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NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗

NASA NTRS1973

Solid motor aft closure insulation erosion

The erosion rate of aft closure insulation in a number of large solid propellant motors was empirically analyzed by correlating the average ablation rate with a number of variables that had previously been demonstrated to affect heat flux. The main correlating parameter was a heat flux based on the simplified Bartz heat transfer coefficient corrected for two-dimensional effects. A multiplying group contained terms related to port-to-throat ratio, local wall angle, grain geometry and nozzle cant angle. The resulting equation gave a good correlation and is a useful design tool.

Stampfl, E.↗

NASA NTRS1990

A three-dimensional approach for analysis of sidewall injector mixing and combustion

A three-dimensional (3-D) analytical approach to calculate the mixing and combustion efficiency along engine combustors that use sidewall fuel injectors is described. The analysis consists of three parts: (1) an empirical correlation for fuel penetration, (2) application of integral conservation laws following jet turning and pressure equilibration, and (3) an analytical solution for the simplified three-dimensional partial differential equations to describe the downstream mixing and combustion process. Numerical results are compared to some empirical and experimental work, and favorable agreements are shown. The importance of including anisotropic turbulence and three-dimensional effects are illustrated by comparison with data and other less comprehensive analyses. The analytical solution is suitable for rapid estimates of engine performance and parametric studies of combustor designs containing transverse or angled injector ports arranged in rows and/or columns.

Quan, Victor↗

NASA NTRS1992

Modeling of SSME fuel preburner ASI

The Augmented Spark Ignitor (ASI) is a LOX/H2/electrical spark system that functions as an ignition source and sustainer for stable combustion. It is used in the SSME preburner combustor, the SSME main combustion chamber, the J-1 and J-2 engines as well as proposed designs of the Space Transportation Main Engine (STME) main combustor and gas generators. In the SSME it is a long circular cylindrical chamber located along the Main Combustor centerline with a truncated conical dome at the top, which contains two oblique LOX injection ports and two spark plugs offset at 90 degrees. Hydrogen injection is through a number of nearly tangential slots downstream which creates a swirl flow intended to cool the AS1 chamber walls. Past incidents of erosion of the AS1 spark plugs have often led to the need for replacement of these very costly devices. Thus it is desirable to understand the complex reactive flow field within the AS1 both during the initial ignition transient and during the main stage steady state combustion (no sparking).

P Y Liang↗

NASA NTRS2002

International Space Station Nickel-Hydrogen Battery On-Orbit Performance

International Space Station (ISS) Electric Power System (EPS) utilizes Nickel-Hydrogen (Ni-H2) batteries as part of its power system to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The batteries are designed to operate at a 35 percent depth of discharge (DOD) maximum during normal operation. Thirty-eight individual pressure vessel (IPV) Ni-H2 battery cells are series-connected and packaged in an Orbital Replacement Unit (ORU). Two ORUs are series-connected utilizing a total of 76 cells to form one battery. The ISS is the first application for low earth orbit (LEO) cycling of this quantity of series-connected cells. The P6 (Port) Integrated Equipment Assembly (IEA) containing the initial ISS high-power components was successfully launched on November 30, 2000. The IEA contains 12 Battery Subassembly ORUs (6 batteries) that provide station power during eclipse periods. This paper will discuss the battery performance data after eighteen months of cycling.

Dalton, Penni↗

NASA NTRS2003

Update on International Space Station Nickel-Hydrogen Battery On-Orbit Performance

International Space Station (ISS) Electric Power System (EPS) utilizes Nickel-Hydrogen (Ni-H2) batteries as part of its power system to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The batteries are designed to operate at a 35% depth of discharge (DOD) maximum during normal operation. Thirty-eight individual pressure vessel (IPV) Ni-H2 battery cells are series-connected and packaged in an Orbital Replacement Unit (ORU). Two ORUs are series-connected utilizing a total of 76 cells, to form one battery. The ISS is the first application for low earth orbit (LEO) cycling of this quantity of series-connected cells. The P6 (Port) Integrated Equipment Assembly (IEA) containing the initial ISS high-power components was successfully launched on November 30, 2000. The IEA contains 12 Battery Subassembly ORUs (6 batteries) that provide station power during eclipse periods. This paper will discuss the battery performance data after two and a half years of cycling.

Dalton, Penni↗

NASA NTRS2007

Magnet-Based System for Docking of Miniature Spacecraft

A prototype system for docking a miniature spacecraft with a larger spacecraft has been developed by engineers at the Johnson Space Center. Engineers working on Mini AERCam, a free-flying robotic camera, needed to find a way to successfully dock and undock their miniature spacecraft to refuel the propulsion and recharge the batteries. The subsystems developed (see figure) include (1) a docking port, designed for the larger spacecraft, which contains an electromagnet, a ball lock mechanism, and a service probe; and (2) a docking cluster, designed for the smaller spacecraft, which contains either a permanent magnet or an electromagnet. A typical docking operation begins with the docking spacecraft maneuvering into position near the docking port on the parent vehicle. The electromagnet( s) are then turned on, and, if necessary, the docking spacecraft is then maneuvered within the capture envelope of the docking port. The capture envelope for this system is approximated by a 5-in. (12.7-cm) cube centered on the front of the docking-port electromagnet and within an angular misalignment of <30 . Thereafter, the magnetic forces draw the smaller spacecraft toward the larger one and this brings the spacecraft into approximate alignment prior to contact. Mechanical alignment guides provide the final rotational alignment into one of 12 positions. Once the docking vehicle has been captured magnetically in the docking port, the ball-lock mechanism is activated, which locks the two spacecraft together. At this point the electromagnet( s) are turned off, and the service probe extended if recharge and refueling are to be performed. Additionally, during undocking, the polarity of one electromagnet can be reversed to provide a gentle push to separate the two spacecraft. This system is currently being incorporated into the design of Mini AERCam vehicle.

Howard, Nathan↗

NASA NTRS2007

Plumbing Fixture for a Microfluidic Cartridge

A fixture has been devised for making the plumbing connections between a microfluidic device in a replaceable cartridge and an external fluidic system. The fixture includes a 0.25-in. (6.35-mm) thick steel plate, to which the cartridge is fastened by two 10-32 thumb screws. The plate holds one plumbing fitting for the inlet and one for the outlet of the microfluidic device. Each fitting includes a fused-silica tube of 0.006-in. (approx.0.15-mm) inside diameter within a fluorinated ethylene-propylene (FEP) tube of 0.0155-in. (approx.0.39-mm) inside diameter and 0.062- in. (approx.1.57-mm) outside diameter. The FEP tube is press-fit through the steel plate so that its exposed end is flush with the surface of the plate, and the silica tube protrudes 0.03 in. (approx.0.76 mm) from the plate/FEP-tube-end surface. The cartridge includes a glass cover plate that contains 0.06-mm-wide access ports. When the cartridge is fastened to the steel plate, the silica tubes become inserted through the access ports and into the body of the cartridge, while the ends of the FEP tubes become butted against the glass cover plate. An extremely tight seal is thereby made.

Francis, Kevin↗

NASA NTRS2008

Distributed solid state programmable thermostat/power controller

A self-contained power controller having a power driver switch, programmable controller, communication port, and environmental parameter measuring device coupled to a controllable device. The self-contained power controller needs only a single voltage source to power discrete devices, analog devices, and the controlled device. The programmable controller has a run mode which, when selected, upon the occurrence of a trigger event changes the state of a power driver switch and wherein the power driver switch is maintained by the programmable controller at the same state until the occurrence of a second event.

Alexander, Jane C.↗

NASA NTRS2010

Foam rigidized inflatable structural assemblies

An inflatable and rigidizable structure for use as a habitat or a load bearing structure is disclosed. The structure consists of an outer wall and an inner wall defining a containment member and a bladder. The bladder is pressurized to erect the structure from an initially collapsed state. The containment member is subsequently injected with rigidizable fluid through an arrangement of injection ports. Exhaust gases from the curing rigidizable fluid are vented through an arrangement of exhaust ports. The rate of erection can be controlled by frictional engagement with a container or by using a tether. A method for fabricating a tubular structure is disclosed.

Tinker, Michael L.↗

NASA NTRS2013

Dual-Compartment Inflatable Suitlock

There is a need for an improvement over current NASA Extravehicular Activity (EVA) technology. The technology must allow the capacity for quicker, more efficient egress/ingress, allow for shirtsleeve suit maintenance, be compact in transport, and be applicable to environments ranging from planetary surface (partial-g) to orbital or deep space zero-g environments. The technology must also be resistant to dust and other foreign contaminants that may be present on or around a planetary surface. The technology should be portable, and be capable of docking with a variety of habitats, ports, stations, vehicles, and other pressurized modules. The Dual-Compartment Inflatable Suitlock (DCIS) consists of three hard inline bulkheads, separating two cylindrical membrane-walled compartments. The Inner Bulkhead can be fitted with a variety of hatch types, docking flanges, and mating hardware, such as the Common Berthing Mechanism (CBM), for the purpose of mating with vehicles, habitats, and other pressurized modules. The Inner Bulkhead and Center Bulkhead function as the end walls of the Inner Compartment, which during operations, would stay pressurized, either matching the pressure of the habitat or acting as a lower-pressure transitional volume. The Inner Compartment contains donning/doffing fixtures and inner suit-port hatches. The Center Bulkhead has two integrated suit-ports along with a maintenance hatch. The Center Bulkhead and Outer Bulkhead function as the end walls of the Outer Compartment, which stays at vacuum during normal operations. This allows the crewmember to quickly don a suit, and egress the suitlock without waiting for the Outer Compartment to depressurize. The Outer Compartment can be pressurized infrequently for both nominal and off-nominal suit maintenance tasks, allowing shirtsleeve inspections and maintenance/repair of the environmental suits. The Outer Bulkhead has a pressure-assisted hatch door that stays open and stowed during EVA operations, but can be closed for environmental protection of the suits, suit maintenance, and pressurization.

Kennedy, Kriss J.↗

NASA NTRS1977

High pressure flame system for pollution studies with results for methane-air diffusion flames

A high pressure flame system was designed and constructed for studying nitrogen oxide formation in fuel air combustion. Its advantages and limitations were demonstrated by tests with a confined laminar methane air diffusion flame over the pressure range from 1 to 50 atm. The methane issued from a 3.06 mm diameter port concentrically into a stream of air contained within a 20.5 mm diameter chimney. As the combustion pressure is increased, the flame changes in shape from wide and convex to slender and concave, and there is a marked increase in the amount of luminous carbon. The height of the flame changes only moderately with pressure.

Miller, I. M.↗

NASA NTRS1989

Monolithic Microwave Switching Matrix

Gallium arsenide integrated-circuit chip switches any of three microwave input signals to any of three output ports. Measuring 4.9 mm on side, chip contains nine field-effect transistor (FET) crosspoint switches. Housed in custom-designed package with standard connectors for easy integration into system. FET's on chip operated as passive switches and consume no static power and insignificant amounts of switching power. Chip module cascades with similar modules into large arrays handling as many as 100 inputs and 100 outputs. Applications include switching and routing vast amounts of data between computers at extremely high speed. On communications satellite, chip switches microwave signals to and from Earth stations and other satellites.

Fujikawa, Gene↗

NASA NTRS1992

Directional spectral emissivity measurement system

Apparatus and process for determining the emissivity of a test specimen including an integrated sphere having two concentric walls with a coolant circulating therebetween, and disposed within a chamber which may be under ambient, vacuum or inert gas conditions. A reference sample is disposed within the sphere with a monochromatic light source in optical alignment therewith. A pyrometer is in optical alignment with the test sample for obtaining continuous test sample temperature measurements during a test. An arcuate slit port is provided through the spaced concentric walls of the integrating sphere with a movable monochromatic light source extending through and movable along the arcuate slit port. A detector system extends through the integrating sphere for continuously detecting an integrated signal indicative of all radiation within its field of view, as a function of the emissivity of the test specimen at various temperatures and various angle position of the monochromatic light source. A furnace for heating the test sample to approximately 3000 K. and control mechanism for transferring the heated sample from the furnace to the test sample port in the integrating sphere is also contained within the chamber.

Halyo, Nesim↗

NASA NTRS2010

Human Health and Performance Considerations for Exploration of Near-Earth Asteroids

This presentation will describe the human health and performance issues that are anticipated for the human exploration of near-Earth asteroids (NEA). Humans are considered a system in the design of any such deep-space exploration mission, and exploration of NEA presents unique challenges for the human system. Key factors that define the mission are those that are strongly affected by distance and duration. The most critical of these is deep-space radiation exposure without even the temporary shielding of a nearby large planetary body. The current space radiation permissible exposure limits (PEL) restrict mission duration to 3-10 months depending on age and gender of crewmembers and stage of the solar cycle. Factors that affect mission architecture include medical capability; countermeasures for bone, muscle, and cardiovascular atrophy during continuous weightlessness; restricted food supplies; and limited habitable volume. The design of a habitat that can maintain the physical and psychological health of the crew and support mission operations with limited intervention from Earth will require an integrated research and development effort by NASA s Human Research Program, engineering, and human factors groups. Limited abort and return options for an NEA mission are anticipated to have important effects on crew psychology as well as influence medical supplies and training requirements of the crew. Other important factors are those related to isolation, confinement, communication delays, autonomous operations, task design, small crew size, and even the unchanging view outside the windows for most of the mission. Geological properties of the NEA will influence design of sample handling and containment, and extravehicular activity capabilities including suit ports and tools. A robotic precursor mission that collects basic information on NEA surface properties would reduce uncertainty about these aspects of the mission as well as aid in design of mission architecture and exploration tasks.

Kundrot, Craig↗

NASA NTRS1992

Positioning Mechanism For Hoisting

Mechanism positions large, heavy objects in container for lifting out by hoist, crane, or winch. Handles objects gently and ensures they are lifted cleanly away in vertical direction without bumping container. Developed for lifting offset pieces of solid-propellant core out of rocket motor through its propellant port. Similar specialized mechanisms can be developed to lift other specially shaped, specially contained heavy objects. Track in base of mechanism guides each trunnion and piece to which attached to middle as hydraulic rods extend. When mechanism lifted, tilted pieces swing inward and come to rest on energy-absorbing paddle.

Marlin, John D., III↗

NASA NTRS2002

Wireless Temperature-Monitoring System

A relatively inexpensive instrumentation system that includes units that are connected to thermocouples and that are parts of a radio-communication network has been developed to enable monitoring of temperatures at multiple locations. Because there is no need to string wires or cables for communication, the system is well suited for monitoring temperatures at remote locations and for applications in which frequent changes of monitored or monitoring locations are needed. The system can also be adapted to monitoring of slowly varying physical quantities, other than temperature, that can be transduced by solid-state electronic sensors. electronic sensors. The system comprises any number of transmitting units and a single receiving unit. Each transmitting unit includes connections for as many as four external thermocouples, a signal-conditioning module, a control module, and a radio-communication module. The signal-conditioning module acts as an interface between the thermocouples and the rest of the transmitting unit and includes a built-in solid ambient temperature sensor that is in addition to the external thermocouples. The control module is a system-on-chip embedded processor that includes analog-to-digital converters, serial and parallel data ports, and an interface for local connection to an analog meter that is used during installation to verify correct operation. The radio-communication module contains a commercial spread-spectrum transceiver that operates in the 900-MHz industrial, scientific, and medical (ISM) frequency band. This transceiver transmits data to the receiving unit at a rate of 19,200 baud. The receiving unit includes a transceiver like that of a transmitting unit, plus a control module that contains a system-on-chip processor that includes serial data port for output to a computer that runs monitoring and/or control software, a parallel data port for output to a printer, and a seven-segment light-emitting-diode display. Each transmitting unit is battery-powered and can operate for at least seven days continuously while reporting temperatures every half hour. The receiving unit is powered by a wall-mounted transformer source. The receiving unit responds to each transmitting unit and reports the readings of each of the four thermocouples and of the ambient-temperature sensor of the transmitting unit. The end-to-end accuracy of the system is plus or minus 0.2 C over the temperature range from 0 to 100 C. The radio-communication range between the receiving and transmitting units is approximately equal to 0.5 mile (approximately equal to 0.8 km).

Solano, Wanda↗

NASA NTRS2003

Wireless Temperature-Monitoring System

A relatively inexpensive instrumentation system that includes units that are connected to thermocouples and that are parts of a radio-communication network has been developed to enable monitoring of temperatures at multiple locations. Because there is no need to string wires or cables for communication, the system is well suited for monitoring temperatures at remote locations and for applications in which frequent changes of monitored or monitoring locations are needed. The system can also be adapted to monitoring of slowly varying physical quantities, other than temperature, that can be transduced by solid-state electronic sensors. The system comprises any number of transmitting units and a single receiving unit (see figure). Each transmitting unit includes connections for as many as four external thermocouples, a signal-conditioning module, a control module, and a radio-communication module. The signal- conditioning module acts as an interface between the thermocouples and the rest of the transmitting unit and includes a built-in solid ambient-temperature sensor that is in addition to the external thermocouples. The control module is a "system-on-chip" embedded processor that includes analog-to-digital converters, serial and parallel data ports, and an interface for local connection to an analog meter that is used during installation to verify correct operation. The radio-communication module contains a commercial spread-spectrum transceiver that operates in the 900-MHz industrial, scientific, and medical (ISM) frequency band. This transceiver transmits data to the receiving unit at a rate of 19,200 baud. The receiving unit includes a transceiver like that of a transmitting unit, plus a control module that contains a system-on-chip processor that includes serial data port for output to a computer that runs monitoring and/or control software, a parallel data port for output to a printer, and a seven-segment light-emitting-diode display.

Solano, Wanda↗