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Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Gradl, Paul

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.

Using Board Games as Subject Matter for Developing Expertise in Model-Based Systems Engineering

As more organizations transition from traditional document-centric systems engineering to a model-based approach, many are challenged to train their staff in new languages, tools, and methodologies, while managing the expectations of stakeholders and their expected model outcomes. In particular, challenges associated with learning a new modeling language and developing skills in the 'art' of modeling present organizations with formidable obstacles to realizing this transition. This paper hypothesizes that systems engineers may more readily learn how to correctly model with SysML, and develop intuition about the art of modeling and using patterns, if their learning references a commonly and thoroughly-understood subject, such as a board game. This paper presents a case for the use of board games as subject matter for new modelers. It demonstrates the concept with a sample model of Hasbro's popular board game, Monopoly, and discusses the limitations of this approach and potential adaptations that may broaden the applicability of the learned skills to projects. Finally, results from a small feasibility assessment and concepts for more formal study to evaluate the hypothesis are presented.

Model-Based Systems Engineering

Using Board Games as Subject Matter for Developing Expertise in Model-Based Systems Engineering

As more organizations transition from traditional document-centric systems engineering to a model-based approach, many are challenged to train their staff in new languages, tools, and methodologies, and manage the expectations of stakeholders and their expected model outcomes. In particular, challenges associated with learning a new modeling language and developing skills in the 'art' of modeling present organizations with formidable obstacles to realizing this transition. This paper hypothesizes that systems engineers may more readily learn how to correctly model with SysML, and develop intuition about the art of modeling and using patterns, if their learning references a commonly and thoroughly-understood subject matter, such as a board game. This paper presents a case for the use of board games as subject matter for new modelers, demonstrates the concept with a sample model of Hasbro's popular board game, Monopoly, and discusses the limitations of this approach and potential adaptations that may broaden the applicability of the learned skills to projects.

Systems Engineering

Search Enhancements using Natural Language Processing Techniques

NASA Goddard Earth Sciences Data and Information Services Center (GESDISC) is one of the 12 NASA Science Mission Directorate Data Centers. The main goal of GESDISC is to provide earth science data, information, and services to the earth science data community. Consequently, data discovery is at the center of our mission and our search engine is the primary tool for our users to interact, find, and access our data. Existing search approaches are largely focused on hard-matching of keywords in the search query with dataset metadata. Here we propose to expand the search by introducing a complementary natural language processing (NLP) search. At the heart of our proposed NLP search, we trained a joint embedding using scientific text corpus and a curated set of dataset metadata. The embedding learns the association between words in our dataset metadata and those of the scientific text corpus. This enables us to go beyond simple hard-matching of a query and data set metadata and have a notion of “similarity” between the search query and the datasets. We further integrated our NLP search into the Elastic Search (ES) framework leveraging similarity search capabilities offered through the “dense_vector” field type. Our preliminary evaluations show that our proposed NLP search has the potential to be utilized to complement the existing search engine and serve as a base for a dataset recommendation system.

Armin Mehrabian

Early Information Parameter-Set Analysis for Satellite Close Approaches using Machine Learning

Understanding orbital mechanics is essential in space flight and navigation applications, and leveraging modern force models for flight path projection remains an important aspect in space mission design and operation. However, force models do not capture all the dynamics or perturbations in the space environment and thus are subject to errors in predicting the state vectors. The further out the predicted miss distance between spacecraft is from the time of closest approach (TCA), the larger the propagated errors in the predicted miss distance at TCA is. The dependency on these force models for spacecraft flight state prediction calls for a more reliable method that can quantify, or even reduce, these propagated errors. With recent advances in the field artificial intelligence, specifically in machine and deep learning algorithms, a model that implements these approaches can improve on the modern force model approach. The goal for this work is to provide an early-information decision-making threshold, in order to prioritize risk assessment implementation, given the ongoing increase of space objects. In analyzing the relationship of several parameters from conjunction data messages(CDMs) and solar information, early information becomes viable in miss distance prediction with unsupervised learning techniques, which learn the parameters that are linked together with miss distance and probability of collision (Pc) variables. Another approach implemented for identifying relationships within CDMs is supervised learning, in which a shallow neural network binary classifier learns to distinguish events with Pc values¡108. These parameters detected in the unsupervised process are then applied to a regression neural network, which predicts the miss distance at TCA for a specific event within a given uncertainty bound. For the regression neural network, a Long Short Term Memory (LSTM) neural network is implemented, which yields memory about each time step in an event. Using an LSTM network, the model learns to predict miss distance within 0.2km of the value measured at TCA. Although there is a limited amount of "close miss" data to train a network, the network learns to associate parameters, like large energy dissipation rates with the secondary object, with an elevated Pc

Brianna I. Robertson

Uncertainty in Servicing and Assembly Tasks for Space Robotic Manipulators

This presentation will discuss a subset of the sources of uncertainty that impact autonomous in-space servicing, assembly, and manufacturing missions. These include robotic manipulator modeling uncertainties in both kinematics and dynamics, perception error associated machine learning models for pose estimation, and sensor noise. Mitigation strategies will be discussed including the incorporation of capture envelopes in the design of robotic tools and selection of robot goal poses to minimize end-effector sensitivity in manipulators with redundant degrees of freedom.

robotics

Big Data Challenges at CCMC

Like other research centers, the Community Coordinated Modeling Center (CCMC, https://ccmc.gsfc.nasa.gov) at NASA Goddard Space Flight Center (GSFC) is also experiencing the big data challenges. CCMC hosts over 80 space weather models for Runs On Request (ROR), Continuous Runs and Instant Runs simulation services for the research community. In addition, CCMC has started to support simulation output onboarding in response to the Open Science initiative. Overall, we have accumulated over petabytes of simulation output data and are rapidly growing. In this presentation, we will discuss our data and storage challenges. We will present our attempts to address our challenges and any associated lessons learned. CCMC uses Apache Airflow to ensure data transfer is consistent. We will give a brief overview on how we leverage Apache Airflow to enhance our environment.

space weather

Big Data Challenges at the Community Coordinated Modeling Center (CCMC)

Like other research centers, the Community Coordinated Modeling Center (CCMC, https://ccmc.gsfc.nasa.gov) at NASA Goddard Space Flight Center (GSFC) is also experiencing the big data challenges. CCMC hosts over 80 space weather models for Runs On Request (ROR), Continuous Runs and Instant Runs simulation services for the research community. In addition, CCMC has started to support simulation output onboarding in response to the Open Science initiative. Overall, we have accumulated over petabytes of simulation output data and are rapidly growing. In this presentation, we will discuss our data and storage challenges. We will present our attempts to address our challenges and any associated lessons learned. CCMC uses Apache Airflow to ensure data transfer is consistent. We will give a brief overview on how we leverage Apache Airflow to enhance our environment.

space weather

The real-time learning mechanism of the Scientific Research Associates Advanced Robotic System (SRAARS)

Scientific research associates advanced robotic system (SRAARS) is an intelligent robotic system which has autonomous learning capability in geometric reasoning. The system is equipped with one global intelligence center (GIC) and eight local intelligence centers (LICs). It controls mainly sixteen links with fourteen active joints, which constitute two articulated arms, an extensible lower body, a vision system with two CCD cameras and a mobile base. The on-board knowledge-based system supports the learning controller with model representations of both the robot and the working environment. By consecutive verifying and planning procedures, hypothesis-and-test routines and learning-by-analogy paradigm, the system would autonomously build up its own understanding of the relationship between itself (i.e., the robot) and the focused environment for the purposes of collision avoidance, motion analysis and object manipulation. The intelligence of SRAARS presents a valuable technical advantage to implement robotic systems for space exploration and space station operations.

Chen, Alexander Y.

Language Research Center's Computerized Test System (LRC-CTS) - Video-formatted tasks for comparative primate research

Automation of a computerized test system for comparative primate research is shown to improve the results of learning in standard paradigms. A mediational paradigm is used to determine the degree to which criterion in the learning-set testing reflects stimulus-response associative or mediational learning. Rhesus monkeys are shown to exhibit positive transfer as the criterion levels are shifted upwards, and the effectiveness of the computerized testing system is confirmed.

Rumbaugh, Duane M.

Control of a simulated arm using a novel combination of Cerebellar learning mechanisms

We present a model of cerebellar cortex that combines two types of learning: feedforward predicitve association based on local Hebbian-type learning between granule cell ascending branch and parallel fiber inputs, and reinforcement learning with feedback error correction based on climbing fiber activity.

cerebellum cerebellar learning dynamic state estim

Development of a computer program to generate typical measurement values for various systems on a space station

The elements of a simulation program written in Ada were developed. The program will eventually serve as a data generator of typical readings from various space station equipment involved with Communications and Tracking, and will simulate various scenarios that may arise due to equipment malfunction or failure, power failure, etc. In addition, an evaluation of the Ada language was made from the viewpoint of a FORTRAN programmer learning Ada for the first time. Various strengths and difficulties associated with the learning and use of Ada are considered.

Deacetis, Louis A.

Engineering Lessons Learned and Systems Engineering Applications

Systems Engineering is fundamental to good engineering, which in turn depends on the integration and application of engineering lessons learned. Thus, good Systems Engineering also depends on systems engineering lessons learned from within the aerospace industry being documented and applied. About ten percent of the engineering lessons learned documented in the NASA Lessons Learned Information System are directly related to Systems Engineering. A key issue associated with lessons learned datasets is the communication and incorporation of this information into engineering processes. As part of the NASA Technical Standards Program activities, engineering lessons learned datasets have been identified from a number of sources. These are being searched and screened for those having a relation to Technical Standards. This paper will address some of these Systems Engineering Lessons Learned and how they are being related to Technical Standards within the NASA Technical Standards Program, including linking to the Agency's Interactive Engineering Discipline Training Courses and the life cycle for a flight vehicle development program.

Gill, Paul S.

Engineering Lessons Learned and Systems Engineering Applications

Systems Engineering is fundamental to good engineering, which in turn depends on the integration and application of engineering lessons learned and technical standards. Thus, good Systems Engineering also depends on systems engineering lessons learned from within the aerospace industry being documented and applied. About ten percent of the engineering lessons learned documented in the NASA Lessons Learned Information System are directly related to Systems Engineering. A key issue associated with lessons learned datasets is the communication and incorporation of this information into engineering processes. Systems Engineering has been defined (EINIS-632) as "an interdisciplinary approach encompassing the entire technical effort to evolve and verify an integrated and life-cycle balanced set of system people, product, and process solutions that satisfy customer needs". Designing reliable space-based systems has always been a goal for NASA, and many painful lessons have been learned along the way. One of the continuing functions of a system engineer is to compile development and operations "lessons learned" documents and ensure their integration into future systems development activities. They can produce insights and information for risk identification identification and characterization. on a new project. Lessons learned files from previous projects are especially valuable in risk

Gill, Paul S.

A self-learning rule base for command following in dynamical systems

In this paper, a self-learning Rule Base for command following in dynamical systems is presented. The learning is accomplished though reinforcement learning using an associative memory called SAM. The main advantage of SAM is that it is a function approximator with explicit storage of training samples. A learning algorithm patterned after the dynamic programming is proposed. Two artificially created, unstable dynamical systems are used for testing, and the Rule Base was used to generate a feedback control to improve the command following ability of the otherwise uncontrolled systems. The numerical results are very encouraging. The controlled systems exhibit a more stable behavior and a better capability to follow reference commands. The rules resulting from the reinforcement learning are explicitly stored and they can be modified or augmented by human experts. Due to overlapping storage scheme of SAM, the stored rules are similar to fuzzy rules.

Tsai, Wei K.