track away from structure. Ultimately, once this capability was fully developed and tested in the Mission Control Center, it could be transferred on-orbit to support development of operations concepts that include more advanced cognitive communications systems. Future applications of this capability are easily foreseen because even more dynamic satellite constellations with more nodes and greater capability are coming. Currently, the ISS fully employs its high-data-rate return link for harvesting payload science. In the coming months, it will double that data rate and is forecast to fully utilize that capability. Already there is talk of an upgrade that quadruples the current data rate allocated to ISS payload science before the end of its mission and laser comm links have already been tested from the ISS. Every data rate upgrade mandates more complicated and sensitive communications equipment which implies greater expertise invested in the human operator. Future on-orbit cognizant comm systems will be needed to meet greater performance demands aboard larger, far more complicated spacecraft. In the LEO environment, the old-style one-satellite-per-spacecraft operations concept will give way to a new concept of a single customer spacecraft simultaneously using multiple comm satellites. Much more highly-dynamic manned LEO missions with decades of crew members potentially increase the demand for communications link performance. A cognizant on-board communications system will meet advanced communications demands from future LEO missions and future planetary missions. The ISS has fledgling components of future exploration programs, both LEO and planetary. Further, the Flight Operations Directorate, through the IAM project, has already begun to develop a communications management system that attempts to solve advanced problems ideally represented by dynamic structure impacting scheduled satellite service. With an earnest project to integrate artificial intelligence into the IAM processor, the ISS Program could develop a cognizant communications system that could be adapted and transferred to future on-orbit avionics designs.

Jackson, Dan↗

A new Mars radiation environment model with visualization

A new model for the radiation environment to be found on the planet Mars due to Galactic Cosmic Rays (OCR) has been developed at the NASA Langley Research Center. Solar modulated primary particles rescaled for Mars conditions are transported through the Martian atmosphere, with temporal properties modeled with variable timescales, down to the surface, with altitude and backscattering patterns taken into account. The Martian atmosphere has been modeled by using the Mars Global Reference Atmospheric Model--version 2001 (Mars-GRAM 2001). The altitude to compute the atmospheric thickness profile has been determined by using a model for the topography based on the data provided by the Mars Orbiter Laser Altimeter (MOLA) instrument on board the Mars Global Surveyor (MGS) spacecraft. The Mars surface composition has been modeled based on averages over the measurements obtained from orbiting spacecraft and at various landing sites, taking into account the possible volatile inventory (e.g., CO2 ice, H2O ice) along with its time variation throughout the Martian year. Particle transport has been performed with the HZETRN heavy ion code. The Mars Radiation Environment Model has been made available worldwide through the Space Ionizing Radiation Effects and Shielding Tools (SIREST) website, a project of NASA Langley Research Center. c2004 COSPAR. Published by Elsevier Ltd. All rights reserved.

NASA Center LaRC↗

Attosecond Probing of Coherent Vibrational Dynamics in CBr 4

A coherent vibrational wavepacket is launched and manipulated in the symmetric stretch (a1) mode of CBr 4 , by impulsive stimulated Raman scattering (ISRS) from nonresonant 400 nm laser pump pulses with various peak intensities on the order of tens of 10 12 W/cm 2 . Extreme ultraviolet (XUV) attosecond transient absorption spectroscopy (ATAS) records the wavepacket dynamics as temporal oscillations in XUV absorption energy at the bromine M 4,5 3d 3/2,5/2 edges around 70 eV. The results are augmented by nuclear timedependent Schrödinger equation simulations. Slopes of the (Br 3d 3/2,5/2 ) –1 10a 1 * core-excited state potential energy surface (PES) along the a 1 mode are calculated to be –9.4 eV/Å from restricted open-shell Kohn–Sham calculations. Using analytical relations derived for the small-displacement limit and the calculated slopes of the core-excited state PES, a deeper insight into the vibrational dynamics is obtained by retrieving the experimental excursion amplitude of the vibrational wavepacket and the amount of population transferred to the vibrational first-excited state as a function of pump-pulse peak intensity. Experimentally, the results show that XUV ATAS is capable of resolving oscillations in the XUV absorption energy on the order of a few to tens of meV with tens of femtosecond time precision. This corresponds to change in C–Br bond length on the order of 10 –4 to 10 –3 Å. The results and the analytic relationships offer a clear physical picture, on multiple levels of understanding, of how the pump-pulse peak intensity controls the vibrational dynamics launched by nonresonant ISRS in the small-displacement limit.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

Colonization of Naive Roots from Populus tremula × alba Involves Successive Waves of Fungi and Bacteria with Different Trophic Abilities

ABSTRACT Through their roots, trees interact with a highly complex community of microorganisms belonging to various trophic guilds and contributing to tree nutrition, development, and protection against stresses. Tree roots select for specific microbial species from the bulk soil communities. The root microbiome formation is a dynamic process, but little is known on how the different microorganisms colonize the roots and how the selection occurs. To decipher whether the final composition of the root microbiome is the product of several waves of colonization by different guilds of microorganisms, we planted sterile rooted cuttings of gray poplar obtained from plantlets propagated in axenic conditions in natural poplar stand soil. We analyzed the root microbiome at different time points between 2 and 50 days of culture by combining high-throughput Illumina MiSeq sequencing of the fungal ribosomal DNA internal transcribed spacer and bacterial 16S rRNA amplicons with confocal laser scanning microscopy observations. The microbial colonization of poplar roots took place in three stages, but bacteria and fungi had different dynamics. Root bacterial communities were clearly different from those in the soil after 2 days of culture. In contrast, if fungi were also already colonizing roots after 2 days, the initial communities were very close to that in the soil and were dominated by saprotrophs. They were slowly replaced by endophytes and ectomycorhizal fungi. The replacement of the most abundant fungal and bacterial community members observed in poplar roots over time suggest potential competition effect between microorganisms and/or a selection by the host. IMPORTANCE The tree root microbiome is composed of a very diverse set of bacterial and fungal communities. These microorganisms have a profound impact on tree growth, development, and protection against different types of stress. They mainly originate from the bulk soil and colonize the root system, which provides a unique nutrient-rich environment for a diverse assemblage of microbial communities. In order to better understand how the tree root microbiome is shaped over time, we observed the composition of root-associated microbial communities of naive plantlets of poplar transferred in natural soil. The composition of the final root microbiome relies on a series of colonization stages characterized by the dominance of different fungal guilds and bacterial community members over time. Our observations suggest an early stabilization of bacterial communities, whereas fungal communities are established following a more gradual pattern.

59 BASIC BIOLOGICAL SCIENCES↗