Results for “Lunar Manufacturing” — Page 23

NASA NTRSDate not supplied

Towards Erecting Straighter Lightweight Towers on the Moon Using Deployable Guy Wires

This paper reports our static stability test findings for a simple guy wire system to correct the natural lateral deflections of an 8.5m tall, compact deployable composite tower intended to support exploration of lunar permanently shadowed regions by nearby robotic assets. Deployable composite booms with microgravity flight heritage are currently being investigated at NASA Langley Research Center (LaRC) and Massachusetts Institute of Technology(MIT)’s Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of NASA’s Artemis campaign. These applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads on landers and rovers, in support of nearby or distant crewed or robotic assets exploring scientifically interesting and hard to reach areas. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight booms have an excellent height to mass ratio, they typically exhibit slight axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment may be required. This paper presents a pathfinder deployable guy wire stability system for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension passively, and can serve as a reconfigurable platform to test new guy wire components, configurations and control algorithms. Using a validated, calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights in Earth’s gravity field was recorded. With real-time tension measurements it was found that guy wires can significantly reduce the tip deflection of a deployable composite boom under dead load. Specifically, we found that (1) control capability is greatest where it is needed most, i.e. for the lever arm closest to being opposite the direction of deflection, and (2) for a tower height of at least 8.5 m and arm length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control capability to correct or significantly reduce boom deflections. We also found that natural deflections occur almost entirely out-of-plane of the seams of the boom cross-section, which was expected, and that the natural boom tip lateral deflection under dead load upon deployment was ~5% of boom deployed length, unexpectedly exceeding the manufacturing acceptance specification of 1%.Ongoing and future collaborative work between LaRC and MIT includes the further investigation of the unexpected lateral deflection, testing of alternative guy wire system designs at higher tensions and higher deployed heights, as well as trade studies of costs and benefits of an optimized integrated guywire system compared to other types of static stability solutions.

lunar towers↗

NASA NTRS2012

Regolith Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

This NIAC project investigated an innovative approach to provide heat shield protection to spacecraft after launch and prior to each EDL thus potentially realizing significant launch mass savings. Heat shields fabricated in situ can provide a thermal-protection system for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Regolith has extremely good insulating properties and the silicates it contains can be used in the fabrication and molding of thermal-protection materials. Such in situ developed heat shields have been suggested before by Lewis. Prior research efforts have shown that regolith properties can be compatible with very-high temperature resistance. Our project team is highly experienced in regolith processing and thermal protection systems (TPS). Routine access to space and return from any planetary surface requires dealing with heat loads experienced by the spacecraft during reentry. Our team addresses some of the key issues with the EDL of human-scale missions through a highly innovative investigation of heat shields that can be fabricated in space by using local resources on asteroids and moons. Most space missions are one-way trips, dedicated to placing an asset in space for economical or scientific gain. However, for human missions, a very-reliable heat-shield system is necessary to protect the crew from the intense heat experienced at very high entry velocities of approximately 11 km/s at approximately Mach 33 (Apollo). For a human mission to Mars, the return problem is even more difficult, with predicted velocities of up to 14 km/s, at approximately Mach 42 at the Earth-atmosphere entry. In addition to human return, it is very likely that future space-travel architecture will include returning cargo to the Earth, either for scientific purposes or for commercial reasons. Platinum, titanium, helium 3, and other metals, elements and minerals are all high-value commodities in limited supply on Earth, and it may be profitable to mine these substances throughout the Solar System and return them to Earth, if an economical method can be found. To date, several private corporations have been launched to pursue these goals. Because the heat shield is the last element to be used in an Earth-return mission, a high penalty is paid in the propellant mass required to carry the heat shield to the destination and back. If the heat shield could be manufactured in space, and then outfitted on the spacecraft prior to the reentry at Earth, then significant propellant and mass savings could be achieved during launch and space operations. Preliminary mission architecture scenarios are described, which explain the potential benefits that may be derived from using an in-situ fabricated regolith heat shield. In order to prove that this is a feasible technology concept, this project successfully fabricated heat shield materials from mineral simulant materials of lunar and Martian regolith by two methods: 1) Sintering and 2) Binding the simulant with a "room-temperature vulcanizing" (RTV) silicone formulated to withstand high temperatures. Initially a third type of fabrication was planned using the hot waste stream from regolith ISRU processes. This fabrication method was discarded since the resulting samples would be too dense and brittle for heat shields. High temperature flame tests at KSC and subsequent arc jet tests at Ames Research Center (ARC) have proved promising. These coupon tests show favorable materials properties and have the potential to be a new way of fabricating heat shields for space entry into planetary atmospheres.

Hogue, Michael D.↗

NASA NTRS2013

Regolith Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

This NIAC project investigated an innovative approach to provide heat shield protection to spacecraft after launch and prior to each EDL thus potentially realizing significant launch mass savings. Heat shields fabricated in situ can provide a thermal-protection system for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Regolith has extremely good insulating properties and the silicates it contains can be used in the fabrication and molding of thermal-protection materials. Such in situ developed heat shields have been suggested before by Lewis. Prior research efforts have shown that regolith properties can be compatible with very-high temperature resistance. Our project team is highly experienced in regolith processing and thermal protection systems (TPS). Routine access to space and return from any planetary surface requires dealing with heat loads experienced by the spacecraft during reentry. Our team addresses some of the key issues with the EDL of human-scale missions through a highly innovative investigation of heat shields that can be fabricated in space by using local resources on asteroids and moons. Most space missions are one-way trips, dedicated to placing an asset in space for economical or scientific gain. However, for human missions, a very-reliable heat-shield system is necessary to protect the crew from the intense heat experienced at very high entry velocities of approximately 11 km/s at approximately Mach 33 (Apollo). For a human mission to Mars, the return problem is even more difficult, with predicted velocities of up to 14 km/s, at approximately Mach 42 at the Earth-atmosphere entry. In addition to human return, it is very likely that future space-travel architecture will include returning cargo to the Earth, either for scientific purposes or for commercial reasons. Platinum, titanium, helium 3, and other metals, elements and minerals are all high-value commodities in limited supply on Earth, and it may be profitable to mine these substances throughout the Solar System and return them to Earth, if an economical method can be found. To date, several private corporations have been launched to pursue these goals. Because the heat shield is the last element to be used in an Earth-return mission, a high penalty is paid in the propellant mass required to carry the heat shield to the destination and back. If the heat shield could be manufactured in space, and then outfitted on the spacecraft prior to the reentry at Earth, then significant propellant and mass savings could be achieved during launch and space operations. Preliminary mission architecture scenarios are described, which explain the potential benefits that may be derived from using an in-situ fabricated regolith heat shield. In order to prove that this is a feasible technology concept, this project successfully fabricated heat shield materials from mineral simulant materials of lunar and Martian regolith by two methods: 1) Sintering and 2) Binding the simulant with a "room-temperature vulcanizing" (RTV) silicone formulated to withstand high temperatures. Initially a third type of fabrication was planned using the hot waste stream from regolith ISRU processes. This fabrication method was discarded since the resulting samples would be too dense and brittle for heat shields. High temperature flame tests at KSC and subsequent arc jet tests at Ames Research Center (ARC) have proved promising. These coupon tests show favorable materials properties and have the potential to be a new way of fabricating heat shields for space entry into planetary atmospheres.

Hogue, Michael D.↗

NASA NTRS1977

Toward large space systems

The design of the Space Transportation System, consisting of the Space Shuttle, Spacelab, and upper stages, provides experience for the development of more advanced space systems. The next stage will involve space stations in low earth orbit with limited self-sufficiency, characterized by closed ecological environments, space-generated power, and perhaps the first use of space materials. The third phase would include manned geosynchronous space-station activity and a return to lunar operations. Easier access to space will encourage the use of more complex, maintenance-requiring satellites than those currently used. More advanced space systems could perform a wide range of public services such as electronic mail, personal and police communication, disaster control, earthquake detection/prediction, water availability indication, vehicle speed control, and burglar alarm/intrusion detection. Certain products, including integrated-circuit chips and some enzymes, can be processed to a higher degree of purity in space and might eventually be manufactured there. Hardware including dishes, booms, and planar surfaces necessary for advanced space systems and their development are discussed.

Daros, C. J.↗

NASA NTRS2016

The Exploration of Mars Launch and Assembly Simulation

Advancing human exploration of space beyond Low Earth Orbit, and ultimately to Mars, is of great interest to NASA, other organizations, and space exploration advocates. Various strategies for getting to Mars have been proposed. These include NASA's Design Reference Architecture 5.0, a near-term flyby of Mars advocated by the group Inspiration Mars, and potential options developed for NASA's Evolvable Mars Campaign. Regardless of which approach is used to get to Mars, they all share a need to visualize and analyze their proposed campaign and evaluate the feasibility of the launch and on-orbit assembly segment of the campaign. The launch and assembly segment starts with flight hardware manufacturing and ends with final departure of a Mars Transfer Vehicle (MTV), or set of MTVs, from an assembly orbit near Earth. This paper describes a discrete event simulation based strategic visualization and analysis tool that can be used to evaluate the launch campaign reliability of any proposed strategy for exploration beyond low Earth orbit. The input to the simulation can be any manifest of multiple launches and their associated transit operations between Earth and the exploration destinations, including Earth orbit, lunar orbit, asteroids, moons of Mars, and ultimately Mars. The simulation output includes expected launch dates and ascent outcomes i.e., success or failure. Running 1,000 replications of the simulation provides the capability to perform launch campaign reliability analysis to determine the probability that all launches occur in a timely manner to support departure opportunities and to deliver their payloads to the intended orbit. This allows for quantitative comparisons between alternative scenarios, as well as the capability to analyze options for improving launch campaign reliability. Results are presented for representative strategies.

Cates, Grant↗

NASA NTRS2016

The Exploration of Mars Launch and Assembly Simulation

Advancing human exploration of space beyond Low Earth Orbit, and ultimately to Mars, is of great interest to NASA, other organizations, and space exploration advocates. Various strategies for getting to Mars have been proposed. These include NASA's Design Reference Architecture 5.0, a near-term flyby of Mars advocated by the group Inspiration Mars, and potential options developed for NASA's Evolvable Mars Campaign. Regardless of which approach is used to get to Mars, they all share a need to visualize and analyze their proposed campaign and evaluate the feasibility of the launch and on-orbit assembly segment of the campaign. The launch and assembly segment starts with flight hardware manufacturing and ends with final departure of a Mars Transfer Vehicle (MTV), or set of MTVs, from an assembly orbit near Earth. This paper describes a discrete event simulation based strategic visualization and analysis tool that can be used to evaluate the launch campaign reliability of any proposed strategy for exploration beyond low Earth orbit. The input to the simulation can be any manifest of multiple launches and their associated transit operations between Earth and the exploration destinations, including Earth orbit, lunar orbit, asteroids, moons of Mars, and ultimately Mars. The simulation output includes expected launch dates and ascent outcomes i.e., success or failure. Running 1,000 replications of the simulation provides the capability to perform launch campaign reliability analysis to determine the probability that all launches occur in a timely manner to support departure opportunities and to deliver their payloads to the intended orbit. This allows for quantitative comparisons between alternative scenarios, as well as the capability to analyze options for improving launch campaign reliability. Results are presented for representative strategies.

Cates, Grant↗

NASA NTRS2017

On Beyond Star Trek: Synthetic Biology and the Future of Space Exploration

A turtle carries its own habitat. While it is reliable, it costs energy. NASA makes the same trade-off when it transports habitats and other structures needed to lunar and planetary surfaces increasing upmass, and affecting other mission goals. Long-term human space presence requires periodic replenishment, adding a massive cost overhead. Even robotic missions often sacrifice science goals for heavy radiation and thermal protection. Biology has the potential to solve these problems because it can replicate and repair itself, and do a wide variety of chemical reactions including making food, fuel and materials. Synthetic biology enhances and expands life's evolved repertoire. Using organisms as feedstock, additive manufacturing could make possible the dream of producing bespoke tools, food, smart fabrics and even replacement organs on demand. Imagine what new products can be enabled by such a technology, on earth or beyond!

Rothschild, Lynn J.↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRSDate not supplied

Internal Architecture of the Common Habitat

The core stage liquid oxygen tank of the Space Launch System can be manufactured as a habitat instead of as a propellant tank, with a common design such that it is equally suitable for use in 0g, 1/6g, 3/8g, 1g, or variable artificial gravity. This Common Habitat can be the central element of a human spaceflight architecture that encompasses the Moon, Mars, and other destinations within the inner solar system. The Common Habitat is specifically used within an alternative architecture study (that is not part of the current NASA baseline) as the core habitation element within a Lunar Basecamp, Mars Basecamp, and the Deep Space Exploration Vehicle. The Common Habitat internal architecture applies a design philosophy to separate crew functions according to deck. The lower deck is reserved for private functions. It includes eight private crew quarters and four waste and hygiene clusters – each with a private waste management compartment, private full body hygiene compartment, and foyer/clothes changing area. The mid deck is primarily allocated to mission-related working functions. It includes an exercise facility, fabrication / maintenance / repair facility, physical science laboratory (physics, geology, and astronomy), and life science laboratory (biology and human research). The mid deck also has four external hatches, clocked one every 90 degrees, centered on the vehicle vertical centerline. Each hatch has a 60-inch tall by 40-inch wide opening with the mid deck floor 16 inches below the bottom lip of the hatch opening. The upper deck is primarily allocated to group or social functions. It includes a large galley, wardroom with projector and display screen, plant growth chambers, bulk stowage, command and control station, medical facility, hygiene compartment, and vehicle subsystems. A Vertical Translation System, based in part on results from a GrabCAD public challenge, enables crew and equipment traverse between habitat decks in 0g, 1/6g, 3/8g, and 1g. A 40-inch by 60-inch vertical translation corridor ensures that anything that can fit through the external hatches can also be moved from deck to deck. The system includes three component systems: a deploying floor to safety barrier system that folds down to become a traversable floor when vertical translation is not in use and deploys to become a safety barrier during vertical translations; a folding ladder that stows in the ceiling when not in use; and an elevator platform that can attach to the ladder for cargo or incapacitated crew member transport. This system is complemented by a Horizontal Translation System, also based in part on the same GrabCAD challenge, provides for horizontal crew translation in microgravity but requires no vehicle reconfiguration for fractional or whole gravity operation. It relies primarily on gecko-inspired grippers, originally developed at Stanford and NASA JPL, attached to footwear to enable crew to emulate walking. Some handrails are also strategically placed throughout the Common Habitat to aid translation in both gravity and microgravity environments.

Common Habitat↗

NASA NTRS2018

Accommodations for Secondary Payloads in NASA's Space Launch System

NASA's new heavy-lift launch vehicle, the Space Launch System (SLS), is moving closer to its planned 2019 launch, with the in-space stage and spacecraft adapters complete and all other major elements of the rocket manufactured and currently being outfitted for flight. Exploration Mission-1 (EM-1), the first flight of SLS and the new Orion crew vehicle, will verify and validate new systems and provide an unparalleled opportunity for 13 6U CubeSat-class payloads to be released into deep space. Payloads are being developed by NASA, industry, international and academic partners and were selected for the EM-1 flight to address strategic knowledge gaps in the agency's plans for human deep space exploration. Destinations range from the lunar surface to an asteroid to an orbit around the Earth-moon L2 libration point. Missions include studying the effects of space radiation on a living organism (yeast), landing the smallest lander to date on the moon, and searching for water in permanently shaded lunar craters. Propulsion technology demonstrations include solar sails, use of inert water to carry out lunar gravity assist maneuvers, and use of new "green" chemical propellants. SLS employs an evolutionary design approach, with an initial capability of at least 26 metric tons (t) to trans-lunar injection (TLI). The later Block 1B configuration, which will become the Agency's workhorse launch vehicle into the 2020s, will lift at least 34 t to TLI in its crew configuration and at least 37 t in the cargo configuration. In addition to greater lift capability, Block 1B will also offer larger payload volume than Block 1 for both co-manifested and secondary payloads. In Block 1B, various combinations of 6U, 12U and 27U payloads may be accommodated in the vehicle's stage adapter. Opportunities for deep space research once out of reach for small science payloads will be within reach, opening many possibilities for exciting new technology demonstrations and scientific missions. This paper will provide an overview of the capabilities and the status of the Block 1 vehicle, with particular emphasis on the secondary payload accommodations and the deployment system. Brief descriptions of the 13 6U EM-1 payloads will be included. In addition, a discussion of the payload developers' responsibilities and the Space Launch System Program's roles and responsibilities in accommodating these and future payloads will be included. Finally, the author will look ahead to SLS Block 1B and missions beyond EM-1 and the opportunities for 6U, 12U and 27U CubeSats.

Robinson, Kimberly F.↗

NASA NTRS1998

Protocol Development for the NASA-JSC Lunar-Mars Life Support Test Project (LMLSTP) Phase 3 Project: A Report on Baseline Studies at KSC for Continuous Salad Production

The Phase 3 Lunar-Mars Life Support Test Project (LMLSTP) was conducted in a 20-foot chamber at Johnson Space Center. The overall objective of the Phase 3 project was to conduct a 90-day regenerative life support system test involving 4 human subjects to demonstrate an integrated biological and physicochemical life support system. A secondary objective of the Phase 3 LMLSTP was to demonstrate the ability to produce salad-type vegetable by integration of a small benchtop growth chamber located within the crew habitat area. This small chamber, commercially manufactured as the Controlled Environment Research Ecosystem (CERES 2010(TM)), functioned as a means to continuously provide fresh lettuce crops for crew members. The CERES 2010(TM) growth chamber utilized hardware components developed for effective plant biomass production in spaceflight applications. These components included: (1) LED lighting; (2) Astroculture(TM) Root Trays; and (3) Zeoponic media. In planning for the LMLSTP Phase 3, a request was put forward for KSC scientists to generate a protocol for successful continuous planting, culturing, and harvesting of the salad-crop, lettuce. By conducting baseline tests with components of the CERES 2010(TM), a protocol was developed.

Goins, G. D.↗

NASA NTRS2012

Launch and Assembly Reliability Analysis for Human Space Exploration Missions

NASA's future human space exploration strategy includes single and multi-launch missions to various destinations including cis-lunar space, near Earth objects such as asteroids, and ultimately Mars. Each campaign is being defined by Design Reference Missions (DRMs). Many of these missions are complex, requiring multiple launches and assembly of vehicles in orbit. Certain missions also have constrained departure windows to the destination. These factors raise concerns regarding the reliability of launching and assembling all required elements in time to support planned departure. This paper describes an integrated methodology for analyzing launch and assembly reliability in any single DRM or set of DRMs starting with flight hardware manufacturing and ending with final departure to the destination. A discrete event simulation is built for each DRM that includes the pertinent risk factors including, but not limited to: manufacturing completion; ground transportation; ground processing; launch countdown; ascent; rendezvous and docking, assembly, and orbital operations leading up to trans-destination-injection. Each reliability factor can be selectively activated or deactivated so that the most critical risk factors can be identified. This enables NASA to prioritize mitigation actions so as to improve mission success.

Cates, Grant↗

NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗

NASA NTRSDate not supplied

Internal Architecture of the Common Habitat

The core stage liquid oxygen tank of the Space Launch System can be manufactured as a habitat instead of as a propellant tank, with a common design such that it is equally suitable for use in 0g, 1/6g, 3/8g, 1g, or variable artificial gravity. It is capable of sustaining a crew size of eight for missions up to 1200 days in duration. This Common Habitat can be the central element of a human spaceflight architecture that encompasses the Moon, Mars, and other destinations within the inner solar system. Within this archtiecture, the Common Habitat is specifically used as the core habitation element within a Lunar Base Camp, Mars Base Camp, and the Deep Space Exploration Vehicle. The Common Habitat internal architecture applies a design philosophy to separate crew functions according to deck. The lower deck is reserved for private functions. It includes eight private crew quarters and four waste and hygiene clusters – each with a private waste management compartment, private full body hygiene compartment, and private foyer/clothes changing area. The mid deck is primarily allocated to mission-related functions. It includes an exercise facility, fabrication / maintenance / repair facility, physical science laboratory (physics, geology, and remote sensing: astronomy, heliophysics, planetary science, and Earth science), and life science laboratory (biology and human research). The mid deck also has four external hatches, clocked one every 90 degrees, centered on the vehicle vertical centerline. Each hatch has a 60-inch tall by 40-inch wide opening with the mid deck floor 16 inches below the bottom lip of the hatch opening. The upper deck also includes some mission functions, but is primarily allocated to social functions. It includes a large galley, wardroom with projector and display screen, plant growth chambers, bulk stowage, command and control station, medical facility, hygiene compartment, and vehicle subsystems.

Habitability↗

NASA NTRSDate not supplied

In-Space Laser Forming Simulated Under Thermal Vacuum (TVAC) Conditions

NASA Marshall Space Flight Center is investigating laser forming under thermal vacuum conditions representative of the space environment through a partnership with the DARPA NOM4D program. The thermal gradient mechanism (TGM) is used to bend a metal sheet towards the laser optics. Laser equipment and process parameters are being optimized for thermal vacuum conditions. Such conditions are representative of the extreme cold and hot temperatures and high vacuum that exist on orbit or on the lunar surface. in situ photogrammetry and thermography assess the bend/counterbend and elucidate the TGM in thermal vacuum. Structured light scanning and metallography after bending reveal the macroscopic and microscopic structure after TGM.

thermal vacuum↗

NASA NTRS2018

NASA's Space Launch System Moves into Testing and Integration

NASA's Space Launch System (SLS) has moved from design and manufacturing into testing and integration for its first flight in fiscal year 2020. In 2017, the NASA/industry team completed manufacturing of all major structural elements for the launch vehicle for Exploration Mission-1 (EM-1). This work included shipping the first major flight hardware element to the launch site. Current work is focused on the initial Block 1 variant of SLS, capable of launching more than 70 metric tons (t) to low Earth orbit (LEO). As the needs of the nation's deep space exploration program grow, SLS performance is designed to evolve to a payload mass of 130 t to LEO and up to 45 metric tons (t) to trans-lunar injection (TLI). The advantages of this mass - as well as volume - are critical to the entire exploration architecture for deep space exploration. They translate to greater capability, greater infrastructure and operational simplicity, less overall mission risk, and opportunities to accomplish unprecedented exploration and discovery.

Honeycutt, John↗

NASA NTRSDate not supplied

Implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield for the Mars Sample Return (MSR) Earth Entry Vehicle (EEV)

he Mars Sample Return (MSR)Program will return Martian soil samples to Earth in the early 2030s. Since the biological content of these samples is unknown, and potentially upsetting to Earth’s biosphere, the Earth Entry Vehicle (EEV) is required to be the most reliable entry probe ever devised. Entering Earth’s atmosphere at ~12 km/s, after up to a 6-day in-space free flight phase, the EEV must tolerate the cis-lunar Micro-Meteoroid environment, the near-Earth Orbital debris environment, and then entry heating of over 3,000 W/cm2 and pressures of250 kPa before ballistically impacting Earth’s surface at nearly 45 m/s. To reliably accomplish such a mission, NASA Ames is implementing the 3-D woven Mid-Density Carbon Phenolic (3MDCP) Heat Shield, derived from the prior Heatshield for Extreme Entry Environments(HEEET) material system [1]. 3MDCP development accomplishments to date, along with the future efforts to deliver the flight hardware are presented, along with a discussion of the manufacturing risks and accompanying mitigations achieved.

J C Vander Kam↗