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The development of mechanical systems for space platforms which have universal application regardless of what platform configuration is built is discussed. The design requirements and fabrication of the orbiter berthing systems, berthing latch interface, berthing umbilical interface, and adaptive end effector are described.
In order to accurately test the AX-5 space suit, a complex series of motions needed to be performed which provided a unique opportunity for mechanism design. The cycle life machine design showed how 3-D computer images can enhance mechanical design as well as help in visualizing mechanisms before manufacturing them. In the early stages of the design, potential problems in the motion of the joint and in the four bar linkage system were resolved using CAD. Since these problems would have been very difficult and tedious to solve on a drawing board, they would probably not have been addressed prior to fabrication, thus limiting the final design or requiring design modification after fabrication.
Recently, there has been a surge of interest in the development and testing of silicon-based ceramics and composite components for a number of aerospace and ground based systems. The designs often require fabrication of complex shaped parts which can be quite expensive. One attractive way of achieving this goal is to build up complex shapes by joining together geometrically simple shapes. However, the joints should have good mechanical strength and environmental stability comparable to the bulk materials. These joints should also be able to maintain their structural integrity at high temperatures. In addition, the joining technique should be practical, reliable, and affordable. Thus, joining has been recognized as one of the enabling technologies for the successful utilization of silicon carbide based ceramic components in high temperature applications. Overviews of various joining techniques, i.e., mechanical fastening, adhesive bonding, welding, brazing, and soldering have been provided in recent publications. The majority of the techniques used today are based on the joining of monolithic ceramics with metals either by diffusion bonding, metal brazing, brazing with oxides and oxynitrides, or diffusion welding. These techniques need either very high temperatures for processing or hot pressing (high pressures). The joints produced by these techniques have different thermal expansion coefficients than the ceramic materials, which creates a stress concentration in the joint area. The use temperatures for these joints are around 700 C. Ceramic joint interlayers have been developed as a means of obtaining high temperature joints. These joint interlayers have been produced via pre-ceramic polymers, in-situ displacement reactions, and reaction bonding techniques. Joints produced by the pre-ceramic polymer approach exhibit a large amounts of porosity and poor mechanical properties. On the other hand, hot pressing or high pressures are needed for in-situ displacement reactions and reaction bonding techniques. Due to the equipment required, these techniques are impractical for joining large or complex shaped components.
The technologies required to design, fabricate, and utilize an inflatable module for space applications has been demonstrated and proven by the TransHab team during the development phase of the program. Through testing and hands-on development several issues about inflatable space structures have been addressed , such as: ease of manufacturing, structural integrity, micrometeorite protection, folding , and vacuum deployment. The TransHab inflatable technology development program has proven that not only are inflatable structures a viable option, but they also offer significant advantages over conventional metallic structures.
Current methods of designing and optimizing antennas by hand are time and labor intensive, and limit complexity. Evolutionary design techniques can overcome these limitations by searching the design space and automatically finding effective solutions. In recent years, evolutionary algorithms have shown great promise in finding practical solutions in large, poorly understood design spaces. In particular, spacecraft antenna design has proven tractable to evolutionary design techniques. Researchers have been investigating evolutionary antenna design and optimization since the early 1990s, and the field has grown in recent years as computer speed has increased and electromagnetic simulators have improved. Two requirements-compliant antennas, one for ST5 and another for TDRS-C, have been automatically designed by evolutionary algorithms. The ST5 antenna is slated to fly this year, and a TDRS-C phased array element has been fabricated and tested. Such automated evolutionary design is enabled by medium-to-high quality simulators and fast modern computers to evaluate computer-generated designs. Evolutionary algorithms automate cut-and-try engineering, substituting automated search though millions of potential designs for intelligent search by engineers through a much smaller number of designs. For evolutionary design, the engineer chooses the evolutionary technique, parameters and the basic form of the antenna, e.g., single wire for ST5 and crossed-element Yagi for TDRS-C. Evolutionary algorithms then search for optimal configurations in the space defined by the engineer. NASA's Space Technology 5 (ST5) mission will launch three small spacecraft to test innovative concepts and technologies. Advanced evolutionary algorithms were used to automatically design antennas for ST5. The combination of wide beamwidth for a circularly-polarized wave and wide impedance bandwidth made for a challenging antenna design problem. From past experience in designing wire antennas, we chose to constrain the evolutionary design to a monopole wire antenna. The results of the runs produced requirements-compliant antennas that were subsequently fabricated and tested. The evolved antenna has a number of advantages with regard to power consumption, fabrication time and complexity, and performance. Lower power requirements result from achieving high gain across a wider range of elevation angles, thus allowing a broader range of angles over which maximum data throughput can be achieved. Since the evolved antenna does not require a phasing circuit, less design and fabrication work is required. In terms of overall work, the evolved antenna required approximately three person-months to design and fabricate whereas the conventional antenna required about five. Furthermore, when the mission was modified and new orbital parameters selected, a redesign of the antenna to new requirements was required. The evolutionary system was rapidly modified and a new antenna evolved in a few weeks. The evolved antenna was shown to be compliant to the ST5 mission requirements. It has an unusual organic looking structure, one that expert antenna designers would not likely produce. This antenna has been tested, baselined and is scheduled to fly this year. In addition to the ST5 antenna, our laboratory has evolved an S-band phased array antenna element design that meets the requirements for NASA's TDRS-C communications satellite scheduled for launch early next decade. A combination of fairly broad bandwidth, high efficiency and circular polarization at high gain made for another challenging design problem. We chose to constrain the evolutionary design to a crossed-element Yagi antenna. The specification called for two types of elements, one for receive only and one for transmit/receive. We were able to evolve a single element design that meets both specifications thereby simplifying the antenna and reducing testing and integration costs. The highest performance antenna found using a getic algorithm and stochastic hill-climbing has been fabricated and tested. Laboratory results correspond well with simulation. Aerospace component design is an expensive and important step in space development. Evolutionary design can make a significant contribution wherever sufficiently fast, accurate and capable software simulators are available. We have demonstrated successful real-world design in the spacecraft antenna domain; and there is good reason to believe that these results could be replicated in other design spaces.
NASA Ames Entry Systems and Technology Division has been leading development and testing of the Adaptable, Deployable, Entry and Placement Technology (ADEPT). A teaming partnership with JPL has been established to study and develop a compelling application of the ADEPT mechanically deployable hypersonic decelerator as part of the Venus Drag Modulated Aerocapture (VDMA) JPL R&TD effort. The primary work of this activity is to develop a design tool for the ADEPT drag skirt (e.g. a CFD-anchored CBAERO model) that enables rapid estimation of aerothermal environments for a range of candidate trajectories. This capability will enable rapid feasibility trades and design assessments for early stage mission concept evaluation for ADEPT Drag Modulated Aerocapture applications. Results of using TPSizer provided an ADEPT carbon fabric design thickness of the required number of fabric layers needed for predicted aerothermal environments and still have sufficient fabric remaining for overall vehicle integrity. This resulted in aerothermal design closure of the ADEPT drag skirt. In addition, the similar methodology for Venus DMA was used to assess a similar DMA operation at Earth as part of a possible Technology Demonstration Mission (TDM) for ADEPT DMA. This analysis showed that there is a close similarity of design approaches for an Earth DMA TDM that would be applicable to Venus DMA mission designs.
A. The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. Idaho National Laboratory (INL), operated for the U.S. Department of Energy (DOE) by Battelle Energy Alliance, LLC (BEA) (Contractor hereafter) is procuring services for the design, analysis, fabrication, testing and delivery of a Secondary Coolant Equipment system (SCE). This specification contains the requirements for design, analysis, fabrication, testing and delivery of the SCE as described herein. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells.” It is intended for the IHX containment to also be filled with NaK. The MARVEL design team has determined that a Heat Extraction System (HES) using pumped NaK will be used to extract heat from the IHXs and deliver it to a downstream system for power generation or alternate process heat users. This Heat Extraction System will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. The objective of this specification is to develop the final design for the HES Secondary Coolant Equipment system (SCE) that will be used as the core of the HES. This system provides control of the NaK circulation between the MARVEL reactor and the subsequent process heat utilization systems. It does not include design of the Intermediate Heat Exchangers and piping inside the T-REXc pit in which the reactor is located. B. The MARVEL microreactor will be installed in the Transient Reactor Test Facility (TREAT) building in the Transient Reactor Test (TREAT) Micro-Reactor Experiment Cell (T-REXc) C. An INL Subcontractor has developed a conceptual design for this system per SPC-71145, referred to in that specification as the Process Heat Extraction System. SPC-71260 is based on the pumped NaK loop concept developed under SPC-71145. D. The SCE system design and (as option scope) fabrication shall be provided by the awardee of the subcontract (Subcontractor hereafter) pertaining to this Specification. Prior to shipment, the SCE will be fabricated, assembled, and tested at the Subcontractor’s facility. After successful completion of acceptance testing, the SCE and associated equipment will be shipped to the Materials and Fuels Complex (MFC) at the INL (Contractor’s Facility hereafter) to be installed by others in TREAT/T-REXc.
This standard establishes requirements and guidance for design and fabrication of ground systems (GS) that includes: ground support equipment (GSE), ground support systems (GSS), and facility ground support systems (F GSS) to provide uniform methods and processes for design and development of robust, safe, reliable, maintainable, supportable, and cost-effective GS in support of space flight and institutional programs and projects.
The SUMC/DV (Space Ultrareliable Modular Computer Demonstration Vehicle), which required the design and fabrication of ten different array types, was designed, partitioned, assembled, tested, and made completely operational in less than one year. This paper describes the assembly, the physical and electrical characteristics, and the basic electrical testing procedures used on SUMC/DV. The paper includes a description of the packaging concepts, the physical assembly, the fabrication and testing of the various components including the LSI/CMOS arrays, the hierarchy of the memory complement, the clock generation and distribution scheme, additional system testing techniques, and the procedure employed in the electrical checkout of the system.
The following report summarizes the results of a Monte Carlo simulation and modeling study of the Lawrence Berkeley National Laboratory’s (LBL) Monoenergetic Photon Source (MPS) as part of a high-energy LiDAR system for use in emergency response applications. A set of image quality indicators (IQI) and nonsensitive phantoms or generalized surrogates for search targets have been identified for use in the planned measurement campaign at the Berkeley Lab Laser Accelerator (BELLA) Center toward the end FY2023. These items were modeled and the time-of-flight (TOF) spectral responses following irradiation were calculated for a set of varying operating conditions. The goal of this study was to both predict the LiDAR system performance as well as determine if minor modifications to the IQI and phantom designs were required before fabrication. It was found that the IQI and target designs both overlap and extend towards the limit of performance of the system and are thus suitable for the final project measurement campaign.
The results of analysis and tests conducted to define the basic 1-m beam configuration required, and the design, development, fabrication, and verification tests of the machine required to automatically produce these beams are presented.
The preponderance of matter over antimatter in the early universe, the dynamics of the supernovae that produced the heavy elements necessary for life, and whether protons eventually decay -- these mysteries at the forefront of particle physics and astrophysics are key to understanding the early evolution of our universe, its current state, and its eventual fate. The Deep Underground Neutrino Experiment (DUNE) is an international world-class experiment dedicated to addressing these questions as it searches for leptonic charge-parity symmetry violation, stands ready to capture supernova neutrino bursts, and seeks to observe nucleon decay as a signature of a grand unified theory underlying the standard model. The DUNE far detector technical design report (TDR) describes the DUNE physics program and the technical designs of the single- and dual-phase DUNE liquid argon TPC far detector modules. Volume III of this TDR describes how the activities required to design, construct, fabricate, install, and commission the DUNE far detector modules are organized and managed. This volume details the organizational structures that will carry out and/or oversee the planned far detector activities safely, successfully, on time, and on budget. It presents overviews of the facilities, supporting infrastructure, and detectors for context, and it outlines the project-related functions and methodologies used by the DUNE technical coordination organization, focusing on the areas of integration engineering, technical reviews, quality assurance and control, and safety oversight. Because of its more advanced stage of development, functional examples presented in this volume focus primarily on the single-phase (SP) detector module.
The Space Station Freedom Furnace (SSFF) Study was awarded on June 2, 1989, to Teledyne Brown Engineering (TBE) to define an advanced facility for materials research in the microgravity environment of Space Station Freedom (SSF). The SSFF will be designed for research in the solidification of metals and alloys, the crystal growth of electronic and electro-optical materials, and research in glasses and ceramics. The SSFF is one of the first 'facility' class payloads planned by the Microgravity Science and Applications Division (MSAD) of the Office of Space Science and Applications of NASA Headquarters. This facility is planned for early deployment during man-tended operations of the SSF with continuing operations through the Permanently Manned Configuration (PMC). The SSFF will be built around a general 'Core' facility which provides common support functions not provided by SSF, common subsystems which are best centralized, and common subsystems which are best distributed with each experiment module. The intent of the facility approach is to reduce the overall cost associated with implementing and operating a variety of experiments. This is achieved by reducing the launch mass and simplifying the hardware development and qualification processes associated with each experiment. The Core will remain on orbit and will require only periodic maintenance and upgrading while new Furnace Modules, samples, and consumables are developed, qualified, and transported to the SSF. The SSFF Study was divided into two phases: phase 1, a definition study phase, and phase 2, a design and development phase. The definition phase 1 is addressed. Phase 1 was divided into two parts. In the first part, the basic part of the effort, covered the preliminary definition and assessment of requirements; conceptual design of the SSFF; fabrication of mockups; and the preparation for and support of the Conceptual Design Review (CoDR). The second part, the option part, covered requirements update and documentation; refinement of the selected conceptual design through additional trades and analyses; design, fabrication, and test of the Development Model; and design, fabrication, and test of the Interrack Demonstration Unit; and support of the requirements definition review (RDR). The purpose of part 2 was to prove concept feasibility.
A summary of the design analyses for a liquid rocket injector using oxygen and RP-1 propellants at high chamber pressures of 20,682 kPa (3000 psia) is presented. This analytical investigation includes combustion efficiency versus injector element type, combustion stability, and combustor cooling requirements. The design and fabrication of a subscale injector/acoustic resonantor assembly capable of providing a nominal thrust of 222K N (50,000 lbF) is presented.
Three 28-inch-diameter solid rocket motor cases were fabricated using 1/8 inch wide boron/epoxy tape. The cases had unequal end closures (4-1/8-inch-diameter forward flanges and 13-inch-diameter aft flanges) and metal attachment skirts. The flanges and skirts were titanium 6Al-4V alloy. The original design for the first case was patterned after the requirements of the Applications Technology Satellite apogee kick motor. The second and third cases were designed and fabricated to approximate the requirements of a small Applications Technology Satellite apogee kick motor. The program demonstrated the feasibility of designing and fabricating large-scale filament-wound solid propellant rocket motor cases with boron/epoxy tape.
A program phase to characterize advanced composite materials for a large reflector support truss on the ATS F & G spacecraft is described. The selection of a Hercules Incorporated, 2002M graphite fiber reinforced epoxy material was based on criteria of spacecraft system requirements and the potential of this material to meet these requirements. The objective of this phase was to develop materials data required for development, design, fabrication, test, and flight of a graphite-fiber, reinforced-plastic spacecraft structure. Testing within a temperature range from -300 F to +200 F covered the generation of data for physical, mechanical, thermophysical, and space environmental properties for the selected material. Additional testing covered adhesive bonded joint materials within the temperature ranges of the spacecraft environment. Descriptions of the spacecraft, reflector support truss, design, requirements, materials, tests, and developed data are presented.
This lecture presents the results of fastener load and retention systems tests which were carried out as a part of the cryogenic models technology development program a the NASA Langley Research Center (LaRC). Various design concepts for the National Transonic Facility (NTF) developmental and production models are discussed. A number of NTF models are described with emphasis on materials used, uniqueness of design and design drivers. Design and fabrication experience is presented in terms of the primary thermal and mechanical considerations required for design as well as fabrication. Cost considerations are addressed in terms of factors influencing costs for NTF models and cost data comparisons which are taken from both NASA Langley and industry experience.
A selective review is presented of the state of the art of metallic laminates and fiber reinforced metals called metallic matrix laminates (MMLs). Design and analysis procedures that are used for, and typical structural components that have been made from MMLs are emphasized. Selected MMLs, constituent materials, typical material properties and fabrication procedures are briefly described, including hybrids and superhybrids. Advantages, disadvantages, and special considerations required during design, analysis, and fabrication of MMLs are examined. Tabular and graphical data are included to illustrate key aspects of MMLs. Appropriate references are cited to provide a selective bibliography of a rapidly expanding and very promising research and development field.