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NASA NTRS2016

Flat H Frangible Joint Evolution

Space vehicle staging and separation events require pyrotechnic devices. They are single-use mechanisms that cannot be tested, nor can failure-tolerant performance be demonstrated in actual flight articles prior to flight use. This necessitates the implementation of a robust design and test approach coupled with a fully redundant, failure-tolerant explosive mechanism to ensure that the system functions even in the event of a single failure. Historically, NASA has followed the single failure-tolerant (SFT) design philosophy for all human-rated spacecraft, including the Space Shuttle Program. Following the end of this program, aerospace companies proposed building the next generation human-rated vehicles with off-the-shelf, non-redundant, zero-failure-tolerant (ZFT) separation systems. Currently, spacecraft and launch vehicle providers for both the Orion and Commercial Crew Programs (CCPs) plan to deviate from the heritage safety approach and NASA's SFT human rating requirements. Both programs' partners have base-lined ZFT frangible joints for vehicle staging and fairing separation. These joints are commercially available from pyrotechnic vendors. Non-human-rated missions have flown them numerous times. The joints are relatively easy to integrate structurally within the spacecraft. In addition, the separation event is debris free, and the resultant pyro shock is lower than that of other design solutions. It is, however, a serious deficiency to lack failure tolerance. When used for critical applications on human-rated vehicles, a single failure could potentially lead to loss of crew (LOC) or loss of mission (LOM)). The Engineering and Safety & Mission Assurance directorates within the NASA Johnson Space Center took action to address this safety issue by initiating a project to develop a fully redundant, SFT frangible joint design, known as the Flat H. Critical to the ability to retrofit on launch vehicles being developed, the SFT mechanisms must fit within the same three-dimensional envelope as current designs as well as meet structural loads requirements. There is increased mass associated with the redundant design, and the goal is to minimize the weight impact as much as possible. These requirements presented significant challenges, both technically and financially; these challenges will be explored in this paper. Perhaps greater than the technical issues confronted during this design process, were the financial considerations. These were a significant part of the story of this design and development plan. Insufficient financial and labor resources were formidable barriers to completing this project. Nevertheless, JSC personnel successfully conducted several test series at JSC with very useful results. The many lessons learned drove design improvements, performance efficiency, and increased functional reliability. This paper examines the significant technical and financial challenges that these requirements posed to the project team. It discusses the evolution of the SFT frangible joint design, including optimization, testing, and successful partnering of the Johnson Space Center (JSC) engineering and JSC safety organizations, to enhance the flight safety margin for America's next generation of human-rated space vehicles.

Diegelman, Thomas E.↗
NASA NTRS2016

CASIS Fact Sheet: Hardware and Facilities

Vencore is a proven information solutions, engineering, and analytics company that helps our customers solve their most complex challenges. For more than 40 years, we have designed, developed and delivered mission-critical solutions as our customers' trusted partner. The Engineering Services Contract, or ESC, provides engineering and design services to the NASA organizations engaged in development of new technologies at the Kennedy Space Center. Vencore is the ESC prime contractor, with teammates that include Stinger Ghaffarian Technologies, Sierra Lobo, Nelson Engineering, EASi, and Craig Technologies. The Vencore team designs and develops systems and equipment to be used for the processing of space launch vehicles, spacecraft, and payloads. We perform flight systems engineering for spaceflight hardware and software; develop technologies that serve NASA's mission requirements and operations needs for the future. Our Flight Payload Support (FPS) team at Kennedy Space Center (KSC) provides engineering, development, and certification services as well as payload integration and management services to NASA and commercial customers. Our main objective is to assist principal investigators (PIs) integrate their science experiments into payload hardware for research aboard the International Space Station (ISS), commercial spacecraft, suborbital vehicles, parabolic flight aircrafts, and ground-based studies. Vencore's FPS team is AS9100 certified and a recognized implementation partner for the Center for Advancement of Science in Space (CASIS

Solomon, Michael R.↗
NASA NTRS2015

Interplanetary Radiation and Fault Tolerant Mini-Star Tracker System

The Charles Stark Draper Laboratory, Inc. is partnering with the NASA Marshall Space Flight Center (MSFC) Engineering Directorate's Avionics Design Division and Flight Mechanics & Analysis Division to develop and test a prototype small, low-weight, low-power, radiation-hardened, fault-tolerant mini-star tracker (fig. 1). The project is expected to enable Draper Laboratory and its small business partner, L-1 Standards and Technologies, Inc., to develop a new guidance, navigation, and control sensor product for the growing small sat technology market. The project also addresses MSFC's need for sophisticated small sat technologies to support a variety of science missions in Earth orbit and beyond. The prototype star tracker will be tested on the night sky on MSFC's Automated Lunar and Meteor Observatory (ALAMO) telescope. The specific goal of the project is to address the need for a compact, low size, weight, and power, yet radiation hardened and fault tolerant star tracker system that can be used as a stand-alone attitude determination system or incorporated into a complete attitude determination and control system for emerging interplanetary and operational CubeSat and small sat missions.

Rakoczy, John↗
NASA NTRS2016

A Year in Space: Early Results and Lessons Learned from the First Year-Long Expedition Aboard the International Space Station

Two ISS crewmembers recently completed the first year-long orbital stay in two decades. International cooperation was central to the success of Mikhail Kornienko from Russia and Scott Kelly from the United States. Their expedition leveraged current mission experience and capitalized on recent advances in health monitoring technology. This unique effort began in 2012 when the program managers of the ISS partner nations adopted two separate goals: greater multilateral cooperation to increase efficiency of inflight research and a year-long expedition to gain familiarity with in-flight durations approaching that required for a Mars mission. These goals were unified when a set of bilateral Russian and American human research investigations was assigned to the year-long mission, augmented by additional investigations from Europe and Japan. For example, Kelly was assigned 18 investigations (twice the complement on standard six-month missions) including two joint U.S.-Russian studies, and two Russian and two Japanese studies. The core set of American investigations was a repetition of six studies Kelly had done on his previous six-month ISS mission, to allow a direct comparison of physiological and behavioral responses of the longer and shorter durations in this single individual. The remainder of his assignments plus those of Kornienko were drawn from currently active national investigations documenting human adaptation to long-duration spaceflight factors or effectiveness of countermeasures against known deleterious adaptations. The two joint U.S.-Russian investigations were the flagship biomedical studies of the year-long expedition. The "Fluid Shifts" study collocated American research equipment alongside a Russian operational stressor device to document the pattern and impacts of the headward fluid shift long known to occur in weightlessness, including its role in ocular changes recently observed in some astronauts. The "Field Test" study investigated the ability of the astronaut and cosmonaut to perform rudimentary tasks requiring sensorimotor coordination immediately after landing to define human capabilities soon after landing on Mars after an extended transit. Both investigations were highly successful in large part to the thorough integration of the implementation processes of the two partners. Kelly's assignment as the one-year crewmember also provided a serendipitous opportunity for the "Twins Study" comparing changes in his body at the genetic level with those occurring on Earth in his identical twin brother Mark Kelly. Data analysis from this expedition will commence in earnest after frozen in-flight samples are delivered to Earth in May aboard a commercial cargo spacecraft. Detailed results are expected in early 2017. Preliminary results and implementation improvements will be reviewed in this presentation.

Charles, J. B.↗
NASA NTRS2017

VIIP 2017 Clinical Update

INTRODUCTION: NASA's Space Medicine community knowledge regarding the "Vision Impairment Intracranial Pressure", or VIIP.has been evolving over time.. Various measures of occupational health related to this condition had to be determined and then plans/processes put into place. The most robust of these processes were inititated in 2010. This presentation will provide a clinic update of the astronaut occupational health data related to VIIP. METHODS: NASA and its international partners require its astronauts to undergo routine health measures deemed important to monitoring VIIP. The concern is that the spaceflight environment aboard ISS could cause some astronauts to have physiologic changes detrimental to either ongoing mission operations or long-term health related to the ocular system and possibly the CNS. Specific medical tests include but are not limited to brain/orbit MRI (NASA unique protocol), OCT, fundoscopy and ocular ultrasound. Measures are taken prior to spaceflight, in-flight and post-flight. Measures to be reported include incidence of disc edema, globe flattening, choroidal folds, ONSD and change in refractive error. RESULTS: 73 ISS astronauts have been evaluated at least partially for VIIP related measures. Of these individuals, approximately 1 in 7 have experienced disc edema. The prevalence of the other findings is more complicated as the medical testing has changed over time. Overall, 26 separate individuals have experienced at least one of the findings NASA has associated with VIIP Another confounding factor is most of the astronauts have prior spaceflight experience at the time of the "pre-flight" testing. DISCUSSION: In 2010 NASA and its US operating segment (USOS) partners (CSA, ESA and JAXA) began routine occupational monitoring and data collection for most VIIP related changes. Interpretation of that data is extremely challenging for several reasons. For example, the determination of disc edema is the most complete finding as we have had highly qualified optometrists routinely and competently performing post-flight funduscopic exams for the entirety of the ISS program. Yet in 2013 NASA added OCT to our in-flight suite of eye exams. Shortly after routine screening with the OCT, a new term appeared within VIIP vernacular - "subclinical disc edema". OCT has much greater ability to measure change within the retina and provides significantly more data to analyze, understand and communicate out. Communicating VIIP data clearly adds even more challenge. Historically we've reported data per eye and not necessarily per person. This has led to difficulty in understanding how many individuals have experienced "VIIP" within the aerospace medicine community. The presenter will attempt to provide clear and concise communication of VIIP findings.

Tarver, William↗
NASA NTRS2016

Genelab: Scientific Partnerships and an Open-Access Database to Maximize Usage of Omics Data from Space Biology Experiments

NASA's mission includes expanding our understanding of biological systems to improve life on Earth and to enable long-duration human exploration of space. The GeneLab Data System (GLDS) is NASA's premier open-access omics data platform for biological experiments. GLDS houses standards-compliant, high-throughput sequencing and other omics data from spaceflight-relevant experiments. The GeneLab project at NASA-Ames Research Center is developing the database, and also partnering with spaceflight projects through sharing or augmentation of experiment samples to expand omics analyses on precious spaceflight samples. The partnerships ensure that the maximum amount of data is garnered from spaceflight experiments and made publically available as rapidly as possible via the GLDS. GLDS Version 1.0, went online in April 2015. Software updates and new data releases occur at least quarterly. As of October 2016, the GLDS contains 80 datasets and has search and download capabilities. Version 2.0 is slated for release in September of 2017 and will have expanded, integrated search capabilities leveraging other public omics databases (NCBI GEO, PRIDE, MG-RAST). Future versions in this multi-phase project will provide a collaborative platform for omics data analysis. Data from experiments that explore the biological effects of the spaceflight environment on a wide variety of model organisms are housed in the GLDS including data from rodents, invertebrates, plants and microbes. Human datasets are currently limited to those with anonymized data (e.g., from cultured cell lines). GeneLab ensures prompt release and open access to high-throughput genomics, transcriptomics, proteomics, and metabolomics data from spaceflight and ground-based simulations of microgravity, radiation or other space environment factors. The data are meticulously curated to assure that accurate experimental and sample processing metadata are included with each data set. GLDS download volumes indicate strong interest of the scientific community in these data. To date GeneLab has partnered with multiple experiments including two plant (Arabidopsis thaliana) experiments, two mice experiments, and several microbe experiments. GeneLab optimized protocols in the rodent partnerships for maximum yield of RNA, DNA and protein from tissues harvested and preserved during the SpaceX-4 mission, as well as from tissues from mice that were frozen intact during spaceflight and later dissected on the ground. Analysis of GeneLab data will contribute fundamental knowledge of how the space environment affects biological systems, and as well as yield terrestrial benefits resulting from mitigation strategies to prevent effects observed during exposure to space environments.

bioinformatics↗
NASA NTRS2016

NASA Collaborative Approach Mitigates Environmentally-Driven Obsolescence

National Aeronautics and Space Administration (NASA) missions, like Department of Defense (DoD) organizations, require the rigorous testing and qualification of critical materials. Obsolescence supply risks created by environmental requirements can affect the cost, schedule and performance of NASA missions and the resilience of critical infrastructure. The NASA Technology Evaluation for Environmental Risk Mitigation (TEERM) Principal Center helps to identify obsolescence supply risks driven by environmental requirements and works proactively with NASA Centers and Programs, the DoD, the European Space Agency (ESA) and other agencies and partners to identify and evaluate environmentally friendly alternatives. TEERM tracks environmental regulations, identifies the potential loss of material availability and works with NASA programs and Centers to evaluate potential impacts through a risk assessment approach. TEERM collaborative projects identify, demonstrate and evaluate commercially viable alternative technologies and materials. A major focus during the Space Shuttle Program was the need to replace ozone depleting substances that were used in spray foam and cleaning applications. The potential obsolescence of coatings containing hexavalent chromium and the risks associated with lead free solder were also of concern for the Space Shuttle and present ongoing risks to new programs such as the Space Launch System. One current project teams NASA and ESA in the evaluation and testing of individual coatings and coating systems as replacements for hexavalent chromium coatings in aerospace applications. The proactive, collaborative approach used by TEERM helps reduce the cost burden on any one team partner, reduces duplication of effort, and enhances the technical quality and overall applicability of the testing and analysis.

environmentall-driven obsolescence↗
NASA NTRS2016

Kickstarting a New Era of Lunar Industrialization via Campaign of Lunar COTS Missions

To support the goals of expanding our human presence and current economic sphere beyond LEO, a new plan was constructed for NASA to enter into partnerships with industry to foster and incentivize a new era of lunar industrialization. For NASA to finally be successful in achieving sustainable human exploration missions beyond LEO, lessons learned from our space history have shown that it is essential for current program planning to include affordable and economic development goals as well as address top national priorities to obtain much needed public support. In the last 58 years of NASA's existence, only Apollo's human exploration missions beyond LEO were successful since it was proclaimed to be a top national priority during the 1960's. However, the missions were not sustainable and ended abruptly in 1972 due to lack of funding and insufficient economic gain. Ever since Apollo, there have not been any human missions beyond LEO because none of the proposed program plans were economical or proclaimed a top national priority. The proposed plan outlines a new campaign of low-cost, commercial-enabled lunar COTS (Commercial Orbital Transfer Services) missions which is an update to the Lunar COTS plan previously described. The objectives of this new campaign of missions are to prospect for resources, determine the economic viability of extracting those resources and assess the value proposition of using these resources in future exploration architectures such as Mars. These missions would be accomplished in partnership with commercial industry using the wellproven COTS Program acquisition model. This model proved to be very beneficial to both NASA and its industry partners as NASA saved significantly in development and operational costs, as much as tenfold, while industry partners successfully expanded their market share and demonstrated substantial economic gain. Similar to COTS, the goals for this new initiative are 1) to develop and demonstrate cost-effective, cis-lunar commercial services, such as lunar transportation, lunar mining and lunar ISRU operations; 2) enable development of an affordable and economical exploration architecture for future missions to Mars and beyond; and 3) to incentivize the creation of new lunar markets through use of lunar resources for economic benefit to NASA, commercial industry and the international community. These cost-effective services would not only enable NASA to economically and sustainably achieve its human exploration missions to the Moon, Mars and beyond but it would also kickstart a new era of lunar industrialization. This paper will describe the goals, objectives and approach for implementing this new campaign of missions. It will also describe the potential benefits and progress that can be accomplished with these low-cost, Lunar COTS missions. Lastly, a preliminary economic analysis approach is proposed for understanding the cost and potential return on investment in the use of lunar resources to reach the goal of lunar industrialization and an expanded and sustainable human presence into cis-lunar space and beyond.

Lunar Exploration↗
NASA NTRS2016

Green Propellant Test Capabilities of the Altitude Combustion Stand at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC) is committed to providing simulated altitude rocket test capabilities to NASA programs, other government agencies, private industry partners, and academic partners. A primary facility to support those needs is the Altitude Combustion Stand (ACS). ACS provides the capability to test combustion components at a simulated altitude up to 100,000 ft. (approx.0.2 psia/10 Torr) through a nitrogen-driven ejector system. The facility is equipped with an axial thrust stand, gaseous and cryogenic liquid propellant feed systems, data acquisition system with up to 1000 Hz recording, and automated facility control system. Propellant capabilities include gaseous and liquid hydrogen, gaseous and liquid oxygen, and liquid methane. A water-cooled diffuser, exhaust spray cooling chamber, and multi-stage ejector systems can enable run times up to 180 seconds to 16 minutes. The system can accommodate engines up to 2000-lbf thrust, liquid propellant supply pressures up to 1800 psia, and test at the component level. Engines can also be fired at sea level if needed. The NASA GRC is in the process of modifying ACS capabilities to enable the testing of green propellant (GP) thrusters and components. Green propellants are actively being explored throughout government and industry as a non-toxic replacement to hydrazine monopropellants for applications such as reaction control systems or small spacecraft main propulsion systems. These propellants offer increased performance and cost savings over hydrazine. The modification of ACS is intended to enable testing of a wide range of green propellant engines for research and qualification-like testing applications. Once complete, ACS will have the capability to test green propellant engines up to 880 N in thrust, thermally condition the green propellants, provide test durations up to 60 minutes depending on thrust class, provide high speed control and data acquisition, as well as provide advanced imaging and diagnostics such as infrared (IR) imaging.

Testing↗
NASA NTRS2017

International Space Station Requirement Verification for Commercial Visiting Vehicles

The COTS program demonstrated NASA could rely on commercial providers for safe, reliable, and cost-effective cargo delivery to ISS. The ISS Program has developed a streamlined process to safely integrate commercial visiting vehicles and ensure requirements are met Levy a minimum requirement set (down from 1000s to 100s) focusing on the ISS interface and safety, reducing the level of NASA oversight/insight and burden on the commercial Partner. Partners provide a detailed verification and validation plan documenting how they will show they've met NASA requirements. NASA conducts process sampling to ensure that the established verification processes is being followed. NASA participates in joint verification events and analysis for requirements that require both parties verify. Verification compliance is approved by NASA and launch readiness certified at mission readiness reviews.

Garguilo, Dan↗
NASA NTRS2017

Validation of SMAP Surface Soil Moisture Products with Core Validation Sites

The NASA Soil Moisture Active Passive (SMAP) mission has utilized a set of core validation sites as the primary methodology in assessing the soil moisture retrieval algorithm performance. Those sites provide well calibrated in situ soil moisture measurements within SMAP product grid pixels for diverse conditions and locations.The estimation of the average soil moisture within the SMAP product grid pixels based on in situ measurements is more reliable when location specific calibration of the sensors has been performed and there is adequate replication over the spatial domain, with an up-scaling function based on analysis using independent estimates of the soil moisture distribution. SMAP fulfilled these requirements through a collaborative CalVal Partner program.This paper presents the results from 34 candidate core validation sites for the first eleven months of the SMAP mission. As a result of the screening of the sites prior to the availability of SMAP data, out of the 34 candidate sites 18 sites fulfilled all the requirements at one of the resolution scales (at least). The rest of the sites are used as secondary information in algorithm evaluation. The results indicate that the SMAP radiometer-based soil moisture data product meets its expected performance of 0.04 cu m/cu m volumetric soil moisture (unbiased root mean square error); the combined radar-radiometer product is close to its expected performance of 0.04 cu m/cu m, and the radar-based product meets its target accuracy of 0.06 cu m/cu m (the lengths of the combined and radar-based products are truncated to about 10 weeks because of the SMAP radar failure). Upon completing the intensive CalVal phase of the mission the SMAP project will continue to enhance the products in the primary and extended geographic domains, in co-operation with the CalVal Partners, by continuing the comparisons over the existing core validation sites and inclusion of candidate sites that can address shortcomings.

SMAP↗
NASA NTRS2018

Development of a Ground Test and Analysis Protocol to Support NASA's NextSTEP Phase 2 Habitation Concepts

The NASA Next Space Technologies for Exploration Partnerships (NextSTEP) program is a public-private partnership model that seeks commercial development of deep space exploration capabilities to support extensive human spaceflight missions around and beyond cislunar space. NASA first issued the Phase 1 NextSTEP Broad Agency Announcement to U.S. industries in 2014, which called for innovative cislunar habitation concepts that leveraged commercialization plans for low Earth orbit. These habitats will be part of the Deep Space Gateway (DSG), the cislunar space station planned by NASA for construction in the 2020s. In 2016, Phase 2 of the NextSTEP program selected five commercial partners to develop ground prototypes. A team of NASA research engineers and subject matter experts have been tasked with developing the ground test protocol that will serve as the primary means by which these Phase 2 prototype habitats will be evaluated. Since 2008, this core test team has successfully conducted multiple spaceflight analog mission evaluations utilizing a consistent set of operational products, tools, methods, and metrics to enable the iterative development, testing, analysis, and validation of evolving exploration architectures, operations concepts, and vehicle designs. The purpose of implementing a similar evaluation process for the NextSTEP Phase 2 Habitation Concepts is to consistently evaluate the different commercial partner ground prototypes to provide data-driven, actionable recommendations for Phase 3.

Beaton, Kara H.↗
NASA NTRS2015

Florida Atlantic Coast Telemetry (FACT) Array: A Working Partnership

The Florida Atlantic Coast Telemetry (FACT) Array is a collaborative partnership of researchers from 24 different organizations using passive acoustic telemetry to document site fidelity, habitat preferences, seasonal migration patterns, and reproductive strategies of valuable sportfish, sharks, and marine turtles. FACT partners have found that by bundling resources, they can leverage a smaller investment to track highly mobile animals beyond a study area typically restrained in scale by funds and manpower. FACT is guided by several simple rules: use of the same type of equipment, locate receivers in areas that are beneficial to all researchers when feasible, maintain strong scientific ethics by recognizing that detection data on any receiver belongs to the tag owner, do not use other members detection data without permission and acknowledge FACT in publications. Partners have access to a network of 480 receivers deployed along a continuum of habitats from freshwater rivers to offshore reefs and covers 1100 km of coastline from the Dry Tortugas, Florida to South Carolina and extends to the Bahamas. Presently, 49 species, (25 covered by Fisheries Management Plans and five covered by the Endangered Species Act) have been tagged with 2736 tags in which 1767 tags are still active.

Scheidt, Douglas↗
NASA NTRS2017

Building an Economical and Sustainable Lunar Infrastructure to Enable Lunar Industrialization

A new concept study was initiated to examine the architecture needed to gradually develop an economical, evolvable and sustainable lunar infrastructure using a public/private partnerships approach. This approach would establish partnership agreements between NASA and industry teams to develop a lunar infrastructure system that would be mutually beneficial. This approach would also require NASA and its industry partners to share costs in the development phase and then transfer operation of these infrastructure services back to its industry owners in the execution phase. These infrastructure services may include but are not limited to the following: lunar cargo transportation, power stations, communication towers and satellites, autonomous rover operations, landing pads and resource extraction operations. The public/private partnerships approach used in this study leveraged best practices from NASA's Commercial Orbital Transportation Services (COTS) program which introduced an innovative and economical approach for partnering with industry to develop commercial cargo services to the International Space Station. This program was planned together with the ISS Commercial Resupply Services (CRS) contracts which was responsible for initiating commercial cargo delivery services to the ISS for the first time. The public/private partnerships approach undertaken in the COTS program proved to be very successful in dramatically reducing development costs for these ISS cargo delivery services as well as substantially reducing operational costs. To continue on this successful path towards installing economical infrastructure services for LEO and beyond, this new study, named Lunar COTS (Commercial Operations and Transport Services), was conducted to examine extending the NASA COTS model to cis-lunar space and the lunar surface. The goals of the Lunar COTS concept are to: 1) develop and demonstrate affordable and commercial cis-lunar and surface capabilities, such as lunar cargo delivery and surface power generation, in partnership with industry; 2) incentivize industry to establish economical and sustainable lunar infrastructure services to support NASA missions and initiate lunar commerce; and 3) encourage creation of new space markets for economic growth and benefit. A phased-development approach was also studied to allow for incremental development and demonstration of capabilities needed to build a lunar infrastructure. This paper will describe the Lunar COTS concept goals, objectives and approach for building an economical and sustainable lunar infrastructure. It will also describe the technical challenges and advantages of developing and operating each infrastructure element. It will also describe the potential benefits and progress that can be accomplished in the initial phase of this Lunar COTS approach. Finally, the paper will also look forward to the potential of a robust lunar industrialization environment and its potential effect on the next 50 years of space exploration.

Zuniga, Allison F.↗
NASA NTRS2017

Carbon-Carbon Nozzle Extension Development in Support of In-Space and Upper-Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. Due to the large size of such nozzles, and the related engine performance requirements, carbon-carbon (C-C) composite nozzle extensions are being considered to reduce weight impacts. Currently, the state-of-the-art is represented by the metallic and foreign composite nozzle extensions limited to approximately 2000 degrees F. used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles. NASA and industry partners are working towards advancing the domestic supply chain for C-C composite nozzle extensions. These development efforts are primarily being conducted through the NASA Small Business Innovation Research (SBIR) program in addition to other low level internal research efforts. This has allowed for the initial material development and characterization, subscale hardware fabrication, and completion of hot-fire testing in relevant environments. NASA and industry partners have designed, fabricated and hot-fire tested several subscale domestically produced C-C extensions to advance the material and coatings fabrication technology for use with a variety of liquid rocket and scramjet engines. Testing at NASA's Marshall Space Flight Center (MSFC) evaluated heritage and state-of-the-art C-C materials and coatings, demonstrating the initial capabilities of the high temperature materials and their fabrication methods. This paper discusses the initial material development, design and fabrication of the subscale carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work. The follow on work includes the fabrication of ultra-high temperature materials, larger C-C nozzle extensions, material characterization, sub-element testing and hot-fire testing at larger scale.

Gradl, Paul R.↗
NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗
NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗
NASA NTRS2017

Development of Augmented Spark Impinging Igniter System for Methane Engines

The Lunar Cargo Transportation and Landing by Soft Touchdown (Lunar CATALYST) program is establishing multiple no-funds-exchanged Space Act Agreement (SAA) partnerships with U.S. private sector entities. The purpose of this program is to encourage the development of robotic lunar landers that can be integrated with U.S. commercial launch capabilities to deliver payloads to the lunar surface. NASA can share technology and expertise under the SAA for the benefit of the CATALYST partners. MSFC seeking to vacuum test Augmented Spark Impinging (ASI) igniter with methane and new exciter units to support CATALYST partners and NASA programs. ASI has previously been used/tested successfully at sea-level, with both O2/CH4 and O2/H2 propellants. Conventional ignition exciter systems historically experienced corona discharge issues in vacuum. Often utilized purging or atmospheric sealing on high voltage lead to remedy. Compact systems developed since PCAD could eliminate the high-voltage lead and directly couple the exciter to the spark igniter. MSFC developed Augmented Spark Impinging (ASI) igniter. Successfully used in several sea-level test programs. Plasma-assisted design. Portion of ox flow is used to generate hot plasma. Impinging flows downstream of plasma. Additional fuel flow down torch tube sleeve for cooling near stoichiometric torch flame. Testing done at NASA GRC Altitude Combustion Stand (ACS) facility 2000-lbf class facility with altitude simulation up to around 100,000 ft. (0.2 psia [10 Torr]) via nitrogen driven ejectors. Propellant conditioning systems can provide temperature control of LOX/CH4 up to test article.

Chemical Propulsion↗