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NASA NTRS2016

NASA's Space Launch System Transitions From Design To Production

NASA's Space Launch System (SLS) successfully completed its Critical Design Review (CDR) in 2015, a major milestone on the journey to an unprecedented era of exploration for humanity. CDR formally marked the program's transition from design to production phase just four years after the program's inception and the first such milestone for a human launch vehicle in 40 years. While challenges typical of a complex development program lie ahead, CDR evaluators concluded that the design is technically and programmatically sound and ready to press forward to Design Certification Review (DCR) and readiness for launch of Exploration Mission 1 (EM-1) in the 2018 timeframe. SLS is prudently based on existing propulsion systems, infrastructure and knowledge with a clear, evolutionary path as required by mission needs. In its initial configuration, designated Block 1, SLS will a minimum of 70 metric tons (t) (154,324 pounds) of payload to low Earth orbit (LEO). It will evolve to a 130 t (286,601 pound) payload capacity by upgrading its engines, boosters, and upper stage, dramatically increasing the mass and volume of human and robotic exploration while decreasing mission risk, increasing safety, and simplifying ground and mission operations. CDR was the central programmatic accomplishment among many technical accomplishments that will be described in this paper. The government/industry SLS team successfully test-fired a flight-like five-segment solid rocket motor, as well as seven hotfire development tests of the RS-25 core stage engine. The majority of the major test article and flight barrels, rings, and domes for the core stage liquid oxygen, liquid hydrogen, engine section, intertank, and forward skirt were manufactured at NASA's Michoud Assembly Facility in New Orleans, Louisiana. Renovations to the B-2 test stand for stage green run testing were completed at NASA's Stennis Space Center (SSC), near Bay St. Louis, Mississippi. Core stage test stands are reaching completion at NASA's Marshall Space Flight Center in Huntsville, Alabama. The modified Pegasus barge for core stage transportation from manufacturing to testing and launch sites was delivered to SSC. The Interim Cryogenic Propulsion System test article was also completed. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Askins, Bruce R.↗
NASA NTRSDate not supplied

Spacesuit and Mobility Performance Changes

The complex interactions between the human body and spacesuit lead to changes inmovement patterns and mobility performancesof the wearer. In general, factors including the geometric properties, such as shape and size, mechanical properties of the suit, and pressurization of the suit are known to be associated with altered movement patterns as compared to an unsuited human.However, their relative contributions have not been explicitly quantified from the mobility performance perspectives. The goal of this study wasthus to assessthe effects fromthe different types of mobility constraintconditions, namely by wearing either a 3D printed hard upper torso (HUT) assembly orfully pressurized spacesuit. The outcome was also compared against the unsuited motions. For this study, an xEMU (exploration Extravehicular Mobility Unit) suitwas considered, which is the next generation spacesuit developed by NASA. In each test condition, the subject was asked to move the arm and hand as prescribedfor different task types, and the corresponding body segment locations were recordedusing a 3D motion capture system. The following three tasks were performedand analyzed: 1) Outward one-handed reaches:the subject in a standing pose made sweeping motions with the extended right arm from the extreme end-to-end positions, including side-to-side at different elevations and top-to-bottom at different azimuths. 2) Outward two-handed reaches:similarto the previous task, howeverthe subject kept the hands together during the motions in order to assessthe areas that can be reached by both hands. 3) Inward one-handed reaches:the subject made right-hand reach motions to the surface of the HUT.The hand traces collected from each task were modeled by a template shape parametrically deformed with a radial basis function. This process enabled foran abstraction of the hand traces into a smooth surface envelope representing the maximally reachable area of the test subject, of which the shapes and sizes were compared across the different test conditions. The preliminary analysis has shown that theoverall size of reachenvelopes decreases in a pressurized suit compared to 3D printed mockup HUT and unsuited conditions. The specific shape of the envelopes, which were determined by the reachable and unreachable zones, alsovary with the testconditions, and the differences werepronounced with the inward reaches to the HUT surface. The latter observation ispotentially relatedto the increased demandfor shoulder and elbow flexions.Overcomingthe resistance from the pressurizedsoft goods and mechanical constraints of the shoulder assemblywas seen to be associated with the difference in motion patterns between the suited and unsuited conditions. Overall, the information quantified from this study is expected to provide structured metrics for spacesuit mobility, which can improve design optimization and human-system integration.

K Han Kim↗
NASA NTRSDate not supplied

Overview of Plume-Surface Interaction Data from Subscale Inert Gas Testing at NASA MSFC Test Stand 300 Vacuum Facilities

Maturation and validation of predictive modeling capabilities for plume-surface interaction, and the effects caused by the impingement of rocket engine exhaust on surface regolith, require relevant, highly characterized ground test data. The multi-phase nature of this problem poses challenges to ground testing across physical scaling, test environments and techniques, and diagnostics. NASA has developed a Physics Focused Ground Test (PFGT) of plume-surface interaction to address this need. The PFGT is a subscale, inert-gas experiment at Mars- and Lunar-relevant ambient pressure conditions that will provide critical data for model validation of cratering, ejecta, and plume physics. In this test, the ambient pressure in a vacuum chamber will be varied, along with the height of a supersonic nozzle above a surface, and the mass flow rate through the nozzle. Testing will be performed on a range of regolith simulants of varying composition and will also include instrumented impingement plate tests in place of regolith simulant to characterize gas-only plume physics. Novel high-speed visual diagnostics will capture temporal data on crater formation and ejecta dynamics, and planar laser-induced fluorescence diagnostics will capture plume structure and behavior. This paper will present an overview of the data collected during this test – for both the cratering and ejecta testing and the gas-only plume physics testing. Emphasis will be placed on trends, effects, and interactions observed in the data across the test parameter space.

Chad J. Eberhart↗
NASA NTRS1980

A design procedure for fan inflow control structures

Significant differences exist in the noise generated by engine in flight and engines operating on the test stand. It was observed that these differences can be reduced by use of an inflow control structure (ICS) in the static test configuration. The results of the second phase of a three phase program are described and the results of a test program conducted to assess and modify various theoretical models, leading to the development of an ICS design system is summarized.

Gedge, M. R.↗
NASA NTRS2010

Hot-Fire Testing of 100 LB(sub F) LOX/LCH4 Reaction Control Engine at Altitude Conditions

Liquid oxygen/liquid methane (LO2/LCH4 ) has recently been viewed as a potential green propulsion system for both the Altair ascent main engine (AME) and reaction control system (RCS). The Propulsion and Cryogenic Advanced Development Project (PCAD) has been tasked by NASA to develop these green propellant systems to enable safe and cost effective exploration missions. However, experience with LO2/LCH4 as a propellant combination is limited, so testing of these systems is critical to demonstrating reliable ignition and performance. A test program of a 100 lb f reaction control engine (RCE) is underway at the Altitude Combustion Stand (ACS) of the NASA Glenn Research Center, with a focus on conducting tests at altitude conditions. These tests include a unique propellant conditioning feed system (PCFS) which allows for the inlet conditions of the propellant to be varied to test warm to subcooled liquid propellant temperatures. Engine performance, including thrust, c* and vacuum specific impulse (I(sub sp,vac)) will be presented as a function of propellant temperature conditions. In general, the engine performed as expected, with higher performance at warmer propellant temperatures but better efficiency at lower propellant temperatures. Mixture ratio effects were inconclusive within the uncertainty bands of data, but qualitatively showed higher performance at lower ratios.

Marshall, William M.↗
NASA NTRS2016

Demonstration of Robustness and Integrated Operation of a Series-Bosch System

Manned missions beyond low Earth orbit will require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. Bosch technology is one option to maximize oxygen recovery, in the form of water, from metabolically-produced carbon dioxide (CO2). A two stage approach to Bosch, called Series-Bosch, reduces metabolic CO2 with hydrogen (H2) to produce water and solid carbon using two reactors: a Reverse Water-Gas Shift (RWGS) reactor and a carbon formation (CF) reactor. Previous development efforts demonstrated the stand-alone performance of a NASA-designed RWGS reactor designed for robustness against carbon formation, two membrane separators intended to maximize single pass conversion of reactants, and a batch CF reactor with both transit and surface catalysts. In the past year, Precision Combustion, Inc. (PCI) developed and delivered a RWGS reactor for testing at NASA. The reactor design was based on their patented Microlith® technology and was first evaluated under a Phase I Small Business Innovative Research (SBIR) effort in 2010. The RWGS reactor was recently evaluated at NASA to compare its performance and operating conditions with NASA's RWGS reactor. The test results will be provided in this paper. Separately, in 2015, a semi-continuous CF reactor was designed and fabricated at NASA based on the results from batch CF reactor testing. The batch CF reactor and the semi-continuous CF reactor were individually integrated with an upstream RWGS reactor to demonstrate the system operation and to evaluate performance. Here, we compare the performance and robustness to carbon formation of both RWGS reactors. We report the results of the integrated operation of a Series-Bosch system and we discuss the technology readiness level.

Abney, Morgan B.↗
NASA NTRS2016

Facility Effect Characterization Test of NASA's HERMeS Hall Thruster

A test to characterize the effect of varying background pressure on NASA's 12.5-kW Hall Effect Rocket with Magnetic Shielding had being completed. This thruster is the baseline propulsion system for the Solar Electric Propulsion Technology Demonstration Mission (SEP TDM). Potential differences in thruster performance and oscillation characteristics when in ground facilities versus on-orbit are considered a primary risk for the propulsion system of the Asteroid Redirect Robotic Mission, which is a candidate for SEP TDM. The first primary objective of this test was to demonstrate that the tools being developed to predict the zero-background-pressure behavior of the thruster can provide self-consistent results. The second primary objective of this test was to provide data for refining a physics-based model of the thruster plume that will be used in spacecraft interaction studies. Diagnostics deployed included a thrust stand, Faraday probe, Langmuir probe, retarding potential analyzer, Wien filter spectrometer, and high-speed camera. From the data, a physics-based plume model was refined. Comparisons of empirical data to modeling results are shown.

Electric Propulsion↗
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↗
DOE OSTI2025

Evaluation of a 5kW Solid Oxide Electrolysis Cell Stack

Solid oxide electrolysis cells (SOECs) are a developing technology for hydrogen production. They are promising due to their utilization of thermal energy to reduce their electricity consumption. The Department of Energy (DOE) has set goals to reduce the price per kilogram of hydrogen, and Idaho National Laboratory (INL) is conducting research to develop and demonstrate advanced methods and technologies to achieve making hydrogen a more affordable, efficient, and sustainable energy source. In this project, INL is collaborating with a vendor to evaluate and validate the design of a 5kW SOEC stack. The test aims to demonstrate a safe startup, operation, and shutdown on INL’s 5kW test stand, providing third-party validation in a different environment. A successful 50-hour test with stable hydrogen production will pave the way for a subsequent 1000-hour test. This project emphasized learning about electrolysis and the various support systems, referred to as balance of plant (BOP) equipment. These systems required modification while swapping to the vendor 5kW SOEC stack, most prominently the furnace door design and the controls system. It also included gaining skills in creating computer-aided design (CAD) drawings for the new door while using available materials and ensuring it met high-temperature requirements. Upon completion of modifications to the test stand, the SOEC will be test-fitted with respective wiring and piping. Instrumentation and piping will be checked for leaks and quality. This must be completed before the vendor’s engineers arrive to observe the test plan, startup, and a collection of 50 hours of data. The vendor’s engineers will ensure their stack performed sufficiently in the 50-hour test to enable the progression to a 1000-hour test.

08 - HYDROGEN↗
NASA NTRS1979

Measured and predicted noise of the AVCO-Lycoming YF-102 turbofan engine

Acoustic testing of the AVCO-Lycoming YF-102 turbofan engine was done on a static test stand at Lewis Research Center in support of the Quiet Short-Haul Research Aircraft (QSRA) acoustic design. Overall noise levels are dominated by the fan noise emanating from the exhaust duct, except at high power settings when combination tones are generated in the fan inlet. Component noise levels, calculated by noise prediction methods developed at Lewis Research Center for the ANOP program, are in reasonable agreement with the measured results. Far-field microphones placed at ground level were found superior to those at engine centerline height, even at high frequencies.

Clark, B. J.↗
NASA NTRS2016

Demonstration of Robustness and Integrated Operation of a Series-Bosch System

Manned missions beyond low Earth orbit will require highly robust, reliable, and maintainable life support systems that maximize recycling of water and oxygen. Bosch technology is one option to maximize oxygen recovery, in the form of water, from metabolically-produced carbon dioxide (CO2). A two stage approach to Bosch, called Series-Bosch, reduces metabolic CO2 with hydrogen (H2) to produce water and solid carbon using two reactors: a Reverse Water-Gas Shift (RWGS) reactor and a carbon formation (CF) reactor. Previous development efforts demonstrated the stand-alone performance of a RWGS reactor containing Incofoam(TradeMark) catalyst and designed for robustness against carbon formation, two membrane separators intended to maximize single pass conversion of reactants, and a batch CF reactor with both transit and surface catalysts. In the past year, Precision Combustion, Inc. (PCI) developed and delivered a RWGS reactor for testing at NASA. The reactor design was based on their patented Microlith(TradeMark) technology and was first evaluated under a Phase I Small Business Innovative Research (SBIR) effort in 2010. The Microlith(TradeMark) RWGS reactor was recently evaluated at NASA to compare its performance and operating conditions with the Incofoam(TradeMark) RWGS reactor. Separately, in 2015, a fully integrated demonstration of an S-Bosch system was conducted. In an effort to mitigate risk, a second integrated test was conducted to evaluate the effect of membrane failure on a closed-loop Bosch system. Here, we report and discuss the performance and robustness to carbon formation of both RWGS reactors. We report the results of the integrated operation of a Series-Bosch system and we discuss the technology readiness level. 1

Abney, Morgan B.↗
NASA NTRS2017

The MINERVA Software Development Process

This paper presents a software development process for safety-critical software components of cyber-physical systems. The process is called MINERVA, which stands for Mirrored Implementation Numerically Evaluated against Rigorously Verified Algorithms. The process relies on formal methods for rigorously validating code against its requirements. The software development process uses: (1) a formal specification language for describing the algorithms and their functional requirements, (2) an interactive theorem prover for formally verifying the correctness of the algorithms, (3) test cases that stress the code, and (4) numerical evaluation on these test cases of both the algorithm specifications and their implementations in code. The MINERVA process is illustrated in this paper with an application to geo-containment algorithms for unmanned aircraft systems. These algorithms ensure that the position of an aircraft never leaves a predetermined polygon region and provide recovery maneuvers when the region is inadvertently exited.

Narkawicz, Anthony↗
NASA NTRS1991

OPAD through 1991 - Status report no. 2

The Optical Plume Anomaly Detection (OPAD) experimental program has attempted to develop a rocket engine health monitor for the detection, and if possible the quantification, of anomalous atomic and molecular species in exhaust plumes. The test program has formulated instrument designs allowing both wide spectral range and high spectral resolution. Attention is presently given to OPAD data collected for the SSME at NASA-Marshall's technology test stand, with a view to spectral emissions at startup and variations in baseline plume emissions due to changes in rated power level.

Powers, W. T.↗
DOE OSTI2024

Development of a half-meter scale Traveling-Wave (TW) SRF cavity

Traveling-wave technology can push the accelerator field gradient of niobium SRF cavity to 70MV/m or higher beyond the fundamental limit of 50~60MV/m in Standing-Wave regime. The 1st demonstration of TW resonance excitation in a proof-of-principle 3-cell SRF cavity in 2K liquid helium was successfully carried out at Fermilab in collaboration with Euclid Techlabs. In parallel with that, the RF design process of 0.5~1 meter scale TW cavity was begun at Fermilab for advancing TW technologies necessary more for future accelerator-scale one. Considering the physical dimensions of existing SRF facilities (for fabrication, processing, and cryogenic testing) and the lessons learned from the 3-cell, Fermilab has proposed a preliminary RF design of a half-meter scale TW SRF cavity. It consists of a 7-cell structure and a power feedback waveguide (WG) loop with new RF configurations to control TW resonance. Here we report a preliminary RF design, development plans, and activities.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

NFPA Distributed Energy Resources Safety Training (DERST) For Emergency Responders

The National Fire Protection Association, with support from the Department of Energy, executed a multi-year initiative to develop, enhance, and disseminate Distributed Energy Resources Safety Training (DERST) tools for U.S. emergency responders. As Distributed Energy Resources (DER)—such as solar photovoltaics, battery energy storage systems (ESS), electric vehicles (EVs), and associated infrastructure—become increasingly prevalent, the NFPA identified a critical need for up-to-date standardized, accessible, and effective safety training tailored for the fire service and related public safety professionals. The project delivered a comprehensive suite of educational resources to improve responders’ abilities to safely manage DER-related incidents. This included: • Revised Modular Training Courses: Updated classroom-based DER safety courses, now modular and accessible nationwide through fire academies and the North American Fire Training Directors (NAFTD) network. • Live Burn Testing & Research: A full-scale controlled burn of a DER-equipped residential structure provided real-world data and insights, forming the basis for updated best practices. • A Gamified Simulation Tool – Firefighters Incident Response Simulation Tool (FIRST): A first-of-its-kind, multiplayer, scenario-based simulation using the Unreal Engine 5.0 to train responders in a realistic virtual, multi-DER incident environment. • Field Familiarization Software Tools & Prop Guide: Digital DER field familiarization evolutions software guide and a prop development manual to support field-based DER training exercises, enhancing responders' hands-on familiarity with DER infrastructure and collaboration on virtual incident responses. • National Dissemination Strategy: Strategic partnerships with NAFTD, Vector Solutions, and others enabled wide-scale distribution, with over 5,000 departments accessing resources and 1,100+ departments adopting the simulator in the first seven months. Also provided a web portal for easy access to all training and simulation programs developed under this grant for the U.S. responder community. Key findings from the project—particularly from the burn test—led to paradigm shifts in fire response tactics. For example, traditional approaches to garage fires may be hazardous if DERs are present, due to explosive off gassing and thermal runaway risks. The new training emphasizes scene assessment, stand-off approaches, thermal imaging verification, and careful post-incident cooling of DER components to prevent reignition. This initiative has had a significant national impact, raising awareness, enhancing preparedness, and supporting safer DER incident response practices. Significant engagement from the media, public safety organizations, and PBS coverage has further amplified the reach and adoption of NFPA’s DER safety training, tools, and simulations.

14 SOLAR ENERGY↗
NASA NTRS1980

Pogo summary report main propulsion test static firings 1-7 for shuttle development flight instrumentation

Problems concerning the shuttle main propulsion system Polar Orbit Geophysical Observatory (POGO) instrumentation and the actions taken to correct them are summarized. Investigations and analyses appear to be providing solutions to correct the majority of questionable measurements. Corrective action in the handling of cables and connectors should increase the POGO measurement quality. Unacceptable levels of very low frequency noise and data level shifts may be related to test stand grounding configuration, but further investigation is required.

Haddick, C. M., Jr.↗
NASA NTRS1980

Chemical vapor deposited tungsten with dispersed carbides for Space Shuttle check valves

A chemical vapor deposited tungsten with dispersed carbides was selected as the material for Space Shuttle Orbital Maneuvering and Reaction Control Systems check valve poppets and seats. The selection followed a NASA-sponsored prototype check valve development program utilizing the cutter-seal shell poppet concept. The poppet material is deposited as a coating approximately 0.9 mm thick and fabricated into a shell as a free standing body. The seat material is deposited as a coating 1.1 mm thick on a seat blank, and the cutter seal is machined in the coating. Module tests demonstrated that the material could be ground and lapped to very sharp edges and could cut through typical system contaminants without excessive damage to the sealing surfaces. The material was also determined to be unaffected by exposure to a strongly oxidizing storable propellant.

Williams, G. E.↗
NASA NTRS2010

Testing to Transition the J-2X from Paper to Hardware

The J-2X Upper Stage Engine (USE) will be the first new human-rated upper stage engine since the Apollo program of the 1960s. It is designed to carry the Ares I and Ares V into orbit and send the Ares V to the Moon as part of NASA's Constellation Program. This paper will provide an overview of progress on the design, testing, and manufacturing of this new engine in 2009 and 2010. The J-2X embodies the program goals of basing the design on proven technology and experience and seeking commonality between the Ares vehicles as a way to minimize risk, shorten development times, and live within current budget constraints. It is based on the proven J-2 engine used on the Saturn IB and Saturn V launch vehicles. The prime contractor for the J-2X is Pratt & Whitney Rocketdyne (PWR), which is under a design, development, test, and engineering (DDT&E) contract covering the period from June 2006 through September 2014. For Ares I, the J-2X will provide engine start at approximately 190,000 feet, operate roughly 500 seconds, and shut down. For Ares V, the J-2X will start at roughly 190,000 feet to place the Earth departure stage (EDS) in orbit, shut down and loiter for up to five days, re-start on command and operate for roughly 300 seconds at its secondary power level to perform trans lunar injection (TLI), followed by final engine shutdown. The J-2X development effort focuses on four key areas: early risk mitigation, design risk mitigation, component and subassembly testing, and engine system testing. Following that plan, the J-2X successfully completed its critical design review (CDR) in 2008, and it has made significant progress in 2009 and 2010 in moving from the drawing board to the machine shop and test stand. Post-CDR manufacturing is well under way, including PWR in-house and vendor hardware. In addition, a wide range of component and sub-component tests have been completed, and more component tests are planned. Testing includes heritage powerpack, turbopump inducer water flow, turbine air flow, turbopump seal testing, main injector and gas generator, injector testing, augmented spark igniter testing, nozzle side loads cold flow testing, nozzle extension film cooling flow testing, control system testing with hardware in the loop, and nozzle extension emissivity coating tests. In parallel with hardware manufacturing, work is progressing on the new A-3 test stand to support full duration altitude testing. The Stennis A-2 test stand is scheduled to be turned over to the Constellation Program in September 2010 to be modified for J-2X testing also. As the structural steel was rising on the A-3 stand, work was under way in the nearby E complex on the chemical steam generator and subscale diffuser concepts to be used to evacuate the A-3 test cell and simulate altitude conditions.

Byrd, Tom↗