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Digital Signal Conditioning for Flight Test, Volume 19 [Le Traitement du Signal Numérique pour les Essais en Vol]

This volume in the AGARD Flight Instrumentation Series provides flight test instrumentation engineers with an introduction to digital processes on aircraft. Flight test instrumentation systems are rapidly evolving from analog intensive to digital intensive systems, including the use of onboard digital computers. Topics include: measurements that are digital in origin, sampling, encoding, transmitting, and storing of data. Particular emphasis is placed on modem avionic data bus architectures and what to be aware of when extracting data from them. Some example data extraction techniques are given. Tradeoffs between digital logic families, trends in digital development, and design testing techniques are discussed. An introduction to digital filtering is also covered.

Flight instruments↗

Achromatic Focal Plane Mask for Exoplanet Imaging Coronagraphy

Recent advances in coronagraph technologies for exoplanet imaging have achieved contrasts close to 1e10 at 4 lambda/D and 1e-9 at 2 lambda/D in monochromatic light. A remaining technological challenge is to achieve high contrast in broadband light; a challenge that is largely limited by chromaticity of the focal plane mask. The size of a star image scales linearly with wavelength. Focal plane masks are typically the same size at all wavelengths, and must be sized for the longest wavelength in the observational band to avoid starlight leakage. However, this oversized mask blocks useful discovery space from the shorter wavelengths. We present here the design, development, and testing of an achromatic focal plane mask based on the concept of optical filtering by a diffractive optical element (DOE). The mask consists of an array of DOE cells, the combination of which functions as a wavelength filter with any desired amplitude and phase transmission. The effective size of the mask scales nearly linearly with wavelength, and allows significant improvement in the inner working angle of the coronagraph at shorter wavelengths. The design is applicable to almost any coronagraph configuration, and enables operation in a wider band of wavelengths than would otherwise be possible. We include initial results from a laboratory demonstration of the mask with the Phase Induced Amplitude Apodization coronagraph.

Achromatic↗

Digital Signal Conditioning for Flight Test Instrumentation

This volume in the AGARD Flight Instrumentation Series provides flight test instrumentation engineers with an introduction to digital measurement processes on aircraft. Flight test instrumentation systems are rapidly evolving from analog-intensive to digital-intensive systems, including the use of onboard digital computers. Topics include measurements that are digital in origin, as well as sampling, encoding, transmitting, and storing of data. Particular emphasis is placed on modern avionic data bus architectures and what to be aware of when extracting data from them. Examples of data extraction techniques are given. Tradeoffs between digital logic families, trends in digital development, and design testing techniques are discussed. An introduction to digital filtering is also covered.

Data acquisition↗

Design, Development and Pre-Flight Testing of the Communications, Navigation, and Networking Reconfigurable Testbed (Connect) to Investigate Software Defined Radio Architecture on the International Space Station

The Communication Navigation and Networking Reconfigurable Testbed (CoNNeCT) is a NASA-sponsored mission, which will investigate the usage of Software Defined Radios (SDRs) as a multi-function communication system for space missions. A softwaredefined radio system is a communication system in which typical components of the system (e.g., modulators) are incorporated into software. The software-defined capability allows flexibility and experimentation in different modulation, coding and other parameters to understand their effects on performance. This flexibility builds inherent redundancy and flexibility into the system for improved operational efficiency, real-time changes to space missions and enhanced reliability/redundancy. The CoNNeCT Project is a collaboration between industrial radio providers and NASA. The industrial radio providers are providing the SDRs and NASA is designing, building and testing the entire flight system. The flight system will be integrated on the Express Logistics Carrier (ELC) on the International Space Station (ISS) after launch on the H-IIB Transfer Vehicle in 2012. This paper provides an overview of the technology research objectives, payload description, design challenges and pre-flight testing results.

Over, Ann P.↗

KRUSTY Reactor Design

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a reactor design, development, and test program to demonstrate the nuclear operation of a Kilopower reactor. Kilopower systems are intended to provide between 1 and 10 kW(electric) in space, or on the surface of planets or moons, with a clear evolution to substantially higher power systems. KRUSTY was a prototype of a 1-kW(electric) highly enriched uranium–fueled Kilopower system. In March of 2018, KRUSTY successfully operated as a fission power system and was the first nuclear-powered operation of any truly new reactor concept in the United States in over 40 years. This paper discusses the design of the KRUSTY reactor along with the philosophy, goals, and engineering work that ultimately led to KRUSTY’s success.

Kilopower↗

A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Tamir, David↗

Ceramic Composite Development for Gas Turbine Engine Hot Section Components

The development of ceramic materials for incorporation into the hot section of gas turbine engines has been ongoing for about fifty years. Researchers have designed, developed, and tested ceramic gas turbine components in rigs and engines for automotive, aero-propulsion, industrial, and utility power applications. Today, primarily because of materials limitations and/or economic factors, major challenges still remain for the implementation of ceramic components in gas turbines. For example, because of low fracture toughness, monolithic ceramics continue to suffer from the risk of failure due to unknown extrinsic damage events during engine service. On the other hand, ceramic matrix composites (CMC) with their ability to display much higher damage tolerance appear to be the materials of choice for current and future engine components. The objective of this paper is to briefly review the design and property status of CMC materials for implementation within the combustor and turbine sections for gas turbine engine applications. It is shown that although CMC systems have advanced significantly in thermo-structural performance within recent years, certain challenges still exist in terms of producibility, design, and affordability for commercial CMC turbine components. Nevertheless, there exist some recent successful efforts for prototype CMC components within different engine types.

DiCarlo, James A.↗

A satellite anemometer

This report describes the design, development, and testing of components of a satellite anemometer, an instrument for measuring neutral winds in the upper atmosphere from a satellite platform. The device, which uses four nearly identical pressure sensors, measures the angle of arrival of the bulk neutral flow in the satellite frame of reference. It could also be used in a feedback loop to control spacecraft attitude with respect to the ram velocity direction. We have now developed miniaturized ionization pressure gauges that will work well from the slip flow region near 115 km up to the base of the exosphere, which covers the entire altitude range currently being considered for Tether. Laboratory tests have demonstrated a very linear response to changes in ram angle out to +/- 20 deg. (transverse wind component of 2.7 km s(exp -1)) from the ram, and a monotonic response to out beyond 45 deg. Pitch (vertical wind) and yaw (horizontal wind) can be sampled simultaneously and meaningfully up to 10 Hz. Angular sensitivity of 30 arc seconds (approximately 1 ms(exp -1) is readily attainable, but absolute accuracy for winds will be approximately 1 deg (130 m/s) unless independent attitude knowledge is available. The critical elements of the design have all been tested in the laboratory.

Hanson, W. B.↗

Developing affordable and efficient heating devices for enhanced live cell imaging in confocal microscopy

Temperature control is crucial for live cell imaging, particularly in studies involving plant responses to high ambient temperatures and thermal stress. This study presents the design, development, and testing of two cost-effective heating devices tailored for confocal microscopy applications: an aluminum heat plate and a wireless mini-heater. The aluminum heat plate, engineered to integrate seamlessly with the standard 160 mm × 110 mm microscope stage, supports temperatures up to 36°C, suitable for studies in the range of non-stressful warm temperatures (e.g., 25-27°C forArabidopsis thaliana) and moderate heat stress (e.g., 30-36°C forA. thaliana). We also developed a wireless mini-heater that offers rapid, precise heating directly at the sample slide, with a temperature increase rate over 30 times faster than the heat plate. The wireless heater effectively maintained target temperatures up to 50°C, ideal for investigating severe heat stress and heat shock responses in plants. Both devices performed well in controlled studies, including the real-time analysis of heat shock protein accumulation and stress granule formation inA. thaliana. Our designs are effective and affordable, with total construction costs lower than $300. This accessibility makes them particularly valuable for small laboratories with limited funding. Future improvements could include enhanced heat uniformity, humidity control to mitigate evaporation, and more robust thermal management to minimize focus drift during extended imaging sessions. These modifications would further solidify the utility of our heating devices in live cell imaging, offering researchers reliable, budget-friendly tools for exploring plant thermal biology.

Plant Sciences↗

Space Shuttle Orbiter Drag Chute Summary

This paper summarizes the development history and technical highlights of the Space Shuttle Orbiter Drag Chute Program. Data and references are given on the design, development, and testing of the system, plus several interesting operational issues and solutions. The last Shuttle flight was completed in 2011 and all the Orbiters have now become museum pieces. Before all the data from system development and the 86 Orbiter Drag Chute (ODC) operational landings is lost or forgotten, it may be useful to summarize it here and to identify data sources for future reference. Much has been written about various aspects of the program, and this summary has attempted to cite many such references to make available more detailed information. The ODC program was a high-visibility NASA program that afforded the opportunity to thoroughly engineer and test the chute system, far beyond so many of today s tight-budget programs. So the ODC program was extremely informative--it provided a wide scope of information including protective door jettison issues and solutions, wind tunnel data and analyses on chute stability and drag behind a huge and rather blunt forebody, component and system reuse, and chute cleaning methods. Technology and data created have aided several current and past parachute programs, and will continue to do so in the future. The original Orbiter preliminary design included a drag parachute-- it was deleted early to save weight. But after the 1987 Challenger accident and during the program redefinition phase that followed, Astronaut John Young presented a strong case for enhancing landing safety by adding nosegear steering, brake improvements, and reviving the drag chute.

Lowry, Charles H.↗

K-Band Latching Switches

Design, development, and tests are described for two single-pole-double-throw latching waveguide ferrite switches: a K-band switch in WR-42 waveguide and a Ka-band switch in WR-28 waveguide. Both switches have structurally simple junctions, mechanically interlocked without the use of bonding materials; they are impervious to the effects of thermal, shock, and vibration stresses. Ferrite material for the Ka-band switch with a proper combination of magnetic and dielectric properties was available and resulted in excellent low loss, wideband performance. The high power handling requirement of the K-band switch limited the choice of ferrite to nickel-zinc compositions with adequate magnetic properties, but with too low relative dielectric constant. The relative dielectric constant determines the junction dimensions for given frequency responses. In this case the too low value unavoidably leads to a larger than optimum junction volume, increasing the insertion loss and restricting the operating bandwidth. Efforts to overcome the materials-related difficulties through the design of a composite junction with increased effective dielectric properties efforts to modify the relative dielectric constant of nickel-zinc ferrite are examined.

Piotrowski, W. S.↗

Understanding Pilot Breathing – A Case Study in Systems Engineering

This position paper assesses the Pilot Breathing Assessment’s driving requirement to collect missing data on pilot breathing pressure, flow, rate, oxygen and CO2, simultaneously with aircraft data. Repeat measures data were collected over a 2-year period from 5 NASA test-pilots flying 8 flight profiles on NASA F-15 and F/A-18 (A, B) aircraft. This Pilot Breathing Assessment Systems Engineering (PiBASE) position paper serves as a case-study of systems engineering that accommodates the human as a distinct part of the whole. It acknowledges that a successful machine design intended for human use must include human systems biology/physiology as an integral part of planning, design, and implementation.

Pilot Breathing Assessment Systems Engineering↗

Design and Preliminary Performance Testing of Electronegative Gas Plasma Thruster

In classical gridded electrostatic ion thrusters, positively charged ions are generated from a plasma discharge of noble gas propellant and accelerated to provide thrust. To maintain overall charge balance on the propulsion system, a separate electron source is required to neutralize the ion beam as it exits the thruster. However, if high-electronegativity propellant gases (e.g., sulfur hexafluoride) are instead used, a plasma discharge can result consisting of both positively and negatively charged ions. Extracting such electronegative plasma species for thrust generation (e.g., with time-varying, bipolar ion optics) would eliminate the need for a separate neutralizer cathode subsystem. In addition for thrusters utilizing a RF plasma discharge, further simplification of the ion thruster power system may be possible by also using the RF power supply to bias the ion optics. Recently, the PEGASES (Plasma propulsion with Electronegative gases) thruster prototype successfully demonstrated proof-of-concept operations in alternatively accelerating positively and negatively charged ions from a RF discharge of a mixture of argon and sulfur hexafluoride.i In collaboration with NASA Marshall Space Flight Center (MSFC), the Georgia Institute of Technology High-Power Electric Propulsion Laboratory (HPEPL) is applying the lessons learned from PEGASES design and testing to develop a new thruster prototype. This prototype will incorporate design improvements and undergo gridless operational testing and diagnostics checkout at HPEPL in April 2014. Performance mapping with ion optics will be conducted at NASA MSFC starting in May 2014. The proposed paper discusses the design and preliminary performance testing of this electronegative gas plasma thruster prototype.

Liu, Thomas M.↗

Optical Modem Enabling Broadband Datacom Links for Crewed Cis-Lunar Missions

We report on the design, development, and testing of our high-power broadband optical modem supporting NASA’s crewed Artemis-2 mission. The O2O modem will be mounted in the crewed Orion module and provide a broadband 505,000 km bi-directional optical link back to earth while en route to the moon. The full-duplex modem consists of a high-power optical transmitter and receiver optimized for serially-concatenated pulse-position modulation (SCPPM). The transmitter is a master-oscillator power-amplifier optical architecture using efficient cladding-pumped amplification in erbium-ytterbium co-doped fiber. The transmitter outputs up to 1 W at ≈1550 nm (limited for eye safety) and supports 6 different user-rates ranging from 20.39 Mb/s to 260.95 Mb/s using PPM16 and PPM32 modulation formats. The optical receiver supports two user-rates: 10.19 Mb/s and 20.39 Mb/s with both rates employing PPM32. The narrowband receiver filtering is optimized to simultaneously accept four separate wavelength channels to mitigate atmospherics through spatial diversity. A configurable interleaver provides additional protection against atmospherics-based signal fading and a powerful soft-decision error correction scheme enables highly sensitive detection. The measured sensitivities at the two bit-rates are -73.8 and -71.8dBm, respectively. The architecture was designed for reliable operation in space, featuring automatic hardware interlocks, pump sparing for the amplifiers, and autonomous operation of all internal hardware and software control loops. The protoflight unit (PFU) was put through rigorous environmental testing which included pyroshock, vibration, electromagnetic interference/compatibility, and thermal-vacuum testing. The modem successfully passed all the environmental screening and has been declared at Technology Readiness Level (TRL) 6.

space communications↗

High-Power Magnetoplasmadynamic Thruster Being Developed

High-power electromagnetic thrusters have been proposed as primary in-space propulsion options for several of the bold new interplanetary and deep space missions envisioned by the Human Exploration and Development of Space (HEDS) Strategic Enterprise. As the lead center for electric propulsion, the NASA Glenn Research Center is actively involved in the design, development, and testing of high-power electromagnetic technologies to meet these demanding mission requirements. One concept of particular interest is the magnetoplasmadynamic (MPD) thruster, shown schematically in the preceding figure. In its basic form, the MPD thruster consists of a central cathode surrounded by a concentric cylindrical anode. A high-current arc is struck between the anode and cathode, which ionizes and accelerates a gas (plasma) propellant. In the self-field version of the thruster, an azimuthal magnetic field generated by the current returning through the cathode interacts with the radial discharge current flowing through the plasma to produce an axial electromagnetic body force, providing thrust. In applied field-versions of the thruster, a magnetic field coil surrounding the anode is used to provide additional radial and axial magnetic fields that can help stabilize and accelerate the plasma propellant. The following figure shows an experimental megawatt-class MPD thruster developed at Glenn. The MPD thruster is fitted inside a magnetic field coil, which in turn is mounted on a thrust stand supported by thin metal flexures. A calibrated position transducer is used to determine the force provided by the thruster as a function of thrust stand displacement. Power to the thruster is supplied by a 250-kJ capacitor bank, which provides up to 30- MW to the thruster for a period of 2 msec. This short period of time is sufficient to establish thruster performance similar to steady-state operation, and it allows a number of thruster designs to be quickly and economically evaluated. In concert with this experimental research, Glenn is also developing and using advanced numerical simulations to predict the performance of self-field and applied-field MPD thrusters.

LaPointe, Michael R.↗

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

Metal-to-Ceramic Joining Methods to Support Development of Advanced Ceramic-Based CSP Components

The National Renewable Energy Laboratory, Missouri University of Science and Technology (MS&T), Massachusetts Institute of Technology (MIT), and Colorado School of Mines (CSM) collaborated to design, develop, and test a material concept at bench scale which will be used to achieve a ceramic-to-metal (C2M) joint between a selected metal HTF loop material and a selected ceramic material used by the Gen3 CSP technology pathway. The final joint assembly will need to possess sufficient mechanical properties to withstand static high-temperature (650 degrees-700 degrees C) and high-pressure (20 MPa) and thermal cycling (between 650 degrees C and 100 degrees C) conditions. The material concept consists of three key components: (1) a ceramic matrix composite (CMC) that serves as a compliant transition material aiming to mitigate the stresses due to the mismatch of coefficient of thermal expansion (CTE) from a direct ceramic-to-metal joint, (2) a metal-end joint utilizing a multi-principal element alloy (MPEA) with changing percentage of particle loading to bond the candidate metal to the CMC, and (3) a ceramic-end joint utilizing a glass ceramic to bond the candidate ceramic to the CMC.

14 SOLAR ENERGY↗

Puck Loop Seal (Final Project Technical Report)

Sandia National Laboratories (SNL) is advancing technical capabilities used in passive loop seals. The “Puck” seal used a set of International Atomic Energy Agency (IAEA) requirements for new passive loop seals published in 2020 as a design guide. The seal is based on an oxygen-sensitive inner mixture encased in an oxygen-impermeable shell, is monolithic rather than two-part, incorporates self-capturing wire features, contains colored water beads and bubbles formed during processing as unique identifiers (UIDs), and visually indicates tamper (whether from seal body penetration or from seal wire removal) by irreversibly changing the seal body from multi-colored to black. This paper will provide details on the design, development, and testing of Puck seal prototypes.

42 ENGINEERING↗