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All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

NASA Crew Exploration Vehicle, Thermal Protection System, Lessons Learned

The Orion (CEV) thermal protection system (TPS) advanced development project (ADP) was initiated in late 2006 to reduce developmental risk by significant investment in multiple heat shield architectural solutions that can meet the needs both the Low Earth orbit (LEO) and Lunar return missions. At the same time, the CEV TPS ADP was also charged with developing a preliminary design for the heat shield to meet the PDR requirement and at the time of the PDR, transfer the design to Lockheed- Martin, the prime contractor. We reported on the developmental activities of the first 18 months at the IPPW5 in Bordeaux, France, last summer. In June 08, at the time of the IPPW6, the CEV TPS ADP would have nearly completed the preparation for the Orion PDR and would be close to the original three-year mark. We plan to report on the progress at the Atlanta workshop. In the past year, Orion TPS ADP investment in TPS Technology, especially in PICA ablative Heat-shield design, development, testing and engineering (DDTE) has paid off in enabling MSL mission to switch from SLA 561 V heat shield to PICA heat shield. CEV TPS ADP considered SLA 561 V as a candidate for LEO missions and our testing identified failure modes in SLA and as a result, we dropped SLA for further evaluation. This close synergy between two projects is a highly visible example of how investment in technology areas can and does benefit multiple missions. In addition, CEV TPS ADP has been able to revive the Apollo ablative system namely AVCOAT honeycomb architecture as an alternate to the baseline PICA architecture and we plan to report the progress we have made in AVCOAT. CEV TPS ADP has invested considerable resources in developing analytical models for PICA and AVCOAT, material property measurements that is essential to the design of the heat-shield, in arcjet testing, in understanding the differences between different arc jet facilities, namely NASA Ames, NASA JSC and Air Force's AEDC, and in Non-Destructive Evaluation (NDE), and in integration of and manufacturing heat shield as a system. The capabilities of the two heat shield systems including failure modes via testing and analysis, once established, can serve the Probe Community and future mission designers to inner and outer planetary exploration very well. For example, missions to Venus, Mars and Titan can use either one of the system by selecting the mission design parameters that utilizes the full characteristics of these system to make use of system efficiency that will result in reduced heat shield mass, system robustness that will enhance mission success and cost. We plan to present significant progresses of the past three years and highlight the significant contributions CEV TPS ADP Project has made to advance the state of the art in Thermal Protection System technology that has and will continue to benefit future entry probe missions.

NASA Crew Exploration Vehicle↗
NASA NTRS1974

Interaction of gases with ablative composites. I - Ar, CO2, and N2

The sorption of argon, carbon dioxide, and nitrogen on two heat shield composites (SLA-561 and SLA-561V) and on the SLA components was measured over the pressure range of 0.001 to 760 torr and in the temperature range of 30 to 50 C. The sorption of the gases by both the composites and the components varied directly with pressure. The sorption of CO2 by the phenolic spheres and the silicone elastomer and of Ar by the silicone elastomer varied inversely with temperature. The mechanism involved in the gas sorption was primarily absorption.

King, C. A.↗
NASA NTRS1979

Application of a hierarchical structure stochastic learning automation

A hierarchical structure automaton was developed using a two state stochastic learning automato (SLA) in a time shared model. Application of the hierarchical SLA to systems with multidimensional, multimodal performance criteria is described. Results of experiments performed with the hierarchical SLA using a performance index with a superimposed noise component of ? or - delta distributed uniformly over the surface are discussed.

Neville, R. G.↗
NASA NTRS1998

Linear System Control Using Stochastic Learning Automata

This paper explains the use of a Stochastic Learning Automata (SLA) to control switching between three systems to produce the desired output response. The SLA learns the optimal choice of the damping ratio for each system to achieve a desired result. We show that the SLA can learn these states for the control of an unknown system with the proper choice of the error criteria. The results of using a single automaton are compared to using multiple automata.

Ziyad, Nigel↗
NASA NTRS1999

Mesoscale Eddies, Satellite Altimetry, and New Production in the Sargasso Sea

Satellite altimetry and hydrographic observations are used to characterize the mesoscale eddy field in the Sargasso Sea near Bermuda and to address the role of physical processes on the supply of new nutrients to the euphotic zone. The observed sea level anomaly (SLA) field is dominated by the occurrence of westward propagating features with SLA signatures as large as 25 cm, Eulerian temporal scales of roughly a month, lifetimes of several months, spatial scales of approximately 200 km, and a propagation of approximately 5 cm/s. Hydrographic estimates of dynamic height anomaly (referenced to 4000 dbar) are well correlated with satellite SLA (r(exp 2) = 0.65), and at least 85% of the observed dynamic height variability is associated with the first baroclinic mode of motion. This allows us to apply the satellite observations to remotely sensed estimate isopycnal displacements and the flux of nutrients into the euphotic zone due to eddy pumping. Eddy pumping is the process by which mesoscale eddies induce isopycnal displacements that lift nutrient-replete waters into the euphotic zone, driving new primary production. A kinematic approach to the estimation of the eddy pumping results in a flux of 0.24 +/- 0.1 mol N/sq m (including a scale estimate for the small contribution due to 18 deg water eddies). This flux is more than an order of magnitude larger than the diapycnal diffusive flux as well as scale estimates for the vertical transport due to isopycnal mixing along sloping isopycnal surfaces. Eddy pumping and wintertime convection are the two dominant mechanisms transporting new nutrients into the euphotic zone, and the sum of all physical new nutrient supply fluxes effectively balances previous geochemical estimates of annual new production for this site. However, if biological transports (e.g., nitrogen fixation, etc.) are significant, the new nitrogen supply budget will be in excess of geochemical new production estimates. This suggests that the various physical and biological transport fluxes, as well as geochemical inferences of new production, still need to be reconciled and many outstanding questions remain.

Siegel, David A.↗
NASA NTRS1999

Mesoscale Eddies, Satellite Altimetry, and New Production in the Sargasso Sea

Satellite altimetry and hydrographic observations are used to characterize the mesoscale eddy field in the Sargasso Sea near Bermuda and to address the role of physical processes on the supply of new nutrients to the euphotic zone. The observed sea level anomaly (SLA) field is dominated by the occurrence of westward propagating features with SLA signatures as large as 25 cm, Eulerian temporal scales of roughly a month, lifetimes of several months, spatial scales of approximately 200 km, and a propagation of approximately 5 cm/s . Hydrographic estimates of dynamic height anomaly (referenced to 4000 dbar) are well correlated with satellite SLA (r(sup 2) = 0.65), and at least 85% of the observed dynamic height variability is associated with the first baroclinic mode of motion. This allows us to apply the satellite observations to remotely estimate isopycnal displacements and the flux of nutrients into the euphotic zone due to eddy pumping. Eddy pumping is the process by which mesoscale eddies induce isopycnal displacements that lift nutrient- replete waters into the euphotic zone, driving new primary production. A kinematic approach to the estimation of the eddy pumping results in a flux of 0.24+/-0.1 mol N/sq m/yr (including a scale estimate for the small contribution due to 18 deg water eddies). This flux is more than an order of magnitude larger than the diapycnal diffusive flux as well as scale estimates for the vertical transport due to isopycnal mixing along sloping isopycnal surfaces. Eddy pumping and wintertime convection are the two dominant mechanisms transporting new nutrients into the euphotic zone, and the sum of all physical new nutrient supply fluxes effectively balances previous geochemical estimates of annual new production for this site. However, if biological transports (e.g., nitrogen fixation, etc.) are significant, the new nitrogen supply budget will be in excess of geochemical new production estimates. This suggests that the various physical and biological transport fluxes, as well as geochemical inferences of new production, still need to be reconciled and many outstanding questions remain.

Siegel, David A.↗
NASA NTRS2006

Impact of Solar Array Designs on High Voltage Operations

As power levels of advanced spacecraft climb above 25 kW, higher solar array operating voltages become attractive. Even in today s satellites, operating spacecraft buses at 100 V and above has led to arcing in GEO communications satellites, so the issue of spacecraft charging and solar array arcing remains a design problem. In addition, micrometeoroid impacts on all of these arrays can also lead to arcing if the spacecraft is at an elevated potential. For example, tests on space station hardware disclosed arcing at 75V on anodized A1 structures that were struck with hypervelocity particles in Low Earth Orbit (LEO) plasmas. Thus an understanding of these effects is necessary to design reliable high voltage solar arrays of the future, especially in light of the Vision for Space Exploration of NASA. In the future, large GEO communication satellites, lunar bases, solar electric propulsion missions, high power communication systems around Mars can lead to power levels well above 100 kW. As noted above, it will be essential to increase operating voltages of the solar arrays well above 80 V to keep the mass of cabling needed to carry the high currents to an acceptable level. Thus, the purpose of this paper is to discuss various solar array approaches, to discuss the results of testing them at high voltages, in the presence of simulated space plasma and under hypervelocity impact. Three different types of arrays will be considered. One will be a planar array using thin film cells, the second will use planar single or multijunction cells and the last will use the Stretched Lens Array (SLA - 8-fold concentration). Each of these has different approaches for protection from the space environment. The thin film cell based arrays have minimal covering due to their inherent radiation tolerance, conventional GaAs and multijunction cells have the traditional cerium-doped microsheet glasses (of appropriate thickness) that are usually attached with Dow Corning DC 93-500 silicone adhesive. In practice, these cover glasses and adhesive do not cover the cell edges. Finally, in the SLA, the entire cell and cell edges are fully encapsulated by a cover glass that overhangs the cell perimeter and the silicone adhesive covers the cell edges providing a sealed environment. These three types of blanket technology have been tested at GRC and Auburn. The results of these tests will be described. For example, 15 modules composed of four state-of-the-art 2x4 cm GaAs solar cells with 150 pm cover glasses connected in two-cell series strings were tested at high voltage, in plasma under hypervelocity impact. A picture of one of the modules is shown in figure 1. These were prepared by standard industry practice from a major supplier and had efficiencies above 18%. The test results and other fabrication factors that influenced the tests will be presented. In addition, results for SLA segments tested under the same conditions will be presented. Testing of thin film blankets at GRC will also be presented. Figure 1 : Typical GaAs Solar Cell Module These results will show significant differences in resistance to arcing that are directly related to array design and manufacturing procedures. Finally, the approaches for mitigating the problems uncovered by these tests will be described. These will lay the foundation for future higher voltage array operation, even including voltages above 300-600 V for direct drive SEP applications.

Brandhorst, Henry W., Jr.↗
NASA NTRS2016

Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM technology to print plastic while laying an internal filament of Kevlar or carbon-fiber inside the printed material. It has been incredible being exposed to this range of technologies and I feel very fortunate to be ready for virtually any kind of printing technology I come across in the future. Design work played a part in my internship this term as well. Working with Hai Nguyen, I was able to design a set of testing tips and a test frame for use with an Arcjet. The testing tips will be made of several different materials that will possibly be used in the heat shield of the Orion space craft. These designs included technical drawings that were presented to the fabrication shop. The frame design was created from 80/20 (a popular brand of frame construction equipment) and included an order form with pricing for fabrication. An independent design was also done for the virtual reality lab. This design was to create a hand-controller based on a previous design. This final design was sent directly to a 3D printer without technical drawings. Overall, my design work has given me experience with using 80/20, helped improve my CAD (Computer Aided Design) proficiency, and increased my knowledge of how to set up technical drawings for fabrication. The final role I have played in this internship has been to assist with testing of the inflatable technology materials working Khadijah Shariff. I began the internship assisting with permeability testing with the initial plan to continue the testing independently after training. Unfortunately, the testing apparatus suffered a technical failure and had funding pulled which cancelled that portion of the project. Further testing with inflatable technology continued with tensile testing of various stitching methods. This testing took place over a two-days and concluded successfully. Final testing was to be more tensile testing but of straps used to connect various inflatable sections. Unfortunately, the needed grips for the tensile tests could not be located and put the testing on hold. It is possible this round of testing will still take place by the end of the internship if the grips can be found. Overall, this portion of the internship has helped me become familiar with one kind of permeability test as well as a popular tensile/compression testing machine. Finally, I also had the chance to be trained using a metal lathe for making very small tips for a soldering iron. These tips will be used to melt threaded brass inserts into 3D printed plastic. Working with James Brown, I was able to successfully machine a brass rod down to as little as 0.064 inches plus or minus 0.001 inches. It was very rewarding to learn how to best use the machine and become familiar with a skill that will undoubtedly be used again in the future. I have been told by several professional engineers that learning to use a lathe and mill will be invaluable skills in the field. This knocks 50 percent of that goal off and I look forward to learning the mill at some point in the future. As is apparent with this list of projects, my internship was not focused on a single over-arching goal. Instead, I was able to gain experience in a myriad of very different areas. I feel like my time here was spent bouncing from one project to the next. Though sometimes difficult to switch gears, it was very rewarding to be a part of so much in so little time. My career and education will be positively impacted by what I have learned at JSC. My experience with 3D printing has improved my ability to handle many issues that may come up in the future with multiple different technologies. The design work I took part in, especially creating technical drawings, will help me better present designs to any engineer or shop I will encounter. My testing experience has helped me become familiar with a popular kind of tensile test machine that will likely be similar to the kinds I will encounter in the future. Finally, my experience with fabrication has given me a rare opportunity, as an engineer, to take part in the fabrication of a part. This experience will help me better tailor my future designs for the manufacturing process and has given me an appreciation for detailed/delicate machining work. My experience at JSC has been successful and will continue to assist me for a long time within the engineering field.

Zusack, Steven↗
NASA NTRS2026

Aerodynamic Performance and Acoustic Impacts of Varying Tip Speeds and Tripping Conditions on Small Rotors in an Anechoic Hover Chamber

Performance and acoustic measurements were taken in a hover chamber for various optimum hovering rotors (OPT2) and a commercial-off-the-shelf (COTS) rotor. A total of 10 rotors are included in this report, all of which have two blades and a tip radius of 0.1905 m (7.5 in.). For the OPT2, results for three additive manufacturing methods of fabrication are presented: stereolithography(SLA) using Accura Xtreme, SLA using FormLabs 10K resin, and selective laser sintering (SLS) using mineral-filled PA12 nylon material. All but one set of rotors were designed with a trailing edge bluntness that is 3% of the chord length, and one set was designed with a bluntness that is 1% of the chord length. Spanwise boundary layer trips were applied to the SLA, FormLabs and COTS rotors. Performance comparisons between untripped and tripped configurations demonstrate the impact of boundary layer state on rotor efficiency. Acoustic results, including periodic and broadband noise components, are presented. The effects of tripping these rotors near the leading edge are also presented. For some of the rotors, acoustic spectra of tip speed sweeps are presented to show how the frequency content changes with tip speed. Amplitude and frequency scaling methods are used to collapse broadband spectra at various tip speeds towards a unified curve. These findings contribute to the understanding of small rotor aeroacoustics and provide valuable datasets for computational model validation in urban air mobility applications.

eVTOL↗
NASA NTRS1992

MESUR probe aerobrake preliminary design study

Aerobrake design for the Mars Environmental Survey (MESUR) vehicles is considered which is intended for both a nominal entry velocity of 7 km/sec and a high-speed case of 9 km/sec. Topics discussed include the entry environment, the thermal protection requirements for several types of heat shield materials, the structural design of the aeroshell, and the total aerobrake masses and mass fractions. For the nominal 7 km/sec entry, a silicone elastometric charring ablator, SLA-561, was found to be the lightest heat shield material. For the 7 km/sec entry, the mass fraction of the aerobrake was 13.2 percent. For the 9 km/sec entry, the heat shield consisted of the medium-density ablator AVCOAT-5026; SLA-561 was used on part of the conical skirt. The aerobrake mass fraction in this case was 18 percent. It is recommended that separate aerobrakes be designed for probes entering at 7 and 9 km/sec.

Tauber, M.↗
NASA NTRS1991

A special purpose silicon compiler for designing supercomputing VLSI systems

Design of general/special purpose supercomputing VLSI systems for numeric algorithm execution involves tackling two important aspects, namely their computational and communication complexities. Development of software tools for designing such systems itself becomes complex. Hence a novel design methodology has to be developed. For designing such complex systems a special purpose silicon compiler is needed in which: the computational and communicational structures of different numeric algorithms should be taken into account to simplify the silicon compiler design, the approach is macrocell based, and the software tools at different levels (algorithm down to the VLSI circuit layout) should get integrated. In this paper a special purpose silicon (SPS) compiler based on PACUBE macrocell VLSI arrays for designing supercomputing VLSI systems is presented. It is shown that turn-around time and silicon real estate get reduced over the silicon compilers based on PLA's, SLA's, and gate arrays. The first two silicon compiler characteristics mentioned above enable the SPS compiler to perform systolic mapping (at the macrocell level) of algorithms whose computational structures are of GIPOP (generalized inner product outer product) form. Direct systolic mapping on PLA's, SLA's, and gate arrays is very difficult as they are micro-cell based. A novel GIPOP processor is under development using this special purpose silicon compiler.

Venkateswaran, N.↗
NASA NTRS1994

Geosat-derived sea level and surface current anomalies in the equatorial Pacific during the 1986-1989 El Nino and La Nina

Equatorial wave dynamics are essential in most oceanic models for reproducing aspects of the El Nino-Southern Oscillation (ENSO) phenomenon. Observational evidence of first baroclinic equatorial Kelvin and first symmetric meridional Rossby waves is found in Geosat-derived sea level anomalies (SLA) and surface zonal current anomalies (ZCA) in the equatorial Pacific ocean during the 1986-1987 El Nino and the ensuing 1988-1989 La Nina. This was made possible after extensive quality control and specific processing of the recently improved Geosat geophysical data records pertaining to the 17-day Exact Repeat Mission. In particular, the processing was made so that the Geosat-derived ZCA best fit near-surface zonal currents from three equatorial moorings at 165 deg E, 140 deg W, and 110 deg W. The Geosat-derived SLA and ZCA are decomposed into first baroclinic equatorial Kelvin and gravest Rossby modes. The emphasis is then put on the chronology of the ZCA at the equator where the currents are the most energetic and where Kelvin and first symmetric Rossby waves explain most of the variance in ZCA, in similar proportion. The 1986-1987 El Nino is mostly characterized by a strong downwelling Kelvin wave in December 1986, a series of downwelling Kelvin waves in March-October 1987, and a strong upwelling Rossby wave in March-September 1987. These waves are consistent with wind forcing, and all give rise to notable eastward ZCA for almost an entire year. During El Nino-La Nina transition period there is the occurrence of two downwelling Rossby waves originating from the eastern Pacific at times of favorable wind forcing. These Rossby waves switch the basin-wide ZCA from eastward to westward, terminating the warm event. Then, the 1988-1989 La Nina shows the generation of a series of upwelling Kelvin waves which are clearly identified in March/April and September/October 1988. These upwelling Kelvin waves are apparently related to the enhencement of the trade wind in the western half of the basin. These waves maintain the basin-wide westward ZCA for more than a year, although the ZCA is slightly reduced ba front of upwelling Rossby waves in phase with the normal seasonal cycle. The Kelvin wave forcing and sign of kelvin wave contribution versus Rossby wave contribution to ZCA in the western Pacific are discussed, and we conclude that neither pleads in favor of the delayed action oscillator mechanism.

Delcroix, Thierry↗
NASA NTRS1998

Application of Rapid Prototyping Methods to High-Speed Wind Tunnel Testing

This study was undertaken in MSFC's 14-Inch Trisonic Wind Tunnel to determine if rapid prototyping methods could be used in the design and manufacturing of high speed wind tunnel models in direct testing applications, and if these methods would reduce model design/fabrication time and cost while providing models of high enough fidelity to provide adequate aerodynamic data, and of sufficient strength to survive the test environment. Rapid prototyping methods utilized to construct wind tunnel models in a wing-body-tail configuration were: fused deposition method using both ABS plastic and PEEK as building materials, stereolithography using the photopolymer SL-5170, selective laser sintering using glass reinforced nylon, and laminated object manufacturing using plastic reinforced with glass and 'paper'. This study revealed good agreement between the SLA model, the metal model with an FDM-ABS nose, an SLA nose, and the metal model for most operating conditions, while the FDM-ABS data diverged at higher loading conditions. Data from the initial SLS model showed poor agreement due to problems in post-processing, resulting in a different configuration. A second SLS model was tested and showed relatively good agreement. It can be concluded that rapid prototyping models show promise in preliminary aerodynamic development studies at subsonic, transonic, and supersonic speeds.

Springer, A. M.↗
NASA NTRS1998

Atmospheric Depolarization Lidar Experimental Receiver: A Space Shuttle Hitchhiker Payload

Development work is underway at the Goddard Space Flight Center to construct a depolarization measuring atmospheric lidar receiver. The Atmospheric Lidar (AL) is tentatively scheduled to fly on the Space Shuttle in a late-1999 time frame. The AL will fly in conjunction with the Shuttle Laser Altimeter (SLA) and the Infrared Spectral Imaging Radiometer (ISIR) to provide a comprehensive package of atmospheric aerosol and cloud information. The AL operates in conjunction with the SLA laser transmitter and measures profiles of atmospheric backscatter at 532 nm. The receiver system discriminates between the parallel and perpendicular polarizations of the backscattered signal, thus providing depolarization ratios for scattering from clouds. The lidar receiver also provides cloud height and thickness measurements to complement the brightness temperature measurements generated by the ISIR thermal imager. The function of the AL is twofold. The primary function is to provide range-resolved measurements of atmospheric aerosol backscatter and depolarization ratio at 532 nm with 75 m vertical resolution. The scientific purpose of these measurements is to determine composition of clouds based on the depolarization ratio (i.e cloud content is water or ice), to determine cloud height and thickness, and to gain further understanding of the global distribution of aerosols. This information, when coupled with the cloud brightness measured by the ISIR thermal imager will provide a significant amount of information on cloud composition and radiative effects, particularly for cirrus and sub-visual cirrus clouds. A secondary function of the AL is to serve as an in-space test bed for lidar technology advancements, including a fully fiber-coupled receiver and photon counting from space. In addition, the data obtained by the AL will be used to develop software for the Geoscience Laser Altimeter System (GLAS) flight mission.

McGill, Matthew J.↗
NASA NTRS2000

POWOW: A Modular, High Power Spacecraft Concept

A robust space infrastructure encompasses a broad range of mission needs along with an imperative to reduce costs of satellites meeting those needs. A critical commodity for science, commercial and civil satellites is power at an affordable cost. The POWOW (POwer WithOut Wires) spacecraft concept was created to provide, at one end of the scale, multi-megawatts of power yet also be composed of modules that can meet spacecraft needs in the kilowatt range. With support from the NASA-sponsored Space Solar Power Exploratory Research and Technology Program, the POWOW spacecraft concept was designed to meet Mars mission needs - while at the same time having elements applicable to a range of other missions. At Mars, the vehicle would reside in an aerosynchronous orbit and beam power to a variety of locations on the surface. It is the purpose of this paper to present the latest concept design results. The Space Power Institute along with four companies: Able Engineering, Inc., Entech, Inc., Primex Aerospace Co., and TECSTAR have produced a modular, power-rich electrically propelled spacecraft design that meets these requirements. In addition, it also meets a range of civil and commercial needs. The spacecraft design is based on multijunction Ill-V solar cells, the new Stretched Lens Aurora (SLA) module, a lightweight array design based on a multiplicity of 8 kW end-of-life subarrays and electric thrusters. The solar cells have excellent radiation resistance and efficiencies above 30%. The SLA has a concentration ratio up to 15x while maintaining an operating temperature of 80 C. The design of the 8 kW array building block will be presented and its applicability to commercial and government missions will be discussed. Electric propulsion options include Hall, MPD and ion thrusters of various power levels and trade studies have been conducted to define the most advantageous options. The present baseline spacecraft design providing 900 kW using technologies expected to be available in 2003 will be described. Areal power densities of nearly 400 W/meters squared at 80 C operating temperatures and wing level specific powers of over 400 W/kg are projected. Details of trip times and payloads to Mars will be presented as well as trade studies of various electric propulsion options. Trip times compare favorably with chemical propulsion options. Because the design is modular, learning curve methodology can be applied to determine expected cost reductions. These results will also be included. This paper has not been presented at a previous meeting.

Brandhorst, Henry W., Jr.↗
NASA NTRS2000

Internally Cooled Monolithic Silicon Nitride Aerospace Components

A set of rapid prototyping (RP) processes have been combined with gelcasting to make ceramic aerospace components that contain internal cooling geometry. A mold and core combination is made using a MM6Pro (Sanders Prototyping, Inc.) and SLA-250/40 (3Dsystems, Inc.). The MM6Pro produces cores from ProtoBuild (trademarked) wax that are dissolved in room temperature ethanol following gelcasting. The SLA-250/40 yields epoxy/acrylate reusable molds. Parts produced by this method include two types of specimens containing a high density of thin long cooling channels, thin-walled cylinders and plates, as well as a model hollow airfoil shape that can be used for burner rig evaluation of coatings. Both uncoated and mullite-coated hollow airfoils has been tested in a Mach 0.3 burner rig with cooling air demonstrating internal cooling and confirming the effectiveness of mullite coatings.

Best, Jonathan E.↗
NASA NTRS1994

Trajectory Based Heating and Ablation Calculations for MESUR Pathfinder Aeroshell

Based on the geometry of Mars Environment Survey (MESUR) Pathfinder aeroshell and an estimated Mars entry trajectory, two-dimensional axisymmetric time dependent calculations have been obtained using GIANTS (Gauss-Siedel Implicit Aerothermodynamic Navier-Stokes code with Thermochemical Surface Conditions) code and CMA (Charring Material Thermal Response and Ablation) Program for heating analysis and heat shield material sizing. These two codes are interfaced using a loosely coupled technique. The flowfield and convective heat transfer coefficients are computed by the GIANTS code with a species balance condition for an ablating surface, and the time dependent in-depth conduction with surface blowing is simulated by the CMA code with a complete surface energy balance condition. In this study, SLA-561V has been selected as heat shield material. The solutions, including the minimum heat shield thicknesses over aeroshell forebody, pyrolysis gas blowing rates, surface heat fluxes and temperature distributions, flowfield, and in-depth temperature history of SLA-561V, are presented and discussed in detail.

Chen, Y. K.↗
NASA NTRS2004

Stretched Lens Array Photovoltaic Concentrator Technology Developed

Solar arrays have been and continue to be the mainstay in providing power to nearly all commercial and government spacecraft. Light from the Sun is directly converted into electrical energy using solar cells. One way to reduce the cost of future space power systems is by minimizing the size and number of expensive solar cells by focusing the sunlight onto smaller cells using concentrator optics. The stretched lens array (SLA) is a unique concept that uses arched Fresnel lens concentrators to focus sunlight onto a line of high-efficiency solar cells located directly beneath. The SLA concept is based on the Solar Concentrator Array with Refractive Linear Element Technology (SCARLET) design that was used on NASA's New Millennium Deep Space 1 mission. The highly successful asteroid/comet rendezvous mission (1998 to 2001) demonstrated the performance and long-term durability of the SCARLET/SLA solar array design and set the foundation for further improvements to optimize its performance.

Piszczor, Michael F., Jr.↗