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At least 37 records · Page 2

Improved Heat Treatment Of Steel Alloy 4340

New process takes significantly less time than prior heat-treatment processes. Involves placing steel plate directly in furnace and heat-treating. Plate then quenched in slowly moving oil to reduce stresses. Any deflection then pressed out. Possible uses of 4340 steel include new and improved bulletproof vests for military and police personnel and armor for bulletproof automobiles for military, police, diplomatic, and private users. Also used in other military land vehicles as tanks and in both military and civilian aircraft. Lighter armorplate enables land vehicles and aircraft to attain greater speed and maneuverability, consume less fuel, and afford better protection from snipers or terrorists.

Cooper, Lawrence B.

Radiation Blocking Lenses

The Biomedical Optical Company of America's Eagle 475 lens absorbs 100 percent of all photowavelengths considered hazardous to eye tissue, including ultraviolet and blue light, which are considered contributors to cataract and age-related macular degeneration. The lens absorbs hazardous wavelengths, but allows a higher percentage of visually useful areas of the spectrum to pass through. Polarization blocks out irritating glint and glare and heightens visual acuity. The Eagle 475 sunglasses are the latest in a series of spinoffs that originated at the Jet Propulsion Laboratory where two scientists developed a protective, welding curtain that filtered out harmful irradiance. The result was a commercial curtain that absorbs filters and scatters light, providing protection for personnel in welding areas. Further research focused on protective industrial glasses and later on consumer products.

Source record

Oxidation Behavior of GRCop-84 Copper Alloy Assessed

NASA's goal of safe, affordable space transportation calls for increased reliability and lifetimes of launch vehicles, and significant reductions of launch costs. The areas targeted for enhanced performance in the next generation of reusable launch vehicles include combustion chambers and nozzle ramps; therefore, the search is on for suitable liner materials for these components. GRCop-84 (Cu-8Cr-4Nb), an advanced copper alloy developed at the NASA Glenn Research Center in conjunction with Case Western Reserve University, is a candidate. The current liner of the Space Shuttle Main Engine is another copper alloy, NARloy-Z (Cu-3Ag-0.1Zr). It provides a benchmark against which to compare the properties of candidate successors. The thermomechanical properties of GRCop-84 have been shown to be superior, and its physical properties comparable, to those of NARloy-Z. However, environmental durability issues control longevity in this application: because copper oxide scales are not highly protective, most copper alloys are quickly consumed in oxygen environments at elevated temperatures. In consequence, NARloy-Z and most other copper alloys are prone to blanching, a degradation process that occurs through cycles of oxidation-reduction as the oxide is repeatedly formed and removed because of microscale fluctuations in the oxygen-hydrogen fuel systems of rocket engines. The Space Shuttle Main Engine lining typically degraded by blanching-induced hot spots that lead to surface roughening, pore formation, and coolant leakage. Therefore, resistance to oxidation and blanching are key requirements for second-generation reusable launch vehicle liners. The rocket engine ambient includes H2 (fuel) and H2O (combustion product) and is, hence, under reduced oxygen partial pressures. Accordingly, our studies were expanded to include oxygen partial pressures as low as 322 parts per million (ppm) at the temperatures likely to be experienced in service. A comparison of 10-hr weight gains of GRCop-84, NARloy-Z, and pure copper in 0.032, 2.2, and 100 percent oxygen from 550 to 750 C is shown. In 2.2 vol% and higher oxygen content, GRCop-84 oxidation was slower than that of NARloy-Z or Cu, but that advantage was lost or diminished in 322-ppm O2. Over longer (50-hr) exposures in 1.0 atm O2, however, the advantage of GRCop-84 increased significantly, its oxidation rate becoming approximately 10 times slower than those of Cu and NARloy-Z from 500 to 700 C. Weight gains were moderate and the kinetics parabolic for all three materials in 2.2 vol% and higher oxygen content; however, in 322-ppm O2, the scales were nonprotective below about 650 C, as reflected in linear kinetics and large weight gains. The superior oxidation resistance of GRCop-84 is likely related to the kinetics of extra oxygen consumption to form the additional oxides of Cr and Nb detected beneath the GRCop-84 oxide layer. While we continue to evaluate the blanching resistance of GRCop-84 in other tests, these oxidation results indicate that GRCop-84 is suitable as a reusable launch vehicle liner, and in applications where it is desired to use a copper alloy but without the risk of oxidative failure. Three bar charts comparing overall specific weight gains by each of the three materials studied. The top chart is for oxidation in 1.0 atm of oxygen, the middle is for 2.2% oxygen (balance argon), and the bottom is for 0.0322% oxygen. GRCop-84 outperforms the other two materials, showing the least weight gain in nearly all cases.

Thomas-Ogbuji, Linus U.

Electromagnetic-Repulsion Systems For Deicing Aircraft

Improved eddy-current electromagnetic-repulsion deicing systems developed for use on variety of exterior aircraft surfaces like leading edges of wings, engine inlets, propellers, and helicopter rotors. Fit to exterior surfaces, as retrofits or original equipment. Systems light in weight, consume little average power, and capable of protecting against severe icing conditions.

Smith, Samuel O.

Operational Philosophy Concerning Manned Spacecraft Cabin Leaks

The last thirty years have seen the Space Shuttle as the prime United States spacecraft for manned spaceflight missions. Many lessons have been learned about spacecraft design and operation throughout these years. Over the next few decades, a large increase of manned spaceflight in the commercial sector is expected. This will result in the exposure of commercial crews and passengers to many of the same risks crews of the Space Shuttle have encountered. One of the more dire situations that can be encountered is the loss of pressure in the habitable volume of the spacecraft during on orbit operations. This is referred to as a cabin leak. This paper seeks to establish a general cabin leak response philosophy with the intent of educating future spacecraft designers and operators. After establishing a relative definition for a cabin leak, the paper covers general descriptions of detection equipment, detection methods, and general operational methods for management of a cabin leak. Subsequently, all these items are addressed from the perspective of the Space Shuttle Program, as this will be of the most value to future spacecraft due to similar operating profiles. Emphasis here is placed upon why and how these methods and philosophies have evolved to meet the Space Shuttle s needs. This includes the core ideas of: considerations of maintaining higher cabin pressures vs. lower cabin pressures, the pros and cons of a system designed to feed the leak with gas from pressurized tanks vs. using pressure suits to protect against lower cabin pressures, timeline and consumables constraints, re-entry considerations with leaks of unknown origin, and the impact the International Space Station (ISS) has had to the standard Space Shuttle cabin leak response philosophy. This last item in itself includes: procedural management differences, hardware considerations, additional capabilities due to the presence of the ISS and its resource, and ISS docking/undocking considerations with a cabin leak occurring. The paper also offers a look at how different equipment configurations on future spacecraft impact the previously defined cabin leak operational philosophy and includes additional operational methods and considerations that result due to various configurations. The intent is to showcase these various considerations and highlight the variability they allow. The paper concludes with a selection of the author s personal observations from a spacecraft operator's point of view and recommendations with the goal of improving the design and operations of future spacecraft.

DeSimpelaere, Edward

Life Support and Habitation Systems: Crew Support and Protection for Human Exploration Missions Beyond Low Earth Orbit

The National Aeronautics and Space Administration (NASA) has recently expanded its mission set for possible future human exploration missions. With multiple options there is interest in identifying technology needs across these missions to focus technology investments. In addition to the Moon and other destinations in cis-lunar space, other destinations including Near Earth Objects and Mars have been added for consideration. Recently, technology programs and projects have been re-organizing to better meet the Agency s strategic goals and address needs across these potential future missions. Life Support and Habitation Systems (LSHS) is one of 10 Foundational Domains as part of the National Aeronautics and Space Administration s Exploration Technology Development Program. The chief goal of LSHS is to develop and mature advanced technologies to sustain human life on missions beyond Low Earth Orbit (LEO) to increase reliability, reduce dependency on resupply and increase vehicle self-sufficiency. For long duration exploration missions, further closure of life support systems is of interest. Focus includes key technologies for atmosphere revitalization, water recovery, waste management, thermal control and crew accommodations. Other areas of focus include technologies for radiation protection, environmental monitoring and fire protection. The aim is to recover additional consumable mass, reduce requirements for power, volume, heat rejection, crew involvement, and meet exploration vehicle requirements. This paper provides a brief description of the LSHS Foundational Domain as defined for fiscal year 2011.

Barta, Daniel J.

Homomorphic Encryption for Electrical Metering Aggregation: Protecting the Privacy of Building Tenants

Electrical meters are devices that measure consumer electricity usage. The data collected by these meters is necessary for utility billing and electrical grid management but can also be used to assess the environmental impact of buildings. Prior research has found that unprotected metering data could potentially be used to infer some information about the behaviors of building tenants by detecting changes in electricity usage. For example, a period of low electricity usage could suggest that the tenants are not in the building. As smart metering becomes more common, there is a growing need for data privacy protections for metering data that do not negatively impact the quality and availability of data used for energy management and billing applications. To identify potential solutions, we developed a Python-based data aggregation platform to analyze the potential efficacy of privacy-enhancing technologies for energy metering applications. This platform aggregates groups of metering sites into virtual buildings, which could potentially detach changes in electrical activity from individual tenants, making it more difficult to track the activity of a specific tenant. To further protect data during analysis, this project utilizes homomorphic encryption as part of its initial approach. Homomorphic encryption offers a means of protecting energy consumption data while permitting mathematical operations to be performed without the need to know the data contents. This allows for data to be processed into usable statistics without revealing energy consumption information. A series of homomorphic encryption libraries were evaluated to determine their applicability and limitations in the context of metering data. The use of these techniques may help to reassure consumers and encourage further adoption of smart grid infrastructure.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Development of Next Generation Hierarchical Hybrid Cu-Si anode Batteries via Direct-Ink Writing Application: End of (6th) Month Report - November 2025

Sustainable renewable energy continues to be in dire need to effectively combat global warming. Emerging technology for electric vehicles/ devices remains in high demand that is not only lower in cost, more efficient, but safer in comparison to commercial materials on the market. Although first-generation lithium-ion batteries have exhibited extensive commercial application, conventional graphite no longer meets this increasing demand as an efficient anode material. Due to the fact that graphite has a subpar theoretical specific capacity (372 mAh g -1 ), thus significant limitations in rate capability (for potential faster charging at higher C-rates currently commercially available.). Alternatively, silicon has gained significant attention as a superior candidate to potentially surpass graphite. Due to silicon’s exceedingly high theoretical capacity (4,200 mAh g -1 ) in comparison to standard graphite, its abundance thus in turn it’s low-cost, in addition to exhibiting a significantly low working potential (< 0.4 V vs Li/Li + ). However, one of the main (and most detrimental) challenges is silicon’s tendency to expand in volume (> 300%) upon discharge as it begins the lithiation process. As a direct result, it causes not only for the particles to both crack and pulverize under mechanical stress as the volume continues to expand and contract during cycling. Upon assembling the cell, it needs to undergo ‘charging’ for initially discharging/ ‘activating’ the cell, otherwise commonly known as the ‘formation’ step. As a result a solid electrolyte interface (SEI) layer begins to form at the anode surface because some of the electrolyte begins to react during the formation process. However, this (SEI) layer is deemed as a ‘protective’ interlayer because in theory it prevents further reaction as the cell continues to cycle. However, due to the volume change it causes significant degradation at the interface. As cracking starts to occur at the anode surface, it results in a ‘new’ altered surface with each cycle that causes further reaction with the electrolyte as a byproduct quickly consuming active Li/ and more electrolyte. Thus, fracturing this ‘protective layer,’ causing significantly higher impedance as a result, and in turn a decline in capacity due to active Li-loss. In addition to the active material exfoliating off from the current collector, further contributing to the steady decline in capacity and overall performance. Current state of the art Si-anode batteries on the market range between a maximum content of 5-10 Si wt%. It has been previously reported Tesla has utilized SiO x -C anodes containing 5 wt% Si within their ‘Model 3/ Model X’ electric vehicles. However, more recent ‘Model 3’ vehicles have started to incorporate 10 Si wt%, in which they were able to increase their energy density upwards by approximately 30%. Recent effort has been focused on continuing to increase the wt% of Si being utilized, eventually to 100 wt% of Si, to maximize the energy density even further.

36 MATERIALS SCIENCE

Galvanic Liquid Applied Coating System for Protection of Embedded Steel Surfaces from Corrosion

The corrosion of reinforcing steel in concrete is an insidious problem for the Kennedy Space Center, government agencies, and the general public. Existing corrosion protection systems on the market are costly, complex, and time-consuming to install, require continuous maintenance and monitoring, and require specialized skills for installation. NASA's galvanic liquid-applied coating offers companies the ability to conveniently protect embedded steel rebar surfaces from corrosion. Liquid-applied inorganic galvanic coating contains one ore more of the following metallic particles: magnesium, zinc, or indium and may contain moisture attracting compounds that facilitate the protection process. The coating is applied to the outer surface of reinforced concrete so that electrical current is established between metallic particles and surfaces of embedded steel rebar; and electric (ionic) current is responsible for providing the necessary cathodic protection for embedded rebar surfaces.

Curran, Joseph

Feasibility and tradeoff study of an aeromaneuvering orbit-to-orbit shuttle (AMOOS)

This study establishes that configurations satisfying the aeromaneuvering orbit-to-orbit shuttle (AMOOS) requirements can be designed with performance capabilities in excess of the purely propulsive space tug. In view of this improved potential of the AMOOS vehicle over the propulsive space tug concept it is recommended that the AMOOS studies be advanced to a stage comparable to those performed for the space tug. This advancement is needed in particular in areas that are either peculiar to AMOOS or not addressed in sufficient detail in these studies to date. These areas include the thermodynamics problems, navigation and guidance, operations and economics analyses, subsystems and interfaces. The aeromaneuvering orbit-to-orbit shuttle (AMOOS) is evaluated as a candidate reusable third stage to the two-stage earth-to-orbit shuttle (EOS). AMOOS has the potential for increased payload capability over the purely propulsive space tug by trading a savings in consumables for an increase in structural and thermal protection system (TPS) mass.

White, J.

Development and Demonstration of Sustainable Surface Infrastructure for Moon/Mars Exploration

For long-term human exploration of the Moon and Mars to be practical, affordable, and sustainable, future missions must be able to identify and utilize resources at the site of exploration. The ability to characterize, extract, processes, and separate products from local material, known as In-Situ Resource Utilization (ISRU), can provide significant reductions in launch mass, logistics, and development costs while reducing risk through increased mission flexibility and protection as well as increased mission capabilities in the areas of power and transportation. Making mission critical consumables like propellants, fuel cell reagents and life support gases, as well as in-situ crew/hardware protection and energy storage capabilities can significantly enhance robotic and human science and exploration missions, however other mission systems need to be designed to interface with and utilize these in-situ developed products and services from the start or the benefits will be minimized or eliminated. This requires a level of surface and transportation system development coordination not typically utilized during early technology and system development activities. An approach being utilized by the US National Aeronautics and Space Administration and the Canadian Space Agency has been to utilize joint analogue field demonstrations to focus technology development activities to demonstrate and integrate new and potentially game changing. mission critical capabilities that would enable an affordable and sustainable surface infrastructure for lunar and Mars robotic and human exploration. Two analogue field tests performed in November 2008 and February 2010 demonstrated first generation capabilities for lunar resource prospecting, exploration site preparation, and oxygen extraction from regolith while initiating integration with mobility, science, fuel cell power, and propulsion disciplines. A third analogue field test currently planned for June 2012 will continue and expand the fidelity and integration of these surface exploration and infrastructure capabilities while adding Mars exploration technologies, improving remote operations and control of hardware, and promoting the use of common software, interfaces, & standards for control and operation for surface exploration and science. The next field test will also attempt to include greater involvement by industry, academia, and other countries/space agencies. This paper will provide an overview of the development and demonstration approach utilized to date, the results of the previous two ISRU-focused field analogue tests in Hawaii, and the current objectives and plans for the 3rd international Hawaii analogue field test.

Sanders, Gerald B.

Challenges, Industry Practice, and Research Opportunities for Protection of IBR-Rich Systems

The objective of this technical report is to outline the challenges of protection design for power systems rich in inverter-based resources (IBRs), synthesize current industrial practices, review new approaches from recent literature, and explore future opportunities in protection. IBRs are experiencing widespread adoption across both transmission and distribution systems. When present in significant quantities, IBRs challenge the performance of many traditional protection functions. To address these issues, the industry has developed sophisticated protection schemes that involve advanced relaying techniques in highly engineered pilot projects. However, these schemes are expensive and time-consuming to develop, build, and test. Researchers have proposed a number of new approaches for protection in IBR-rich distribution systems. Despite their potential, these new approaches do not address some major shortcomings of industry approaches stemming from complexity, practical requirements, and reliability.

24 POWER TRANSMISSION AND DISTRIBUTION

Lightning protection of the Fokker 100 CFRP rudder

The construction of the structural parts of the Fokker 100 CFRP rudder is described with respect to the requirements for electrical bonding and lightning protection. Furthermore, the philosophy for the selection of a consumable trailing edge is given. A description of possible alternative designs for trailing edges and their advantages and disadvantages with respect to damage after lightning impact will also be reviewed. An overview of the tests performed on test samples and the rudder construction are presented and discussed. The effectiveness of both the selected structural provisions and trailing edge are described (and proven) by reporting the results of the simulated lightning tests performed. Proof is given that the trailing edge construction and its bonding through the structural parts of the rudder to the main aircraft structure is a solution which results in minor damage to the rudder after lightning impact. Furthermore, it is shown that the selected trailing edge construction is less favored by the structural designers due to the weight penalty.

Ruiter, A. J. M.

Performance of a 100V Half-Bridge MOSFET Driver, Type MIC4103, Over a Wide Temperature Range

The operation of a high frequency, high voltage MOSFET (metal-oxide semiconductor field-effect transistors) driver was investigated over a wide temperature regime that extended beyond its specified range. The Micrel MIC4103 is a 100V, non-inverting, dual driver that is designed to independently drive both high-side and low-side N-channel MOSFETs. It features fast propagation delay times and can drive 1000 pF load with 10ns rise times and 6 ns fall times [1]. The device consumes very little power, has supply under-voltage protection, and is rated for a -40 C to +125 C junction temperature range. The floating high-side driver of the chip can sustain boost voltages up to 100 V. Table I shows some of the device manufacturer s specification.

Patterson, Richard L.

Sound Guard

Lubrication technology originally developed for a series of NASA satellites has produced a commercial product for protecting the sound fidelity of phonograph records. Called Sound Guard, the preservative is a spray-on fluid that deposits a microscopically thin protective coating which reduces friction and prevents the hard diamond stylus from wearing away the softer vinyl material of the disc. It is marketed by the Consumer Products Division of Ball Corporation, Muncie, Indiana. The lubricant technology on which Sound Guard is based originated with NASA's Orbiting Solar Observatory (OSO), an Earth-orbiting satellite designed and built by Ball Brothers Research Corporation, Boulder, Colorado, also a division of Ball Corporation. Ball Brothers engineers found a problem early in the OSO program: known lubricants were unsuitable for use on satellite moving parts that would be exposed to the vacuum of space for several months. So the company conducted research on the properties of materials needed for long life in space and developed new lubricants. They worked successfully on seven OSO flights and attracted considerable attention among other aerospace contractors. Ball Brothers now supplies its "Vac Kote" lubricants and coatings to both aerospace and non-aerospace industries and the company has produced several hundred variations of the original technology. Ball Corporation expanded its product line to include consumer products, of which Sound Guard is one of the most recent. In addition to protecting record grooves, Sound Guard's anti-static quality also retards particle accumulation on the stylus. During comparison study by a leading U.S. electronic laboratory, a record not treated by Sound Guard had to be cleaned after 50 plays and the stylus had collected a considerable number of small vinyl particles. The Sound Guard-treated disc was still clean after 100 plays, as was its stylus.

Source record

Pantex Plant Ogallala Aquifer and Perched Groundwater Contingency Plan

The Pantex Plant Ogallala Aquifer and Perched Groundwater Contingency Plan has been developed in accordance with the requirements identified in the: • Interagency Agreement for the Pantex Superfund Site, Article 8.5 Work to be Performed, • Compliance Plan Provision of Hazardous Waste Permit No. 50284, and • Record of Decision for Groundwater, Soil, and Associated Media, Pantex Plant. A Long‐Term Monitoring System Design has been designed to monitor conditions in the perched groundwater including changes in the perched aquifer as a result of implementing the response actions. Monitoring is required for verifying the effectiveness of perched groundwater response actions (i.e., conditions in the perched aquifer are being affected as intended) and for confirming that the perched aquifer and Ogallala Aquifer characterization as defined in the Resource Conservation and Recovery Act Facility Investigation Report and the Corrective Measure Studies/Feasibility Study remains accurate. If monitoring results obtained through the monitoring network identify an unexpected condition or deviation, contingent actions will be considered and implemented as necessary to ensure continued protection of the Ogallala Aquifer and human health and the environment. Potential deviations to expected technology performance may be encountered for each of the four primary response actions that compose the selected remedy for perched groundwater; Playa 1 Pump and Treat System, Southeast Area Pump and Treat System, Southeast Area In‐Situ Bioremediation System (comprised of the Southeast In‐Situ Bioremediation System Original System, Southeast Area In‐Situ Bioremediation System Extension System, Offsite In‐Situ Bioremediation System, Perchlorate/Chromium ISB, Northeast ISB and County Road 8 ISB), and Zone 11 In‐Situ Bioremediation System. Monitoring will also be conducted to determine if there are deviations to the expected characterization, e.g., contaminants not expected as a result of the RCRA Facility Investigation characterization. Deviations to expected conditions in the Ogallala Aquifer could also be encountered if the response actions in the perched groundwater are not performing as expected, i.e., preventing contaminants from migrating to the Ogallala Aquifer. Currently, Pantex has begun investigation of detections of high explosives above groundwater protection standards in wells on the Texas Tech University property and a plume that is moving to the northeast from that area. Due to those detections, this Plan recognizes the fact that future detections in the Ogallala will be focused on first‐ time detections of analytes. After a remedy is determined, this Plan will require modification to address-deviations and contingent actions. This Plan was developed to identify the contingent actions necessary to mitigate impacts resulting from deviations to site conditions or response action performance. The Plan defines the environmental problem being addressed by the response actions, clarifies the expected conditions and objectives of the response actions, and identifies the potential deviations to the response actions (due to site conditions or technology performance) that could be encountered. The deviations were evaluated to determine the likelihood of occurrence, potential impact, and time to respond to avoid impact. The Plan also identifies the monitoring outlined in the Long‐Term Monitoring System Design Report (Consolidated Nuclear Security, 2024) and Sampling Analysis Plan (PanTeXas Deterrence, 2024) that will be used to detect the deviations. Lastly, the Plan specifies the contingent actions that could be implemented in response to the deviations. Because each response focuses on a discrete portion of the perched aquifer and contaminant plume, each response action has a different set of expected conditions, and therefore differing impacts from deviations to the site and technology expectations. As a result, the contingent actions are identified for each response action and potential deviation including specific constituents, location, and conditions. If deviations are encountered that impact the ability of the response action to meet performance objectives, the contingent actions will be focused on ensuring the response action can meet the performance objective. Contingent actions may be implemented as interim actions (ISMs/removal actions) in accordance with the Record of Decision, Interagency Agreement, and Hazardous Waste Permit‐50284, if warranted by the specific circumstances. For deviations to site characterization expected conditions, the contingent action will focus on determination of the source of the deviation, determination of the appropriate response, and evaluation of additional work to be completed. However, if the deviation to characterization impacts the performance of the response action, the contingent action will again focus on ensuring performance objectives can be met. Early source term removals and cleanup actions have been implemented to protect the Ogallala Aquifer. Because of these actions and based on modeling results, the expected conditions in the Ogallala Aquifer are that constituents of concern will not be detected above the Groundwater Protection Standards (GWPSs) nor will they reach potential points of exposure above the GWPS. The primary deviation of concern for the Ogallala is if constituents are detected in the Ogallala Aquifer near or above GWPSs. If it occurs, this change in expected conditions would require further evaluation of site and contaminant characteristics to determine an appropriate course of action. The evaluation would include additional monitoring, source identification, implementation of interim protective measures (if necessary), and delineation of extent. These evaluations are necessary to determine an appropriate response action for the Ogallala. The primary goal of the Plan is to provide for the continued protection of the Ogallala Aquifer and the health of its consumers. In recognition, this Plan presents a flexible and rational approach for making future decisions associated with confirming the change in perched and Ogallala aquifer conditions and identifying a response (technical activities, changes to response actions, regulatory oversight, and public involvement).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W

Nonchamber, Root-Side, Inert-Gas Purging During Welding

Improved apparatus distributes inert gas to protect against oxidation on root side of weld during welding and after welding while joint remains hot. Simple and lightweight; readily moved along weld path in synchronism with torch. Because it concentrates inert gas where needed, consumes gas at relatively low rate, and not necessary to monitor oxygen content of protective atmosphere. Apparatus does not obscure view of root side of weld. Used for full-penetration plasma-arc welding of such reactive metals as aluminum/lithium alloys and titanium.

Mcgee, William F.

Design Optimisation and Mass Saving of the Structure of the Orion-MPCV European Service Module

This paper presents an overview of the design optimisation measures that have been proposed and analysed in order to reduce the mass of the structure, including the MMOD (Micro-Meteoroid and Orbital Debris) protection system, of the ESM (European Service Module) for the “Orion” MPCV (Multi-Purpose Crew Vehicle). Under an agreement between NASA and ESA, the NASA Orion MPCV for human space exploration missions will be powered by a European Service Module, based on the design and experience of the ATV (Automated Transfer Vehicle). The development and qualification of the European Service Module is managed and implemented by ESA. The ESM prime contractor and system design responsible is Airbus Defence and Space. Thales Alenia Space Italia is responsible for the design and integration of the ESM Structure and MMOD protection system in addition to the Thermal Control System and the Consumable Storage System. The Orion Multi-Purpose Crew Vehicle is a pressurized, crewed spacecraft that transports up to four crew members from the Earth’s surface to a nearby destination or staging point. Orion then brings the crew members safely back to the Earth’s surface at the end of the mission. Orion provides all services necessary to support the crew members while on-board for short duration missions (up to 21 days) or until they are transferred to another orbiting habitat. The ESM supports the crew module from launch through separation prior to re-entry by providing: in-space propulsion capability for orbital transfer, attitude control, and high altitude ascent aborts; water and oxygen/nitrogen needed for a habitable environment; and electrical power generation. In addition, it maintains the temperature of the vehicle's systems and components and offers space for unpressurized cargo and scientific payloads. The ESM has been designed for the first 2 Lunar orbit missions, EM-1 (Exploration mission 1) is an un-crewed flight planned around mid-2020, and EM-2, the first crewed flight, is planned in 2022. At the time where the first ESM is about to be weighted, the predicted mass lies slightly above the initial requirement. For future builds, mass reduction of the Service Module has been considered necessary. This is being investigated, together with other design improvements, in order to consolidate the ESM design and increase possible future missions beyond the first two Orion MPCV missions. The mass saving study has introduced new optimised structural concepts, optimisation of the MMOD protection shields, and optimised redesign of parts for manufacturing through AM (Additive Manufacturing).

Micro-Meteroids and Orbital Debris Protection Syst