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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 469 records · Page 26

Materials, Structures and Manufacturing: An Integrated Approach to Develop Expandable Structures

Membrane dominated space structures are lightweight and package efficiently for launch; however, they must be expanded (deployed) in-orbit to achieve the desired geometry. These expandable structural systems include solar sails, solar power arrays, antennas, and numerous other large aperture devices that are used to collect, reflect and/or transmit electromagnetic radiation. In this work, an integrated approach to development of thin-film damage tolerant membranes is explored using advanced manufacturing. Bio-inspired hierarchical structures were printed on films using additive manufacturing to achieve improved tear resistance and to facilitate membrane deployment. High precision, robust expandable structures can be realized using materials that are both space durable and processable using additive manufacturing. Test results show this initial work produced higher tear resistance than neat film of equivalent mass. Future research and development opportunities for expandable structural systems designed using an integrated approach to structural design, manufacturing, and materials selection are discussed.

Belvin, W. Keith↗

Fault Tolerant State Machines

State machines are commonly used to control sequential logic in FPGAs and ASKS. An errant state machine can cause considerable damage to the device it is controlling. For example in space applications, the FPGA might be controlling Pyros, which when fired at the wrong time will cause a mission failure. Even a well designed state machine can be subject to random errors us a result of SEUs from the radiation environment in space. There are various ways to encode the states of a state machine, and the type of encoding makes a large difference in the susceptibility of the state machine to radiation. In this paper we compare 4 methods of state machine encoding and find which method gives the best fault tolerance, as well as determining the resources needed for each method.

encoding↗

HIRF Tolerance and Avoidance for Advanced Air Mobility Vehicles

Advanced Air Mobility (AAM), including Urban Air Mobility (UAM), and Unmanned Aerial Systems (UAS) vehicles may fly in similar airspace to Transport Category Rotorcraft, thereby requiring meeting the same stringent High-Intensity Radiated Fields (HIRF) certification requirements. In a previous effort, a proposed map-based approach protects a vehicle by keeping it away from high power sources at safe distances based on its tolerance level. By designing to a lower tolerance level, significant cost savings can be achieved at the cost of slightly more complex flight planning. However, too low a threshold can result in large avoidance areas, potentially reducing the vehicle operating space. This current effort suggests a minimum threshold for vehicles operating in an urban area. It is derived from analyzing regulatory transmitter data for New York City as a representative metropolitan. As a result, a vehicle can tolerate common lower-power transmitters by default and only needs to avoid far less common high-power sources. It is also found the existing HIRF requirements may be insufficient against many powerful transmitters such as weather radars and satellite uplink transmitters, and that the map-based approach can address this concern.

HIRF↗

Evaluation of an Ultra-Low Power Reed Solomon Encoder for NASA's Space Technology 5 Mission

Radiation test results and analyses are presented for ultra-low power Reed Solomon encoder circuits that are being considered for use on the Space Technology 5 (ST5) mission. The total ionizing dose tolerance is in excess of 100 krad(Si) and is due to the low supply voltage and the use of back-bias, which suppresses radiation-induced leakage currents in the n-channel devices. The circuits do not latch-up for ion LET values of at least 90 MeV-sq cm/mg. A hardened-by-design approach to SEU has achieved an upset threshold of about 20 MeV-sq cm/mg. The SEU rate expected for these circuits in the geosynchronous transfer orbit of ST5 is low.

Lei, K. E.↗

A fault tolerant design for autonomous attitude control of the DSCS-III communication satellite

The first of a new series of satellites, which will provide the principal elements in the Defense Space Communications System (DSCS), was launched on Oct. 31, 1982. This satellite, DSCS-III, is part of a system which will consist of super-high frequency communications satellites in synchronous, equatorial orbits, continuously operating in four widely separate geographic regions. The DSCS-III is designed both to maintain critical communications in the presence of an electronic jamming threat and to survive nuclear radiation exposure. The results of the present investigation are to provide a basis for the design of a spacecraft tolerant of on-board failures, survivable against external threats, and capable of performing its mission autonomously for periods as long as six months.

Matijevic, J.↗

Utilization of spray on foam insulation for manned and unmanned spacecraft and structures

The idea of using spray-on foam insulation as a passive thermal and micrometeorite protection system is explored. The benefits of applying an exterior coating of foam insulation can be: (1) the foam can provide a thermally stable shield that can assist in reducing the strain on traditional space radiator systems and can also act as a passive thermal guard, allowing a greater fault tolerance if the standard system should fail; (2) the foam can act as an ablative shell diminishing the effects of natural and manmade debris striking the structure; (3) the foam is lightweight - about 1/2 ounce per sq ft; (4) the foam is low cost and easy to maintain; and (5) the foam is a stable material that does not react when exposed to earth or lunar environments.

Hancock, Thomas M., III↗

Fault Mitigation Schemes for Future Spaceflight Multicore Processors

Future planetary exploration missions demand significant advances in on-board computing capabilities over current avionics architectures based on a single-core processing element. The state-of-the-art multi-core processor provides much promise in meeting such challenges while introducing new fault tolerance problems when applied to space missions. Software-based schemes are being presented in this paper that can achieve system-level fault mitigation beyond that provided by radiation-hard-by-design (RHBD). For mission and time critical applications such as the Terrain Relative Navigation (TRN) for planetary or small body navigation, and landing, a range of fault tolerance methods can be adapted by the application. The software methods being investigated include Error Correction Code (ECC) for data packet routing between cores, virtual network routing, Triple Modular Redundancy (TMR), and Algorithm-Based Fault Tolerance (ABFT). A robust fault tolerance framework that provides fail-operational behavior under hard real-time constraints and graceful degradation will be demonstrated using TRN executing on a commercial Tilera(R) processor with simulated fault injections.

software based↗

HIRF Tolerance and Avoidance for Advanced Air Mobility Vehicles

Advanced Air Mobility (AAM), including Urban Air Mobility (UAM), and Unmanned Aerial Systems (UAS) vehicles may fly in similar airspace to Transport Category Rotorcraft, thereby requiring meeting the same stringent High-Intensity Radiated Fields (HIRF) certification requirements. In a previous effort, a proposed map-based approach protects a vehicle by keeping it away from high power sources at safe distances based on its tolerance level. By designing to a lower tolerance level, significant cost savings can be achieved at the cost of slightly more complex flight planning. However, too low a threshold can result in large avoidance areas, potentially reducing the vehicle operating space. This current effort suggests a minimum threshold for vehicles operating in an urban area. It is derived from analyzing regulatory transmitter data for New York City as a representative metropolitan area. As a result, a vehicle can tolerate common lower-power transmitters by default and only needs to avoid far less common high-power sources. It is also found the existing HIRF requirements may be insufficient against many powerful transmitters such as weather radars and satellite uplink transmitters, and that the map-based approach can address this concern.

HIRF↗

Stereology techniques in radiation biology

Clinicians involved in conventional radiation therapy are very concerned about the dose-response relationships of normal tissues. Before proceeding to new clinical protocols, radiation biologists involved with conformal proton therapy believe it is necessary to quantify the dose response and tolerance of the organs and tissues that will be irradiated. An important focus is on the vasculature. This presentation reviews the methodology and format of using confocal microscopy and stereological methods to quantify tissue parameters, cell number, tissue volume and surface area, and vessel length using the microvasculature as a model tissue. Stereological methods and their concepts are illustrated using an ongoing study of the dose response of the microvessels in proton-irradiated hemibrain. Methods for estimating the volume of the brain and the brain cortex, the total number of endothelial cells in cortical microvessels, the length of cortical microvessels, and the total surface area of cortical microvessel walls are presented step by step in a way understandable for readers with little mathematical background. It is shown that stereological techniques, based on a sound theoretical basis, are powerful and reliable and have been used successfully.

Non-NASA Center↗

A Passive Gravitational Attitude Control System for Satellites

It is shown how the gravity-gradient effect may be utilized to design a long-lived, earth-pointing satellite attitude control system which requires no fuel supplies, attitude sensors or active control equipment. This two-body system is provided with a magnetic hysteresis damper which effectively damps out oscillations (librations) about the local vertical. The long rods, which must be extended in space from coiled up metal tapes, provide the required large moments of inertia and possess adequate rigidity and sufficient strength to endure the rigors of the extension process. The system is compatible with the requirements of multiple satellite launchings from a single last-stage vehicle. Analysis indicates that the gravitational torques are sufficient to keep the disturbing effects of solar radiation pressure, residual magnetic dipole moments, orbit eccentricity, rod curvature, eddy currents, and meteorite impacts within tolerable limits. It is believed that the high-performance, earth-pointing system described and analyzed in this paper represents an essential step in the development of high-capacity communications satellites requiring long life.

GRAVITY↗

Performance of LI-1542 reusable surface insulation system in a hypersonic stream

The thermal and structural performance of a large panel of LI-1542 reusable surface insulation tiles was determined by a series of cyclic heating tests using radiant lamps and aerothemal tests in the Langley 8-foot high-temperature structures tunnel. Aerothermal tests were conducted at a free-stream Mach number of 6.6, a total temperature of 1830 K, Reynolds numbers of 2.0 and 4,900,000 per meter, and dynamic pressures of 29 and 65 kPa. The results suggest that pressure gradients in gaps and flow impingement on the header walls at the end of longitudinal gaps are sources for increased gap heating. Temperatures higher than surface radiation equilibrium temperature were measured deep in gaps and at the header walls. Also, the damage tolerance of the LI-1542 tiles appears to be very high. Tile edge erosion rate was slow; could not be tolerated in a shuttle application. Tiles soaked with water and subjected to rapid depressurization and aerodynamic heating showed no visible evidence of damage.

Hunt, L. R.↗

SRAM Based Re-programmable FPGA for Space Applications

An SRAM (static random access memory)-based reprogrammable FPGA (field programmable gate array) is investigated for space applications. A new commercial prototype, named the RS family, was used as an example for the investigation. The device is fabricated in a 0.25 micrometers CMOS technology. Its architecture is reviewed to provide a better understanding of the impact of single event upset (SEU) on the device during operation. The SEU effect of different memories available on the device is evaluated. Heavy ion test data and SPICE simulations are used integrally to extract the threshold LET (linear energy transfer). Together with the saturation cross-section measurement from the layout, a rate prediction is done on each memory type. The SEU in the configuration SRAM is identified as the dominant failure mode and is discussed in detail. The single event transient error in combinational logic is also investigated and simulated by SPICE. SEU mitigation by hardening the memories and employing EDAC (error detection and correction) at the device level are presented. For the configuration SRAM (CSRAM) cell, the trade-off between resistor de-coupling and redundancy hardening techniques are investigated with interesting results. Preliminary heavy ion test data show no sign of SEL (single event latch-up). With regard to ionizing radiation effects, the increase in static leakage current (static I(sub CC)) measured indicates a device tolerance of approximately 50krad(Si).

Wang, J. J.↗

Heterogeneous Integration, An Approach to High Density and High Flexibility Electronic Packaging

Key to the design of spacecraft for exploration of the outer planets will be the development of highly integrated and mass/volume efficient electronic systems. Exploration of the outer planets will require optimized propulsion approaches which mandates mass minimization. If one looks at a mission such as the Europa Lander, a high mass/volume efficiency feeds back directly into lower mass for radiation shielding. Concurrently the long mission lengths will drive the need for fault isolation and fault tolerance. The ability to build distributed electronic systems is an inherent requirement and one which is enabled by heterogeneous integration. The electronic packaging approach must be capable of interconnecting various components at a scale comparable with that on the components themselves (chip scale) and it must facilitate efficient integration of the electronics with elements of the spacecraft such as structure or antennae. The concept of 'Heterogeneous Integration' is being explored in the System On A Chip (SOAC) Project at JPL. The goal, of this approach to electronic packaging, is to enable the fabrication and assembly of complete electronic subsystems from components fabricated by a range of processes. Included in such a system could be MEMS sensors, SOI mixed signal ASICs, micro scale passive components and micro power. Secondarily the compact size will enable distributed architectures and integrated assemblies. Additional information is contained in the original extended abstract.

DAgostino, S. A.↗

Potential Lunar In-Situ Resource Utilization Experiments and Mission Scenarios

The extraction and use of resources on the Moon, known as In-Situ Resource Utilization (ISRU), can potentially reduce the cost and risk of human lunar exploration while also increasing science achieved. By not having to bring all of the shielding and mission consumables from Earth and being able to make products on the Moon, missions may require less mass to accomplish the same objectives, carry more science equipment, go to more sites of exploration, and/or provide options to recover from failures not possible with delivery of spares and consumables from Earth alone. The concept of lunar ISRU has been considered and studied for decades, and scientists and engineers were theorizing and even testing concepts for how to extract oxygen from lunar soil even before the Apollo 11 mission to the Moon. There are four main areas where ISRU can significantly impact how human missions to the Moon will be performed: mission consumable production, civil engineering and construction, energy production, storage, and transfer, and manufacturing and repair. The area that has the greatest impact on mission mass, hardware design and selection, and mission architecture is mission consumable production, in particular, the ability to make propellants, life support consumables, and fuel cell reagents. Mission consumable production allows for refueling and reuse of spacecraft, increasing power production and storage, and increased capabilities and failure tolerance for crew life support. The other three areas allow for decreased mission risk due to radiation and plume damage, alternative power systems, and failure recover capabilities while also enabling infrastructure growth over Earth delivered assets. However, while lunar ISRU has significant potential for mass, cost, and risk reduction for human lunar missions, it has never been demonstrated before in space. To demonstrate that ISRU can meet mission needs and to increase confidence in incorporating ISRU capabilities into mission architectures, terrestrial laboratory and analog field testing along with robotic precursor missions are required. A stepwise approach with international collaboration is recommended. The first step is to understand the resources available through orbital and surface exploration missions. Resources of particular interest are hydrogen, hydroxyl, water, and other polar volatile resources recently measured by Chandrayaan, Lunar Reconnaissance Orbiter (LRO), and the Lunar Crater Observation and Sensing Satellite (LCROSS). The second step is to demonstrate critical aspects of ISRU systems to prove ISRU is feasible under lunar environmental and resource conditions (ex. subscale oxygen extraction from regolith). The third step is to perform integrated missions with ISRU and other connected systems, such as power, consumable storage, surface mobility, and life support at a relevant mission scale to demonstrate ISRU capabilities as well as the critical interfaces with other exploration systems. If possible, the mission should demonstrate the use of ISRU products (ex. in a rocket engine or fuel cell). This dress rehearsal mission would be the final step before full implementation of ISRU into human missions, and may be performed during human lunar exploration activities. This stepwise approach is the most conservative approach, and may only be possible with international cooperation due to the limited number of robotic missions each nation/space agency can perform within their budget.

Sanders, Gerald B.↗

Thermal Analysis of Landers using Radioisotope Power Systems on Ice Worlds

The surfaces of Ice Worlds record evidence of interior processes, chemical potential, habitability, and potentially life within the interior. Volatile and organic chemistry at the surface is critical in determining habitability and detecting the presence of past or extant life. Radioisotope Power Systems (RPS) could be an enabling technology for in situ missions to ice worlds, providing both power and heat for long durations where solar power would not be feasible. However, it is necessary to understand the potential impact of RPS upon the local environment, to ensure that the rejected heat from RPS does not compromise science measurements or planetary protection requirements. To address these concerns, an RPS Ice World Lander Study was carried out in 2019 to investigate possible requirements on RPS surface mission concepts and approaches to excess heat management. The study focused on two destinations that are representative of the range of potential environments: Europa and Enceladus.Initial analysis showed that, due to the very low pressures on the surfaces of most ice world targets, surface melting does not occur because the water ice does not meet the triple-point. A 4 kW heat source suspended above the surface of Europa or Enceladus would not cause any melting, only sublimation.The study used a surface sublimation limit of 10 cm over a two-year period (the baseline for the recent Europa Lander study). To stay within this limit, Europa, with its relatively warm surface, could tolerate only 10 W/m2 of surface heat flux. Enceladus, with its relatively cold pure ice composition, could tolerate up to 100 W/m2.Various lander and heat shield configurations were analyzed for their heat flux radiated from the RPS to the surface. For a given heat shield configuration, the study team determined the minimum height of the RPS above the surface for which the heat flux would be within the accepted parameters for Europa and for Enceladus. Based on these thermal analyses, such RPS-powered landers could remain compliant with science investigation and planetary protection requirements with only modest mass allocated to spacecraft thermal accommodations.

Perl, Scott↗

Flight Computer Processing Avionics for Space Station Microgravity Experiments: A Risk Assessment of Commercial Off-the-Shelf Utilization

NASA/Marshall Space Flight Center (MSFC) is continually looking for ways to reduce the costs and schedule and minimize the technical risks during the development of microgravity programs. One of the more prominent ways to minimize the cost and schedule is to use off-the-shelf hardware (OTS). However, the use of OTS often increases the risk. This paper addresses relevant factors considered during the selection and utilization of commercial off-the-shelf (COTS) flight computer processing equipment for the control of space station microgravity experiments. The paper will also discuss how to minimize the technical risks when using COTS processing hardware. Two microgravity experiments for which the COTS processing equipment is being evaluated for are the Equiaxed Dendritic Solidification Experiment (EDSE) and the Self-diffusion in Liquid Elements (SDLE) experiment. Since MSFC is the lead center for Microgravity research, EDSE and SDLE processor selection will be closely watched by other experiments that are being designed to meet payload carrier requirements. This includes the payload carriers planned for the International Space Station (ISS). The purpose of EDSE is to continue to investigate microstructural evolution of, and thermal interactions between multiple dendrites growing under diffusion controlled conditions. The purpose of SDLE is to determine accurate self-diffusivity data as a function of temperature for liquid elements selected as representative of class-like structures. In 1999 MSFC initiated a Center Director's Discretionary Fund (CDDF) effort to investigate and determine the optimal commercial data bus architecture that could lead to faster, better, and lower cost data acquisition systems for the control of microgravity experiments. As part of this effort various commercial data acquisition systems were acquired and evaluated. This included equipment with various form factors, (3U, 6U, others) and equipment that utilized various bus structures, (VME, PC104, STD bus). This evaluation of hardware was performed in conjunction with a trade study that considered over twenty (20) different factors relevant to the selection of an optimum design approach. These factors included; safety, sizing and timing, radiation hardness and single event upset, power consumption, heat dissipation, size and volume, expected service life, maintainability, heritage, operating systems, requirements for software reuse, availability of compatible interface boards, relative cost, schedule, reliability, EMI/EMC factors, "hot swap" capability, standards for conduction cooling, I/O capabilities, unique carrier requirements and operating system considerations. The approach to evaluate Safety as part of this study included a review of the Preliminary Hazard Analysis (PHA) for each of the experiment designs and a determination of how each hazard could be addressed and eliminated when different processors were selected. This included evaluating various design approaches and trade-offs between fault tolerant designs and fail-safe designs in accordance with NSTS 1700.7B. This will include the results of radiation testing where available. Various operating systems, such as VxWorks, Linux, QNX, and Embedded NT are evaluated and the advantages and disadvantages of their utilization are also addressed. Design implementation strategies for the various operating systems are considered and discussed. This paper presents the results and recommendations from this trade study. Preliminary conclusions from this study are that safety concerns from lack or radiation testing on COTS equipment can be addressed by additional testing and design considerations, the PC104 bus provided adequate I/O for the SDLE and EDSE microgravity experiments, and PC104 bus components offered significant advantages over VME and cPCI for weight and space reductions.

Estes, Howard↗

Validation of Fault-Tolerant Plans for Europa Clipper

The Europa Clipper mission will explore that icy moon in a series of brief flybys through the Jovian radiation belts. A single event upset in the spacecraft flight computer during these critical scientific periods could jeopardize the success of the mission. Rather than safing and awaiting operator intervention, the Clipper mission envisions limited onboard autonomy that can restore spacecraft state sufficiently to resume the encounter observation plan as rapidly as possible. The contingency plan is contained in an Activity Restart Timeline (ART) that is transmitted in parallel with the nominal plan, which must be co-validated jointly against all spacecraft state and resource constraints amid unpredictable fault timing. A prototype validation tool was built that leverages declarative spacecraft models and automated search techniques to find such potential inconsistencies in the unified contingent mission plan. Early validation results within motivating scenarios are presented.

Ferguson, Eric↗

Enabling Reliable, Fault-Tolerant Autonomous Lunar Habitats with High-Performance Spaceflight Computing

The lunar surface presents unfavorable constraints and harsh living conditions. To address these challenges, autonomous habitats will require complex integrated systems that combine advanced software, high-performance hardware, and cutting-edge sensors to ensure sustainability, safety, and operational efficiency. Consequently, maintaining a sustainable presence on the Moon requires reliable infrastructure and efficient development, precise monitoring, and utilization of resources within a lunar installation. These elements are essential not only to ensure that lunar settlement can be long-term, self-sustaining, and resource-efficient, but also to serve as a foundation for future missions and eventual human habitation on Mars. Humans are not native to the Moon; therefore, our survival and ability to thrive will depend on autonomous systems that can foster safety and resilience through high-availability architectures, graceful degradation, and highly fault-tolerant spaceflight hardware capable of continuing operation during failures. This requires advanced human-rated distributed systems architectures with specialized electronics, scalable capabilities, and an integrated design approach. Unlike current practices focused on short-term missions and regularly maintained components, permanent lunar compute systems must be designed for extended operations beyond mission durations. This paper explores the necessity of transitioning toward fault- tolerant, highly autonomous hardware systems designed for multi-year missions. It also identifies critical subsystems that require high levels of autonomy, supported by radiation-hardened processors and extreme thermal loads, which are essential to mitigate long-term degradation and ensure sustainable lunar habitation. Finally, the paper aligns with NASA’s identified Civil Space Shortfalls, particularly in high-performance onboard computing, advanced data acquisition, extreme-environment avionics, radiation monitoring and countermeasures, and autonomous health management. It proposes NASA’s new High-Performance Spaceflight Computing (HPSC) processor as a turnkey solution, delivering 100 times the performance-per-watt of legacy rad-hard CPUs and enabling onboard AI, edge computing, and fault-tolerant features essential for sustained lunar autonomy and beyond.

Sarkis S Mikaelian↗