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At least 361 records · Page 20

Systems and Methods for Designing and Fabricating Contact-Free Support Structures for Overhang Geometries of Parts in Powder-Bed Metal Additive Manufacturing

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step.

Chou, Yuag-Shan↗

Systems and Methods for Designing and Fabricating Support Structures for Overhang Geometries of Parts in Additive Manufacturing

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is minimally or not connected to the part, the support structure can be removed with minimal or no post-processing step.

Chou, Yuag-Shan↗

A New Vision and A More Rational Process Will Advance Space Life Support Through Better Projects

Many space life support assumptions are obviously mistaken but they are generally accepted because they mutually support each other and because they advance a mistaken futuristic vision of closed human ecosystems in space. Many projects have been mistakenly selected to increase life support system closure or reduce launch mass in order to implement this impractical vision. Project members rarely challenge their project’s assumptions and guiding vision. Systems engineering including cost, reliability, risk, and system trade-offs has been very strongly discouraged to prevent rational criticism of these dubious assumptions, the projects, and the ecosystem vision. A more realistic vision can define better near term life support goals and future aspirations that will improve mission support and increase public interest. Given more realistic goals, it will be possible to develop effective technical alternatives, use open rational project selection methods, conduct professional project management, and make swifter progress in the inevitable human advance into space. The current unworkable human space settlement scenario involves moon visits and permanent bases, zero gravity trips to Mars, Mars visits and bases, all leading to extensive human settlements on the moon and Mars. This is unrealistic because the moon and Mars have less than Earth normal gravity and high radiation that can seriously damage human health. A better alternative would use rotating space colonies that produce Earth gravity and are radiation shielded. The attractive fantasy of reproducing terrestrial ecology in space should be replaced by the idea of building a closed system based on advancing technology such as artificial photosynthesis. Past mistaken projects include growing plants for food to replicate terrestrial food sources, recovering small amounts of water from difficult to process waste to achieve high system closure, and using newly designed, lighter, but unreliable hardware to reduce launch mass. The political process supporting the false assumptions, projects, and vision has deliberately prevented the usual systems engineering and cost-benefit analysis. We are going to do much better.

Harry W. Jones↗

Remote Support of ISS Payload Operations During the COVID19 Pandemic

As part of the Human Health and Performance Contract (HHPC) with the NASA Johnson Space Center, the Human Research Program’s (HRP) Research Operations and Integration (ROI) element conducts the planning, implementation, and closing of human research operations on-board the International Space Station (ISS). These operations are supported out of the Telescience Support Center (TSC) located in the Mission Control Center at Houston’s Johnson Space Center (MCC-H). HRP ROI has an Emergency Response Plan in place to allow for remote operations to be completed in the case of inclement weather or other natural disaster; however, nominally, the remote support is only expected to last one to two weeks. In response to the COVID-19 global pandemic, HRP ROI was challenged to complete a quick transition to supporting on-orbit operations remotely and distanced for an indefinite amount of time. This shift in ground support required close collaboration with various external groups as well as the implementation or adaptation of various technologies and tools to ensure no loss of science data. Operational adjustments were put into place for ground commanding, telemetry monitoring, personnel staffing and private and public audio and video with the ISS. Adjustments were also put in place for communication and collaboration with MCC-H, the Payload Operation and Integration Center (POIC) at Marshall Space Flight Center (MSFC), as well as between the various HRP ROI console team members spread across Houston, TX. The ability to successfully support a variety of on-orbit operations from any remote location is more in demand as the commercialization of low Earth orbit is expanding.

Operations↗

Maven Orbital Trajectory Analysis: Design and Implementation of Lander Relay Support

NASA’s successful Mars Atmosphere and Volatile Evolution Mission (MAVEN), currently engaged in a survey of the Martian atmosphere and its evolution over time, has successfully completed a series of orbit changes, including a two-month aerobraking campaign, to satisfy additional mission roles. Launched on 18 November 2013, it entered Martian orbit on 22 September 2014. Having finished its primary one-year mission, the NASA Mars Program Office (MPO) started discussions with the MAVEN project on feasible options for extending the mission lifetime along with providing support for various Mars lander functions. MAVEN is the latest of the three active NASA Mars orbiters, with no others planned for the foreseeable future. Given that the landers need orbital relay support for years to come, and the MRO and Odyssey orbiters are aging, MAVEN’s role in providing critical orbital relay support has become increasingly important. After several years of studies, MPO directed the MAVEN project in 2018 to reduce its orbit size to provide better telecommunications relay support for Martian surface landers and to support Mars 2020 EDL under the constraint that MAVEN will have enough fuel to operate until 2030. As a part of this effort, the recent aerobraking campaign was one of several steps crucial to accomplishing this goal. This paper discusses the challenges of the entire mission design and its distillation into a concrete set of targeted objectives. With the successful orbit change, MAVEN will be able to provide support for the Mars 2020 relay activities from EDL through surface operations beyond 2030. This effort can serve as an excellent example for future missions having similar needs and requirements.

Jakosky, B. M.↗

Clinical Decision Support For Exploration Space Flight: Software Augmentation To Enhance Progressively Earth-Independent Medical Operations

This panel identifies the challenges of supporting medical events in deep space using integrated systems software to augment existing capabilities during increasingly Earth-independent missions where an asynchronous communication environment becomes routine. An interdisciplinary team of software designers, physicians, human factors engineers, and computational modelers applied their respective expertise to develop a roadmap for supporting the crew making medical decisions in more autonomous fashion with time-delayed ground support. The first presentation describes predictive modeling implemented to assist medical system design and address risk reduction using robust clinical decision support software. The second presentation details how operational and environmental challenges guide assumptions and, in turn, by what means requirements for medical decision-making in deep space are derived. The third presentation describes and defines the skills and capabilities an exploration spaceflight medical officer will need to perform effectively during extended-duration spaceflight missions. The fourth presentation covers the potential models and function of the software element for supporting clinical decisions. The final presentation covers how these elements may work together with ground support to provide comprehensive care despite deep space travel's extreme challenges and limitations.

Dana Levin↗

NASA Support for Commercial Crew Launch Capabilities

Since the earliest days of U.S. human spaceflight, NASA’s Marshall Space Flight Center in Huntsville, Alabama, has played a key role in American crew launch capability, from engineering support for the first Mercury-Redstone launches, to the Saturn launches to the Moon, through Shuttle and now Artemis. Today, Marshall brings that expertise gained through decades of crewed space launches to NASA’s Commercial Crew Program (CCP), providing launch vehicle engineering and programmatic support. The team’s responsibilities have included human certification of commercial launch systems for the CCP missions, including Atlas V and Falcon 9, and verifying each launch vehicle complies with flight certification. MSFC provides expertise in nearly all aspects of launch vehicle design and performance including solid motors and liquid engines, stage propulsion, thrust vector control, structural and dynamics, safety and mission assurance. During each commercial crew launch, an engineering support team is on console at Marshall’s Huntsville Operations Support Center, which has provided launch operations support since Apollo, providing real-time oversight to safety standards for the vehicle and verifying data. Launch vehicle support for Commercial Crew has come as a paradigm shift for the MSFC team, inspiring new approaches that leverage expertise and best practices from past NASA-developed launch vehicle missions, while at the same time providing new synergies from work with commercial partners on CCP. This paper will explore the role that the Marshall launch vehicle services team plays in the Commercial Crew Program, as well as lessons learned from the program that will continue to benefit a new era of spaceflight partnerships.

Commercial Crew↗

Content and Representation of Information Needed to Support Time-Constrained Problem Solving

NASA’s current mission-operations paradigm originated with Project Mercury and endured with minimum evolution through the Apollo Program, Space Shuttle Program, and ISS missions. At its foundation is a near-complete real-time dependence on a ground team to manage the combined state of the mission, vehicle, and crew. Utilizing many engineers and operators with broad and deep expertise; large, distributed datasets including extensive telemetry; and expansive analytical and computing power, this ground team has served as the safety net for crewed spaceflight missions over the past 60 years. This approach must change to address challenges associated with missions beyond low Earth orbit (BLEO), including infrequent resupply, reduced ability to evacuate, and delayed communications that prohibit real-time operational support. We anticipate that a necessary part of this change will be increased independence for the crew, as roles and responsibilities traditionally performed by ground teams move on board the vehicle. While many risks are associated with Earth-independent operations, one particular concern is ensuring that the crew will have adequate onboard support to perform urgent problem solving when communication with the ground is delayed or intermittent. A key resource that enables the ground team to respond to anomalies quickly and effectively is the extraordinary expertise and experience it possesses. It is comprised of 80+ experts on at any given time, with a combined 600+ years of system-specific experience across 22 unique console disciplines. A small crew will face the unprecedented challenge of independently responding to anomalies that have historically been handled by a team 20 times their size. Another important resource upon which the ground heavily relies to support procedure execution and anomaly response is data. The amount of telemetry data that each flight controller monitors is extensive. In addition, as the ground team works to further assess impacts, trouble shoot, identify workarounds, and oversee procedure execution, it accesses and synthesizes engineering and procedure information, as well as system build, test, and configuration documentation. It is not feasible nor useful to put all these data onboard as crews become more Earth independent. Each member of a small Mars mission small crew will have multiple roles beyond monitoring telemetry and data gathering, and multiple roles within anomaly resolution processes, thereby limiting their capacity for copious amounts of information. Moreover, while access is necessary, it alone is insufficient. Information will need to be compiled, refined, and represented appropriately to support the crew’s reduced attention and expertise. This work seeks to understand the content and representation of information needed to support time-constrained problem solving and decision making by the crew without real-time ground support. To build this understanding, we first surveyed the literature, focusing on how expert problem solvers construct and manipulate their mental models. Next, we interviewed expert problem solvers in spaceflight and analogous domains and surveyed industry solutions for data presentation. Finally, we analyzed current spaceflight operations by investigating flight controller anomaly resolution processes during ISS training simulations and real operational events. These methods led to creating a problem-solving framework that details common themes and features of attending to, assessing, analyzing, and acting on problems in complex, time-constrained domains. Using this framework and the results of our analysis, we identified conceptual data representations needed for crew-led problem-solving. Preliminary onboard user interface concepts to meet identified needs will be presented.

anomaly response↗

OpenACC Profiling Support for Clang and LLVM using Clacc and TAU

Since its launch in 2010, OpenACC has evolved into one of the most widely used portable programming models for accelerators on HPC systems today. Clacc is a project funded by the US Exascale Computing Project (ECP) to bring OpenACC support for C and C++ to the popular Clang and LLVM compiler infrastructure. In this paper, we describe Clacc's support for the OpenACC Profiling Interface, a critical component of the OpenACC specification that standardizes an interface that profiling tools and libraries can depend upon across OpenACC implementations. As part of Clacc's general strategy to build OpenACC support upon OpenMP, we describe how Clacc builds OpenACC Profiling Interface support upon an extended version of OMPT. We then describe how a major profiling and tracing toolkit within ECP, the TAU Performance System, takes advantage of this support. We also describe TAU's selective instrumentation support for OpenACC. Finally, using Clacc and TAU, we present example visualizations for several SPEC ACCEL OpenACC benchmarks running on an IBM AC922 node, and we show that the associated performance overhead is negligible.

Coti, Camille↗

Supports with integrated sensors for nuclear reactor steam generators, and associated systems and methods

Supports with integrated sensors for nuclear reactor steam generators, and associated systems and methods, are disclosed. A representative method for forming a nuclear-powered steam generator includes forming an instrumented support, the instrumented support including a carrier portion and a retainer portion, with at least one of the carrier portion or the retainer portion being integrally formed with a sensor via an additive manufacturing process. The method can further include coupling the sensor to a communication link, supporting a helical steam conduit on the instrumented support, and installing the helical steam conduit and the instrumented support in a nuclear reactor. The helical steam conduit is positioned along a primary flow path, which is in turn positioned to circulate a heated primary flow in thermal communication with the helical steam conduit.

Welter, Kent↗

Calorimetric Energies and Chemical Potentials of Metal Atoms in Catalytic Nanoparticles on Oxide and Carbon Supports: Improved Size Dependencies and Adhesion Energies

The chemical potential of metal atoms, μM, in supported metal nanoparticles is an important descriptor related to both the catalytic activity and the stability of the nanoparticles. Here, we derive an expression relating μM to the radius of the particle’s contact area with the support and the adhesion energy at the metal/support interface (E adh ) that assumes the particles have the shape of spherical caps but of arbitrary contact angle with the support (θ c ) and includes an empirical correction for the increase in metal surface energy and adhesion energy with decreasing radius of curvature. We then show that, at any assumed contact angle, we can simultaneously fit previously reported measurements of both calorimetric μ M (from heats of metal vapor adsorption during nanoparticle growth by vapor deposition) versus metal coverage data and the He + low-energy ion scattering (LEIS) intensities for the metal and/or support versus metal coverage (using our recently developed spherical cap model for quantitative LEIS intensities), to determine the particle size versus coverage and E adh . Only one choice of contact angle gives a pair of values for contact angle and E adh , which is consistent with the Young–Dupré equation for the equilibrium shape of a spherical particle. At this equilibrium shape, we then applied this spherical cap model (SCM) to reanalyze microcalorimetric metal chemical potentials and LEIS signals versus coverage data for nine metal/support combinations that were previously analyzed by assuming that the particles had the shape of hemispherical caps, i.e., with a contact angle of 90°. We show that this revised approach gives close agreement with the calorimetric and LEIS data; the best-fit contact angles vary from 64 to 84°, correcting the earlier assumption of 90°. Furthermore, these results provide significant accuracy improvements in particle size versus coverage, metal chemical potential versus size and coverage, metal/support adhesion energies and contact angles for Cu, Ag and Au on CeO 2 (111), Ni on MgO(100), Ag on Fe 3 O 4 (111) and TiO 2 (100), and Ag, Ni and Pd on Ni-supported graphene. This revised approach is much more broadly applicable than the earlier hemispherical cap model (HCM).

99 GENERAL AND MISCELLANEOUS↗

Bioregenerative life support: not a picnic

If humans are to live permanently in space, regenerative life support systems are an enabling technology and must replace the picnic approach of taking all supplies required for each mission. These systems are classified by technologies as either physical/chemical or bioregenerative. Both of these system-types can recycle water, remove carbon dioxide, produce oxygen, and recover essential elements from waste products. Bioregenerative can also produce food, thus, making it essential if humans are to exist in space independent of earth. A solely bioregenerative life support system includes plants as a biomass production module and microbial organisms in bioreactors as a resource recovery module. In the Advanced Life Support Program, bioregenerative life support systems are being investigated through a research and technology development project which includes large scale testing as part of the Breadboard Project and human tests conducted in the soon to be constructed BioPlex facility. Research and technology development efforts are directed toward optimizing biomass productivity in controlled chambers by developing light weight, energy efficient, and automated systems; recycling liquid and solid wastes; baselining the operation of bioreactors; determining system microbial stability; assessing chemical contamination; and building models required for long term system operations. The program will include space flight studies in the near future to determine if these life support technologies will function in microgravity. When a bioregenerative system is finally incorporated into a mission, the conversion from a picnic and resupply mentality to permanent recycling and independence from earth will be complete.

NASA Center KSC↗

Methods and Costs to Achieve Ultra Reliable Life Support

A published Mars mission is used to explore the methods and costs to achieve ultra reliable life support. The Mars mission and its recycling life support design are described. The life support systems were made triply redundant, implying that each individual system will have fairly good reliability. Ultra reliable life support is needed for Mars and other long, distant missions. Current systems apparently have insufficient reliability. The life cycle cost of the Mars life support system is estimated. Reliability can be increased by improving the intrinsic system reliability, adding spare parts, or by providing technically diverse redundant systems. The costs of these approaches are estimated. Adding spares is least costly but may be defeated by common cause failures. Using two technically diverse systems is effective but doubles the life cycle cost. Achieving ultra reliability is worth its high cost because the penalty for failure is very high.

deep space life support↗

Fabrication and Scale-Up of Porous Polybenzimidazole (PBI) Supports for Gas Separation Composite Membranes

Industrial gas separation often uses thin film composite (TFC) membranes comprising a porous support overlaid with a single-/multi-layer gas-selective thin film. An optimal porous support should possess high surface porosity to minimize gas transport resistance and nano-sized pores to ease pore penetration occurring during the thin film coating process. Good chemical and thermal stabilities are essential to withstand the aggressive solvents and heat required for the thin film coating and curing. However, few porous membranes satisfy all these requirements. This study presents a scalable membrane formation method of making highly porous polybenzimidazole (PBI) supports via non-solvent induced phase separation. This presentation also details the scale-up fabrication of PBI supports using a custom roll-to-roll membrane casting machine.

gas separation↗

Porous FeCo Glassy Alloy as Bifunctional Support for High-Performance Zn-Air Battery

Zn-air battery (ZAB) is attracting increasing attention due to its high safety and performance. However, the practical application of ZAB relies heavily on developing durable support materials to replace conventional carbon supports which have unrecoverable corrosion issues, severely jeopardizing ZAB performance. Herein, a novel porous FeCo glassy alloy was developed as bifunctional catalytic support for ZAB. Specifically, the conducting skeleton of the porous glassy alloy was used to stabilize oxygen reduction cocatalysts, and more importantly, the FeCo served as the primary phase for oxygen evolution. To prove the concept of catalytic glassy alloy support, ultra-small Pd nanoparticles were anchored, as oxygen reduction active sites, on the porous FeCo (noted as Pd/FeCo) for ZAB. The Pd/FeCo exhibited a significantly improved electrocatalytic activity for oxygen reduction (a half-wave potential of 0.85 V) and oxygen evolution (a potential of 1.55 V to reach 10 mA cm –2 ) in the alkaline media. When used in the ZAB, the Pd/FeCo delivered an output power density of 117 mW cm –2 and outstanding cycling stability for over 200 h (400 cycles), surpassing the conventional carbon-supported Pt/C+IrO 2 catalysts. Such an integrated design of combining highly active components with porous architecture provides a new strategy to develop novel nanostructured electrocatalysts.

36 MATERIALS SCIENCE↗

Divanadium substituted keggin [PV 2 W 10 O 40 ] on non-reducible supports-Al 2 O 3 and SiO 2 : synthesis, characterization, and catalytic properties for oxidative dehydrogenation of propane

Molecular metal oxide cluster, K 5 [α-1,2-PV 2 W 10 O 40 ] (PV 2 W 10 ), was found to have intrinsic catalytic activity for the oxidative dehydrogenation of propane with high selectivity (> 80%) to propylene at low propane conversion (0.3%). Synthesis of dispersed PV 2 W 10 in non-reducible supports, γ-Al 2 O 3 and SiO 2 , was done by incipient wetness impregnation. The supported catalysts were characterized by IR, Raman spectroscopy, nitrogen adsorption, x-ray powder diffraction (PXRD), elemental analysis, hydrogen temperature-programmed reduction (H 2 –TPR), and ammonia temperature-programmed desorption (NH 3 –TPD). Catalytic testing of the supported PV 2 W 10 at equimolar cluster concentration revealed that when supported in γ-Al 2 O 3 it is more active (sevenfold increase in propane conversion) but in SiO 2 it is more selective to propylene (94%). The observed performance was due to both an increase in reducibility and higher concentration of strong acid sites for PV 2 W 10 supported in γ-Al 2 O 3 versus SiO 2 . Lastly, PV 2 W10 was shown to remain intact under reaction conditions indicating its thermal and oxidative stability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

HCOOH Decomposition on Sub-Nanometer Pd 6 Cluster Catalysts: The Effect of Defective Boron Nitride Supports Through First Principles

The catalytic properties of a hexagonal boron nitride- (h-BN) supported Pd 6 sub-nanometer cluster in the context of formic acid (HCOOH) decomposition were studied by means of periodic Density Functional Theory (DFT) calculations. The effect of support defectivity – boron (h-B v N) and nitrogen (h-BN v ) monovacancies – on the competition between the formate (HCOO)- and carboxyl (COOH)-mediated decomposition pathways was analyzed. Defects are responsible for charge-transfer leading to a positively or negatively charged cluster, and open new reactive channels in which vacancy-mediated dehydrogenation pathways can occur. Pd 6 cluster reconstructions, induced by the adsorption of reaction intermediates and by the presence of monovacancies in the support, greatly stabilize the formation of CO from COOH, which could drastically decrease the selectivity towards hydrogen production. Here, a simplified descriptor-based analysis, based on selected thermochemical quantities calculated on charged cluster models, suggests that Pd 6 sub-nanometer clusters supported on pristine h-BN and h-BN v can be more selective than Pd 6 supported on defective h-B v N towards HCOOH dehydrogenation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Atomically dispersed zeolite-supported rhodium complex: Selective and stable catalyst for acetylene semi-hydrogenation

In this study, supported rhodium catalysts are known to be unselective for semi-hydrogenation reactions. Here, by tuning the electronic structure of supported mononuclear rhodium sites determined by the metal nuclearity and the electron-donor properties of the support, we report that atomically dispersed HY zeolite-supported rhodium with reactive acetylene ligands affords a stable ethylene selectivity > 90 % for acetylene semi-hydrogenation at 373 K and atmospheric pressure, even when ethylene is present in a large excess over acetylene. Infrared and X-ray absorption spectra and measurements of rates of the catalytic reaction complemented with calculations at the level of density functional theory show how the catalyst performance depends on the electronic structure of the rhodium, influenced by the support as a ligand that is a weak electron donor.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗