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NASA NTRS2012

Materials, Structures and Manufacturing: An Integrated Approach to Develop Expandable Structures

Membrane dominated space structures are lightweight and package efficiently for launch; however, they must be expanded (deployed) in-orbit to achieve the desired geometry. These expandable structural systems include solar sails, solar power arrays, antennas, and numerous other large aperture devices that are used to collect, reflect and/or transmit electromagnetic radiation. In this work, an integrated approach to development of thin-film damage tolerant membranes is explored using advanced manufacturing. Bio-inspired hierarchical structures were printed on films using additive manufacturing to achieve improved tear resistance and to facilitate membrane deployment. High precision, robust expandable structures can be realized using materials that are both space durable and processable using additive manufacturing. Test results show this initial work produced higher tear resistance than neat film of equivalent mass. Future research and development opportunities for expandable structural systems designed using an integrated approach to structural design, manufacturing, and materials selection are discussed.

Belvin, W. Keith↗

NASA NTRS2015

Analysis of Fluorinated Polyimides Flown on the Materials International Space Station Experiment

This Technical Memorandum documents the results from the Materials on International Space Station Experiment (MISSE) series involving fluorinated polyimide films analyzed at NASA Marshall Space Flight Center. These films may be used in thermal control, sunshield, solar sail, solar concentrator, and other lightweight polymer film applications. Results include postflight structural integrity, visual observations, determination of atomic oxygen erosion yield, and optical property changes as compared to preflight values.

Finckenor, M. M.↗

NASA NTRS2003

Places Only Sails Can Go

Solar sails are a near term, low thrust, propellantless propulsion technology suitable for orbital maneuvering, station keeping, and attitude control applications for small payloads. Furthermore, these functions can be highly integrated, reducing mass, cost and complexity. The solar sail concept is based on momentum exchange with solar flux reflected from a large, deployed thin membrane. Thrust performance increases as the square of the distance to the sun. In comparison to conventional chemical systems, there are missions where solar sails are vastly more and less economical. The less attractive applications involve large payloads, outer solar system transfers, and short trip times. However, for inclination changes and station keeping at locations requiring constant thrust, the solar sail is the only economical option for missions of more than a few weeks duration. We compare the location and energies required for these applications between solar sails, advanced electric propulsion, and conventional rockets. We address the effect on mass fraction to understand solar sail mission cost and capability. Finally, the benefit of potential applications to near term science missions is reported.

Montgomery, Edward E., IV↗

NASA NTRS2005

Study of a 30-M Boom For Solar Sail-Craft: Model Extendibility and Control Strategy

Space travel propelled by solar sails is motivated by the fact that the momentum exchange that occurs when photons are reflected and/or absorbed by a large solar sail generates a small but constant acceleration. This acceleration can induce a constant thrust in very large sails that is sufficient to maintain a polar observing satellite in a constant position relative to the Sun or Earth. For long distance propulsion, square sails (with side length greater than 150 meters) can reach Jupiter in two years and Pluto in less than ten years. Converting such design concepts to real-world systems will require accurate analytical models and model parameters. This requires extensive structural dynamics tests. However, the low mass and high flexibility of large and light weight structures such as solar sails makes them unsuitable for ground testing. As a result, validating analytical models is an extremely difficult problem. On the other hand, a fundamental question can be asked. That is whether an analytical model that represents a small-scale version of a solar-sail boom can be extended to much larger versions of the same boom. To answer this question, we considered a long deployable boom that will be used to support the solar sails of the sail-craft. The length of fully deployed booms of the actual solar sail-craft will exceed 100 meters. However, the test-bed we used in our study is a 30 meter retractable boom at MSFC. We first develop analytical models based on Lagrange s equations and the standard Euler-Bernoulli beam. Then the response of the models will be compared with test data of the 30 meter boom at various deployed lengths. For this stage of study, our analysis was limited to experimental data obtained at 12ft and 18ft deployment lengths. The comparison results are positive but speculative. To observe properly validate the analytic model, experiments at longer deployment lengths, up to the full 30 meter, have been requested. We expect the study to answer the extendibility question of the analytical models. In operation, rapid temperature changes can be induced in solar sails as they transition from day to night and vice versa. This generates time dependent thermally induced forces, which may in turn create oscillation in structural members such as booms. Such oscillations have an adverse effect on system operations, precise pointing of instruments and antennas and can lead to self excited vibrations of increasing amplitude. The latter phenomenon is known as thermal flutter and can lead to the catastrophic failure of structural systems. To remedy this problem, an active vibration suppression system has been developed. It was shown that piezoelectric actuators used in conjunction with a Proportional Feedback Control (PFC) law (or Velocity Feedback Control (VFC) law) can induce moments that can suppress structural vibrations and prevent flutter instability in spacecraft booms. In this study, we will investigate control strategies using piezoelectric transducers in active, passive, and/or hybrid control configurations. Advantages and disadvantages of each configuration will be studied and experiments to determine their capabilities and limitations will be planned. In particular, special attention will be given to the hybrid control, also known as energy recycling, configuration due to its unique characteristics.

Keel, Leehyun↗

NASA NTRS2019

Setting Sail for the Sun: The NEA Scout & Solar Cruiser Missions

Join HAL5 as we welcome back Les Johnson, who will talk about his work on developing solar sails at Marshall Space Flight Center and its role in propulsion and exploration of the Sun. With the successful flights of NASA's NanoSail-D and the Planetary Society's LightSail, solar sails are making the transition from an interesting idea to be demonstrated to technology ready for use on space missions. Scientists and engineers here in Huntsville are doing just that with the development of the Near Earth Asteroid Scout's 925 square foot solar sail that will fly in 2020. And that's not all, in August, a team led by NASA MSFC was selected as a finalist to develop an 18,000 square foot solar sail for a project called, Solar Cruiser, that may fly as early as 2024. If you would like to learn the fundamentals of solar sailing and get the scoop on these two innovative and exciting missions, then hang on as we "Set Sail for the Sun!"

Heliophysics↗

NASA NTRS2005

Propellantless AOCS Design for a 160-m, 450-kg Sailcraft of the Solar Polar Imager Mission

An attitude and orbit control system (AOCS) is developed for a 160-m, 450-kg solar sail spacecraft of the Solar Polar Imager (SPI) mission. The SPI mission is one of several Sun- Earth Connections solar sail roadmap missions currently envisioned by NASA. A reference SPI sailcraft consists of a 160-m, 150-kg square solar sail, a 250-kg spacecraft bus, and 50-kg science payloads, The 160-m reference sailcraft has a nominal solar thrust force of 160 mN (at 1 AU), an uncertain center-of-mass/center-of-pressure offset of +/- 0.4 m, and a characteristic acceleration of 0.35 mm/sq s. The solar sail is to be deployed after being placed into an earth escaping orbit by a conventional launch vehicle such as a Delta 11. The SPI sailcraft first spirals inwards from 1 AU to a heliocentric circular orbit at 0.48 AU, followed by a cranking orbit phase to achieve a science mission orbit at a 75-deg inclination, over a total sailing time of 6.6 yr. The solar sail will be jettisoned after achieving the science mission orbit. This paper focuses on the solar sailing phase of the SPI mission, with emphasis on the design of a reference AOCS consisting of a propellantless primary ACS and a microthruster-based secondary (optional) ACS. The primary ACS employs trim control masses running along mast lanyards for pitch/yaw control together with roll stabilizer bars at the mast tips for quadrant tilt (roll) control. The robustness and effectiveness of such a propellantless primary ACS would be enhanced by the secondary ACS which employs tip-mounted, lightweight pulsed plasma thrusters (PPTs). The microPPT-based ACS is mainly intended for attitude recovery maneuvers from off-nominal conditions. A relatively fast, 70-deg pitch reorientation within 3 hrs every half orbit during the orbit cranking phase is shown to be feasible, with the primary ACS, for possible solar observations even during the 5-yr cranking orbit phase.

Wie, Bong↗

NASA NTRS2010

FeatherSail--Design, Development and Future Impact

This CD contains the slide presentation and a brief video of the solar sail concept. Solar Sailing is a method of space flight propulsion, which utilizes the light photons to propel spacecrafts through the vacuum of space. The goal of the FeatherSail project is to create a sail vehicle with the ability to provide steering from the sails and increase the areal density.

Alhorn, Dean C.↗

NASA NTRS2015

NEA Scout and Lunar Flashlight: Two NearTerm Interplanetary CubeSat Missions

NASA is developing two small satellite missions as part of the Advanced Exploration Systems (AES) Program, both of which will use a solar sail to enable their scientific objectives. Solar sails reflect sunlight from a large, mirror‐like sail made of a lightweight, highly reflective material to provide thrust. This continuous photon pressure provides propellantless thrust, allowing for very high delta V maneuvers in space. Lunar Flashlight, managed by the NASA Jet Propulsion Laboratory, will search for and map volatiles in permanently shadowed lunar craters using a solar sail as a gigantic mirror to steer sunlight into them, then examine the reflected light with a spectrometer. The Lunar Flashlight spacecraft will also use the solar sail to maneuver into a lunar polar orbit. The mission will demonstrate a low‐cost capability to explore, locate and estimate the size and composition of ice deposits on the Moon. The Near Earth Asteroid (NEA) Scout mission, managed by the NASA Marshall Space Flight Center will survey and image a Near Earth Asteroid for possible future human exploration using a smallsat propelled by a solar sail. Detections of NEAs are expected to grow in the near future, offering increasing target opportunities. Obtaining and analyzing relevant data about these bodies via robotic precursors before committing a crew to visit them is essential. The NEA Scout spacecraft is nearly identical to the one being developed for Lunar Flashlight, with the science instrument package being the primary difference. The NEA Scout solar sail will provide the primary propulsion taking the 6U cubesat from near the Earth to its final asteroid destination and the Lunar Flashlight sail will provide the propulsion necessary for its spacecraft to enter lunar orbit. Both projects will use an 85 m2 solar sail developed by NASA MSFC. The NEA Scout and Lunar Flashlight flight systems are based on a 6U cubesat form factor, with a stowed envelope of 10 x 20 x 30 cm and a mass of less than 12 kg. The solar sail for NEA Scout and Lunar Flashlight will be based on the technology developed and flown by the NASA NanoSail‐D and The Planetary Society's Lightsail‐A. Four 7 m stainless steel booms wrapped on two spools (two overlapping booms per spool) will be motor deployed and pull the sail from its stowed volume. The sail material will be 3 micron CP1, an aluminized polyimide that was extensively tested for solar sail applications. The sail will spooled rather than Z‐folded. This paper will describe both the Lunar Flashlight and NEA Scout missions and their solar sails.

Johnson, Les↗

NASA NTRSDate not supplied

Zero-G Experiments of the BionicWingsat - A 2U-Cubesat with Deployable, Biologically-Inspired Wings

In this paper, recent testing of a novel deployable structure with several potential applications in space will be described, with the focus on performed deployment experiments in a DLR Zero-g flight campaign and in ground tests. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically-inspired structurally-integrated membrane featuring distributed functional elements has been developed and integrated into the 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for all sorts of applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper focuses on testing of developed design concepts for such structural systems. To do so 24 fully integrated wings on two BionicWingSats in 2U Cubesat format were experimentally deployed in a microgravity environment during a dedicated DLR Zero-g flight campaign in 2021. The results of these experiments, the built hardware and test articles, the test arrangement, as well as a comparison to ground tests are discussed in this paper.

Spacecraft structures↗

NASA NTRSDate not supplied

Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings

In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.

CubeSat↗

NASA NTRSDate not supplied

Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings

CubeSat↗

NASA NTRS1998

A Solar Polar Sail Mission: Report of a Study to Put a Scientific Spacecraft in a Circular Polar Orbit about the Sun

The Solar Polar Sail Mission uses solar-sail propulsion to place a spacecraft in a circular orbit 0.48 AU from the Sun with an inclination of 90 °.

Solar↗

NASA NTRS2011

The Heliogyro Reloaded

The heliogyro is a high-performance, spinning solar sail architecture that uses long - order of kilometers - reflective membrane strips to produce thrust from solar radiation pressure. The heliogyro s membrane blades spin about a central hub and are stiffened by centrifugal forces only, making the design exceedingly light weight. Blades are also stowed and deployed from rolls; eliminating deployment and packaging problems associated with handling extremely large, and delicate, membrane sheets used with most traditional square-rigged or spinning disk solar sail designs. The heliogyro solar sail concept was first advanced in the 1960s by MacNeal. A 15 km diameter version was later extensively studied in the 1970s by JPL for an ambitious Comet Halley rendezvous mission, but ultimately not selected due to the need for a risk-reduction flight demonstration. Demonstrating system-level feasibility of a large, spinning heliogyro solar sail on the ground is impossible; however, recent advances in microsatellite bus technologies, coupled with the successful flight demonstration of reflectance control technologies on the JAXA IKAROS solar sail, now make an affordable, small-scale heliogyro technology flight demonstration potentially feasible. In this paper, we will present an overview of the history of the heliogyro solar sail concept, with particular attention paid to the MIT 200-meter-diameter heliogyro study of 1989, followed by a description of our updated, low-cost, heliogyro flight demonstration concept. Our preliminary heliogyro concept (HELIOS) should be capable of demonstrating an order-of-magnitude characteristic acceleration performance improvement over existing solar sail demonstrators (HELIOS target: 0.5 to 1.0 mm/s2 at 1.0 AU); placing the heliogyro technology in the range required to enable a variety of science and human exploration relevant support missions.

Wilkie, William K.↗

NASA NTRS2005

Solar Array Sails: Possible Space Plasma Environmental Effects

An examination of the interactions between proposed "solar sail" propulsion systems with photovoltaic energy generation capabilities and the space plasma environments. Major areas of interactions ere: Acting from high voltage arrays, ram and wake effects, V and B current loops and EMI. Preliminary analysis indicates that arcing will be a major risk factor for voltages greater than 300V. Electron temperature enhancement in the wake will be produce noise that can be transmitted via the wake echo process. In addition, V and B induced potential will generate sheath voltages with potential tether like breakage effects in the thin film sails. Advocacy of further attention to these processes is emphasized so that plasma environmental mitigation will be instituted in photovoltaic sail design.

Mackey, Willie R.↗

NASA NTRSDate not supplied

Near Earth Asteroid Scout - Mission Update

After its deployment from NASA’s Space Launch System (SLS), the Near-Earth Asteroid (NEA) Scout mission will travel to and image an asteroid during a close flyby using an 86m^2 solar sail as its primary propulsion. Solar sails are large, mirror-like structures made of a lightweight material that reflects sunlight to propel the spacecraft. The continuous solar photon pressure provides thrust with no need for the heavy, expendable propellants used by conventional chemical and electric propulsion systems. Developed by NASA’s Marshall Space Flight Center (MSFC) and Jet Propulsion Laboratory (JPL), the NEA Scout is based on the industry-standard CubeSat form factor. The spacecraft measures 11 cm x 24 cm x 36 cm and weighs less than 14 kilograms. Following deployment from the Space Launch System (SLS), the solar sail will deploy, and the spacecraft will begin its 2.0 – 2.5-year journey. About one month before the asteroid flyby, NEA Scout will search for the target and start its Approach Phase using a combination of radio tracking and optical navigation and perform a relatively slow flyby (10-20 m/s) of the target. A summary of the mission, sailcraft, mission design, and its first several months of deep space operation will be described.

Near Earth Asteroid↗

NASA NTRS2006

MISSE Materials Results for Applications in the Vision for Space Exploration

Marshall Space Flight Center has a role in the development of the Crew Launch Vehicle and Crew Exploration Vehicle, as well as the Robotic Lunar Exploration Program (RLEP-2) and In-Space Propulsion. The success of these programs depends upon understanding the space environment, the requirements imposed on the spacecraft materials, and data gleaned from materials returned from space. Station Experiment (MISSE) were analyzed at the Marshall Space Flight Center. Changes in mass, optical properties, and mechanical integrity for these samples can indicate which materials may be suitable for use on exploration spacecraft, which materials need further testing, and which materials should not be recommended for long term missions. A number of materials for in-space propulsion were flown on MISSE. These include the conductive, insulative, and non-conductive tether materials selected for the ProSEDS mission. Also included were candidate solar sail materials. The solar sail materials were flown underneath a magnesium fluoride window that allowed ultraviolet radiation through to the sample but blocked any atomic oxygen. Over two hundred materials samples from the Materials on International Space

Source record↗

NASA NTRS2008

Materials Needs for Future In-space Propulsion Systems

NASA is developing the next generation of in-space propulsion systems in support of robotic exploration missions throughout the solar system. The propulsion technologies being developed are non-traditional and have stressing materials performance requirements. (Chemical Propulsion) Earth-storable chemical bipropellant performance is constrained by temperature limitations of the columbium used in the chamber. Iridium/rhenium (Ir/Re) is now available and has been implemented in initial versions of Earth-Storable rockets with specific impulses (Isp) about 10 seconds higher than columbium rocket chambers. New chamber fabrication methods that improve process and performance of Ir/Re and other promising material systems are needed. (Solar Sail Propulsion) The solar sail is a propellantless propulsion system that gains momentum by reflecting sunlight. The sails need to be very large in area (from 10000 m2 up to 62500 m2) yet be very lightweight in order to achieve adequate accelerations for realistic mission times. Lightweight materials that can be manufactured in thicknesses of less than 1 micron and that are not harmed by the space environment are desired. (Aerocapture) Blunt Body Aerocapture uses aerodynamic drag to slow an approaching spacecraft and insert it into a science orbit around any planet or moon with an atmosphere. The spacecraft is enclosed by a rigid aeroshell that protects it from the entry heating and aerodynamic environment. Lightweight, high-temperature structural systems, adhesives, insulators, and ablatives are key components for improving aeroshell efficiencies at heating rates of 1000-2000 W/cu cm and beyond. Inflatable decelerators in the forms of ballutes and inflatable aeroshells will use flexible polymeric thin film materials, high temperature fabrics, and structural adhesives. The inflatable systems will be tightly packaged during cruise and will be inflated prior to entry interface at the destination. Materials must maintain strength and flexibility while packaged at cold temperatures (_100oC) for up to 10 years and then withstand the high temperatures (500oC) encountered during aerocapture. The presentation will describe the status of each propulsion technology and summarize the materials needed for their implementation.

Johnson, Charles Les↗

NASA NTRS2000

Propulsion Options For Interstellar Exploration

NASA is considering missions to explore near-interstellar space (40 - 250 Astronomical Units) early in the next decade as the first step toward a vigorous interstellar exploration program. A key enabling technology for such an ambitious science and exploration effort is a propulsion system capable of providing fast trip times, yet which has low enough mass to allow for the use of inexpensive launch vehicles. Advanced propulsion technologies that might support the First interstellar precursor mission by the end of the first decade of the new millennium include solar sails and nuclear electric propulsion. Solar sails and electric propulsion are two technology areas that may hold promise for the next generation of interstellar precursor missions as well - perhaps a thousand astronomical units traveled in a professional lifetime. Future missions to far beyond the Heliosphere will require the development of propulsion technologies that are only at the conceptual stage today. For years, the scientific community has been interested in solar sail and electric propulsion technologies to support robotic exploration of the solar system. Progress in thin-film materials fabrication and handling, and advancement in technologies that may enable the deployment of large sails in space are only now maturing to the point where ambitious interstellar precursor missions using sails can be considered. Xenon ion propulsion is now being demonstrated for planetary exploration by the Deep Space 1 mission. The primary issues for the adaptation of electric propulsion to interstellar precursor applications include the development of low specific mass nuclear power systems, engine lifetime, and high power operation. Recent studies of interstellar precursor mission scenarios that use these propulsion systems will be described, and the range of application of each technology will be explored.

Johnson, Les↗