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575 records · Page 21

SERFE Ground Unit EVA Series After Three Year Spacesuit Stowage Period

NASA’s spacesuit government reference design for returning to the Moon is called the Exploration Extravehicular Mobility Unit (xEMU). The xEMU subassembly that provides life support, such as oxygen and thermal control, is the Portable Life Support System (PLSS). Inside the PLSS is a new technology that NASA wanted to test to provide cooling to the crew during EVAs (ExtraVehicular Activity). This technology is called the Spacesuit Water Membrane Evaporator (SWME). In order to test SWME in an improved thermal control loop (TCL) both on Earth and in Space, the Spacesuit Evaporation Rejection Flight Experiment (SERFE) was created. The Ground unit, or testbed at Johnson Space Center (JSC), tested the cooling technology in Earth’s gravity, while the Flight unit, or payload on the International Space Station (ISS), tested the cooling technology in micro-gravity. Since fluids flow differently in micro-gravity, testing in both environments would provide important data for improving cooling performance during EVAs. Both units completed 25 simulated EVAs with the same settings so SWME performance on the ground could be compared to the ISS. The Flight unit was completed first and performed EVAs on the ISS between 2020 and 2022. The Ground unit performed EVAs between 2021 and 2022. When the Flight unit came back from the ISS, it was taken apart for analysis. This analysis looked at how well SWME was able to maintain its heat rejection capability after various dwell times, such as a 90 day Airlock Coolant Loop Recovery (ALCLR) cycle, when the Extravehicular Mobility Unit (EMU) currently on the ISS would normally need maintenance. After a three year simulated spacesuit dwell, the Ground unit performed another EVA series in 2025 to test SWME’s shelf life. The results from this test series will inform mission planning as NASA plans to go back to the Moon and beyond.

SWME

Battery charge control: Which approach is best?

The question of the best approach for battery charge control is addressed from two points of view: from the battery point-of-view; and from the spacecraft/mission point-of-view. In terms of performance, more aggressive charging can result in higher discharge voltage and capacity; however, aggressive charging usually implies more overcharge at higher rates and a concomitant higher end of charge temperature (higher stress, shorter life). In terms of life, benign charging can result in lower discharge voltage and capacity (poorer performance). Additionally, benign, or low stress charging, usually implies less overcharge at lower rates with lower end of charge temperature (lower stress, longer life). A discussion of these topics is presented in viewgraph form.

Lurie, Charles

Lithium-Ion Small Cell Battery Shorting Study

Positive Temperature Coefficient (PTC) provides adequate sustained hard short protection for AEA batteries with up to 8 cells in series. PTC cannot protect against sustained hard short in AEA batteries with 10 cells or more in series. Protective fused connector is a proven way to protect larger batteries from hard short damage: a) Hard short not credible in unmanned missions; b) However, recommended during ground handling; c) Inexpensive item. Preliminary diode protection scheme has passed manned space safety requirements for high voltage batteries. SCM confirmed fused connector did not affect battery health, however, this affect of hard short on the its long calendar and cycle life performance needs to be verified.

Pearson, Chris

The Contaminant Footprint of Landed Spacecraft: Toward an Inventory and Modelling Framework

All spacecraft generate and carry contaminants, i.e., unwanted and potentially harmful material. When a spacecraft lands and operates in vacuum, as onto Earth’s Moon, it introduces contaminants into its environment that may compromise mission science objectives and engineering performance. Contamination may degrade sites of unique value to planetary science or in situ resource utilization. This presentation will identify and compare source terms and transport vectors for contaminants – in particular, organic material – generated by landed spacecraft. An integrated modeling framework for the organic contamination footprint of spacecraft missions will be described and presented.

Gas Dynamics

NASA University Research Centers: Technical Advances in Aeronautics, Space Sciences and Technology, Earth Systems Sciences, Global Hydrology, and Education

This volume chronicles the proceedings of the 1998 NASA University Research Centers Technical Conference (URC-TC '98), held on February 22-25, 1998, in Huntsville, Alabama. The University Research Centers (URCS) are multidisciplinary research units established by NASA at 11 Historically Black Colleges or Universities (HBCU's) and 3 Other Minority Universities (OMU's) to conduct research work in areas of interest to NASA. The URC Technical Conferences bring together the faculty members and students from the URC's with representatives from other universities, NASA, and the aerospace industry to discuss recent advances in their fields.

T L Coleman

High-Order Methods in NASA’s Next Generation of Computational Fluid Dynamics Tools

The missions of the National Aeronautics and Space Administration (NASA) routinely produce unique requirements and challenges for development and application of Computational Fluid Dynamics (CFD) methods. NASA presently embodies four distinct Mission Directorates: Aeronautics Research, Exploration Systems, Science, and Space Operations. These missions generate requirements for systems that operate in a wide variety of environments. They range from the high-speed flight of aerodynamically optimized vehicles operating in the earth’s atmosphere to spacecraft designed for missions that don’t favor aerodynamic optimization, some operating in the atmosphere of planets and planetary moons such as Mars and Venus or Saturn’s moon Titan. Systems supporting these vehicles, such as rocket and jet propulsion, reaction control systems, fluid and thermal transfer systems, etc. can also generate their own unique set of flow phenomena that challenge today’s CFD methodology. Through the NASA Engineering and Safety Center (NESC), NASA annually conducts state-of-the-discipline assessments in fifteen distinct engineering disciplines. These assessments are performed by the NASA Technical Fellows that lead Technical Discipline Teams (TDT) of recognized experts in these fifteen areas. In the Aerosciences discipline, three topics have been identified as the top challenges for the discipline: aero-plume interaction prediction, unsteady separated flows, and aerothermodynamic prediction. These challenge areas are defined by the Agency’s high-risk projects and problems on which the NESC is requested to perform independent testing, analysis, and assessments. When viewed as a whole, these tests, analyses, and assessments provide a clear view of the recurring technical challenges facing Agency engineers and researchers and can be used to guide future research and technology development. The present state-of-the-art in the application of CFD at NASA is the use of Reynolds-Averaged Navier- Stokes (RANS) solvers, primarily executed in a steady-state mode of operation. In isolated cases, Unsteady RANS (URANS) solvers have been employed when steady RANS solutions produce poorly converging or oscillating results or in cases, such as aeroelastic analysis, which require unsteady aerodynamic simulation. For most traditional external and internal aerodynamic flows, structured overset grids or unstructured grids are employed to minimize geometric modeling and grid generation times. Grid adaptation, primarily as a series of coarse-grain intermediate processing steps is also seeing use on particularly complex flow problems and configurations. In the case of aerothermodynamic flows, engineers have been forced to continue to employ structured grid techniques as the present unstructured grid methodology has proven inadequate in the prediction of surface heating. In the area of aero-plume interaction modeling, two-gas, frozen chemistry simulation is generally the state-of-the- art, with some production solvers capable of predicting flows with only a single gas component. Prediction of flows falling into the afore-mentioned top Aerosciences technical challenges have severely stressed the present state-of-the-art in CFD prediction and for some problems, such as unsteady separated flows and aero-plume interaction cases, engineers have begun employing Large Eddy Simulation (LES) and Hybrid RANS/LES techniques. In some isolated aero-propulsion interaction cases, chemically reacting flow simulations have been applied. These methods are highly evolutionary and engineers have little experience in their application, so they cannot be heavily relied upon in today’s application environment. Therefore, this leads one to muse over which numerical technologies will be included in the CFD tools that will be employed 30 years in the future. This presentation will describe specific technical problems that have stressed NASA’s traditional CFD methods to their breaking point and will link these issues to the Agency’s top Aerosciences technical challenges. The discussion will then shift to the characteristics of future CFD solvers that will be required to attack these challenges and how these characteristics differ from the present state-of-the- art. High-order methods certainly appear to have a place in the development of future CFD tools and some of the physical characteristics of our most challenging problems suggest that high-order methods are the only way to effectively solve them. But there are some relatively severe implementation issues that face these methods, particularly in the area of general applicability and robust operation as an engineering tool. Desired characteristics of next-generation CFD solvers will be discussed and the author’s view of which emerging numerical technologies might be employed to address these attributes will also be presented

David M Schuster

Effect of Barely Visible Impact Damage on Thermoplastic Welded Structure

Spirit Aerosystems recently conducted screening tests on thermoplastic skin/stringer panels manufactured with Automated Fiber Placement (AFP) and stamp forming which were joined using Spirit’s Co-Fusion process. Skin and stringer gauge were both set to 0.168 cm. The resulting panel design is 48 cm tall, 49 cm wide, and has 3 stringers welded at a 21.5 cm pitch. Barely Visible Impact Damage (BVID) and Residual Compressive Strength were chosen to conduct a damage tolerance study. Zee stringers, made with IM8/PEKK-FC material, were Co-Fusion welded to a T1100/TC1225 skin. Out of these 5 panels, 1 was chosen to be a BVID survey panel, 1 for pristine compressive strength determination, and 3 to be impacted to create BVID followed by testing for residual compressive strength. On the survey panel, impacts ranged in energy from 40J – 65J and dent depth measurements were conducted at 24 hours, 48 hours, and two weeks after impacting. The residual compressive strength panel failed near the predicted load of 214 MPa. For the residual compressive strength panels, BVID was created at two different mid-bay locations: 1) striking the OML coincident with the stringer and 2) striking the skin IML 2.5 cm away from the stringer flange. Pulse Echo Ultrasonic Testing was used to inspect the panels before and after creating BVID.

HiCAM

Dynamic analysis of a photovoltaic power system with battery storage capability

A photovolataic power system with a battery storage capability is analyzed. A dual battery current control concept is proposed, which enables the battery to either supply or accept power depending upon system environment and load conditions. A simulation of the power system, including the battery current control, is developed and evaluated. The evaulation demonstrate the visbility of the battery control concept of switch the battery from a charge to discharge mode and back as required by load and environmental conditions. An acceptable system operation is demonstrated over the entire insolation range. Additionally, system sensitivity, bandwidth, and damping characteristics of the battery control are shown to be acceptable for a projected hardware implementation.

Merrill, W. C.

Advanced nickel-hydrogen spacecraft battery development

Eagle-Picher currently has several advanced nickel-hydrogen (NiH2) cell component and battery designs under development including common pressure vessel (CPV), single pressure vessel (SPV), and dependent pressure vessel (DPV) designs. A CPV NiH2 battery, utilizing low-cost 64 mm (2.5 in.) cell diameter technology, has been designed and built for multiple smallsat programs, including the TUBSAT B spacecraft which is currently scheduled (24 Nov. 93) for launch aboard a Russian Proton rocket. An advanced 90 mm (3.5 in.) NiH2 cell design is currently being manufactured for the Space Station Freedom program. Prototype 254 mm (10 in.) diameter SPV batteries are currently under construction and initial boilerplate testing has shown excellent results. NiH2 cycle life testing is being continued at Eagle-Picher and IPV cells have currently completed more than 89,000 accelerated LEO cycles at 15% DOD, 49,000 real-time LEO cycles at 30 percent DOD, 37,800 cycles under a real-time LEO profile, 30 eclipse seasons in accelerated GEO, and 6 eclipse seasons in real-time GEO testing at 75 percent DOD maximum. Nickel-metal hydride battery development is continuing for both aerospace and electric vehicle applications. Eagle-Picher has also developed an extensive range of battery evaluation, test, and analysis (BETA) measurement and control equipment and software, based on Hewlett-Packard computerized data acquisition/control hardware.

Coates, Dwaine K.

Reliability Analysis of Single Crystal NiAl Turbine Blades

As part of a co-operative agreement with General Electric Aircraft Engines (GEAE), NASA LeRC is modifying and validating the Ceramic Analysis and Reliability Evaluation of Structures algorithm for use in design of components made of high strength NiAl based intermetallic materials. NiAl single crystal alloys are being actively investigated by GEAE as a replacement for Ni-based single crystal superalloys for use in high pressure turbine blades and vanes. The driving force for this research lies in the numerous property advantages offered by NiAl alloys over their superalloy counterparts. These include a reduction of density by as much as a third without significantly sacrificing strength, higher melting point, greater thermal conductivity, better oxidation resistance, and a better response to thermal barrier coatings. The current drawback to high strength NiAl single crystals is their limited ductility. Consequently, significant efforts including the work agreement with GEAE are underway to develop testing and design methodologies for these materials. The approach to validation and component analysis involves the following steps: determination of the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; measurement of the failure strength envelope of the material; coding of statistically based reliability models; verification of the code and model; and modeling of turbine blades and vanes for rig testing.

Joseph Palko

The Entry Plasma Sheath and Its Effects on Space Vehicle Electromagnetic Systems, Volume 1

This symposium is the fourth in a series on the plasma sheath. The first three were held in Boston, Massachusetts, and were sponsored by the Air Force Cambridge Research Laboratories. The papers included in the symposium cover theoretical and experimental results of research and flight tests of many different specific aspects of the general problem of plasma sheath degradation of reentry vehicle electromagnetic systems. Only the newer advances and more recent developments in the field are included in the Fourth Plasma Sheath Symposium, with no particular attempt being made to review the general background and history of the problem or to cover those aspects discussed in the previous symposia. Flight data from both NASA and DOD programs are included.

Source record

Preliminary Study of a Nuclear Rocket System for Manned Planetary Missions

The primary purpose of the NERVA nuclear rocket currently under development Once developed, is to demonstrate the feasibility of nuclear rocket propulsion. Once developed, it may have application in missions such as a manned lunar landing or space station supply. Unfortunately, it is too small for manned interplanetary missions. This being the case, it was decided to examine a second-generation nuclear rocket suitable for manned interplanetary flight in order to get an idea of component characteristics and problem areas. This examination is, in general, based on current technology and includes the graphite reactor concept, a nozzle fabricated from Inconel X tubing, and conventional turbopump blading and bearings. Some of the preliminary results of this examination are reported herein.

John H Povolny

Solar Array Automation Limitations

Significant progress in the automation of the spacecraft electrical power systems has been made within the past few years. This is especially important with the development of the space station and the increasing demand on the electrical power systems for future satellites. The key element of the spacecraft power system, the solar arrays which supply the power, will have to grow to supply many tens of kilowatts of power within the next twenty years. This growth will be accompanied by the problems associated with large distributed power systems. The growth of the arrays, the on-array management problems and potential solutions to array degradation or failure are discussed. Multilowatt arrays for unmanned spacecraft with comments on the implications of array degradation for manned spacecraft are discussed.

Terry M Trumble

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems

Artemis I Space Launch System Base Heat Shield Thermal Protection System Performance

The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.

aerothermodynamics

Optimal Battery Charging for Damage Mitigation

Our control philosophy is to charge the NiH2 cell in such a way that the damage incurred during the charging period is minimized, thus extending its cycle life. This requires nonlinear dynamic model of NiH2 cell and a damage rate model. We must do this first. This control philosophy is generally considered damage mitigating control or life-extending control. This presentation covers how NiH2 cells function, electrode behavior, an essentialized model, damage mechanisms for NiH2 batteries, battery continuum damage modeling, and battery life models. The presentation includes graphs and a chart illustrating how charging a NiH2 battery with different voltages and currents affects damages the battery and affects its life. The presentation concludes with diagrams of control system architectures for tracking battery recharging.

Hartley, Tom T.

Enhanced Decoding for the Galileo S-Band Mission

A coding system under consideration for the Galileo S-band low-gain antenna mission is a concatenated system using a variable redundancy Reed-Solomon outer code and a (14,1/4) convolutional inner code. The 8-bit Reed-Solomon symbols are interleaved to depth 8, and the eight 255-symbol codewords in each interleaved block have redundancies 64, 20, 20, 20, 64, 20, 20, and 20, respectively (or equivalently, the codewords have 191, 235, 235, 235, 191, 235, 235, and 235 8-bit information symbols, respectively). This concatenated code is to be decoded by an enhanced decoder that utilizes a maximum likelihood (Viterbi) convolutional decoder; a Reed Solomon decoder capable of processing erasures; an algorithm for declaring erasures in undecoded codewords based on known erroneous symbols in neighboring decodable words; a second Viterbi decoding operation (redecoding) constrained to follow only paths consistent with the known symbols from previously decodable Reed-Solomon codewords; and a second Reed-Solomon decoding operation using the output from the Viterbi redecoder and additional erasure declarations to the extent possible. It is estimated that this code and decoder can achieve a decoded bit error rate of 1 x 10 -7 at a concatenated code signal-to-noise ratio of 0.76 dB. By comparison, a threshold of 1.17 dB is required for a baseline coding system consisting of the same (14,1/4) convolutional code, a (255,223) Reed-Solomon code with constant redundancy 32 also interleaved to depth 8, a one-pass Viterbi decoder, and a Reed Solomon decoder incapable of declaring or utilizing erasures. The relative gain of the enhanced system is thus 0.41 dB. It is predicted from analysis based on an assumption of infinite interleaving that the coding gain could be further improved by approximately 0.2 dB if four stages of Viterbi decoding and four levels of Reed-Solomon redundancy are permitted. Confirmation of this effect and specification of the optimum four-level redundancy profile for depth-8 interleaving is currently being done.

S Dolinar