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Progress of Cometary Science in the Past 100 Years

Enormous strides made by cometary science during the 20th century defy any meaningful comparison of its state 100 years ago and now. The great majority of the subfields enjoying much attention nowadays did not exist in the year 1900. Dramatic developments, especially in the past 30-50 years, have equally affected observational and theoretical studies of comets. The profound diversification of observing techniques has been documented by the ever widening limits on the electromagnetic spectrum covered. While the time around 1900 marked an early period of slow and painful experimentation with photographic methods in cometary studies, observations of comets from the x-ray region to the radio waves have by now become routine. Many of the new techniques, and all those involved with the wavelengths shorter than about 300 nm, were made possible by another major breakthrough of this century - observing from space. Experiments on dedicated Earth-orbiting satellites as well as several deep-space probes have provided fascinating new information on the nature and makeup of comets. In broader terms, much of the progress has been achieved thanks to fundamental discoveries and major advances in electronics, whose applications resulted in qualitatively new instruments (e.g. radiotelescopes) and sensors or detectors (e.g. CCD arrays). The most universal effect on the entire cometary science, from observing to data handling to quantitative interpretations, has been, as in any other branch of science, due to the introduction of electronic computers, with their processing capabilities not only unheard of, but literally unimaginable, in the age of classical desk calculators. As if all this should not be enough, the today's generations of comet scientists have, in addition, been blessed with nature's highly appreciated cooperation. Indeed, in the span of a dozen years, between 1985 and 1997, we were privileged to witness four remarkable cometary events: (i) a return of Halley's celebrated comet; (ii) the impact of an extensively fragmented comet Shoemaker-Levy 9 into Jupiter - a once-in-a-millenium episode; (iii) a closeup, appearance of a small but very active Earth-approaching comet Hyakutake; and (iv) an unforgettable celestial show of comet Hale-Bopp, one of the brightest and the most massive comets ever observed. We have been - and for many years to come will be - harvesting scientifically lucrative findings based on the flood of data accumulated during observational campaigns organized for these and other recent objects. Our understanding of cometary phenomena will continue to grow as observing techniques are further being improved and as more sophisticated theories are being developed. Recent accomplishments achieved in the rapidly expanding field of comets are certain to stimulate the members of this astronomical community in their quest for new discoveries in the 21st century!

Sekanina, Zdenek↗

The development of inflatable array antennas

The deployable array antenna using an inflatable or thin-membrane structure has been identified as one of the enabling technologies to achieve low-mass, high packaging efficiency, low cost, and reliable deployment for future NASNJPL spacebome high-gain and large aperture antennas. Array antennas, when compared to parabolic reflectors, although suffering from limited bandwidth performance, offer wide-angle beam scanning capability and a more reliable flat “natural” aperture. To demonstrate the feasibility and capability of this low-mass array technology, three antenna concepts using inflatable and thin-membrane structures were initiated in 1997 at JPL and several breadboard units have been successfully developed. These three concepts are (1) the inflatable phased array, (2) the inflatable reflectarray, and (3) frame-supported thin membrane array antenna. All three concepts utilize the printed microstrip antenna technology. Although all three concepts will be briefly presented, this paper will discuss in more detail of the recent development of the second concept. The first concept of inflatable phased arrays that have been constructed are 3 to 5-meter size L-band dual-polarized synthetic aperture radar (SAR) arrays for Earth remote sensing application. They all consist of a rectangular configuration with inflatable cylindrical tubes that support and tension a multi-layer thin-membrane radiating aperture with microstrip patches and microstrip power divider lines. For the second concept, an inflatable reflectarray was developed for future deep-space telecom applications. It is a 3m Ka-band inflatable reflectarray (1.8 kg/m2). This reflectarray uses inflated torus tubes to support and tension a flat-membrane reflectarray surface. The reflectarray surface emulates a curved parabolic reflecting surface. However, because of its flat surface being a “natural surface”, it is much easier to achieve and more reliable to maintain the required surface tolerance than that of a curved parabola during long space flight. For the third concept, an L-band dual polarized SAR array with a 5m x 3m aperture and 2.5 kg/m2 of mass has recently been demonstrated. It consists of seven foldable panels each having a rectangular frame that supports a two-layer thinmembrane microstrip subarray aperture. Each frame is made of light-weight graphite composite material. The chief advantage of this deployable “frame” concept is that each frame is able to rigidly support an appropriate number of T/R modules and phase shifters to achieve the desired power distribution and beam scanning. Several technology challenges, such as the development of rigidizable inflatable tubes, a controlled deployment mechanism, thin-membrane thermal effects, a low-mass inflation system, membrane mounted T/R modules, means to counter surface tolerance issues, etc. are being investigated and will be discussed in the presentation. With foreseeable success in the development of these challenging areas, the inflatable/thin-membrane array antennas could be mature enough in a few years for actual space flight.

Lou, Michael↗

On-the-Fly Mapping for Calibrating Directional Antennas

An improved method of calibrating a large directional radio antenna of the type used in deep-space communication and radio astronomy has been developed. This method involves a raster-scanning-and-measurement technique denoted on-the-fly (OTF) mapping, applied in consideration of the results of a systematic analysis of the entire measurement procedure. Phenomena to which particular attention was paid in the analysis include (1) the noise characteristics of a total-power radiometer (TPR) that is used in the measurements and (2) tropospherically induced radiometer fluctuations. The method also involves the use of recently developed techniques for acquisition and reduction of data. In comparison with prior methods used to calibrate such antennas, this method yields an order-of-magnitude improvement in the precision of determinations of antenna aperture efficiency, and improvement by a factor of five or more in the precision of determination of pointing error and beam width. Prerequisite to a meaningful description of the present method is some background information concerning three aspects of the problem of calibrating an antenna of the type in question: In OTF mapping measurements in which a TPR is used, the desired data are the peak temperature corresponding to a radio source, the pointing offset when the antenna is commanded to point toward the source, and the shape of the main lobe of the antenna beam, all as functions of the antenna beam elevation and azimuth angles. These data enable one to calculate the (1) antenna aperture efficiency by comparing the measured peak temperature with that expected for a 100-percent-efficient antenna, (2) the mechanical pointing error resulting from small misalignments of various parts of the antenna structure, and (3) misalignments of the antenna subreflector and other mirrors. For practical reasons having to do with obtaining adequate angular resolution and all-sky coverage, it is necessary to perform azimuth and elevation scans fairly rapidly. Many natural radio sources used in calibrating antennas are only approximately pointlike: some sources subtend angles greater than the beam width of a given antenna. In such a case, the antenna partially resolves the source structure and does not collect all of the radiation emitted by the source. This makes it necessary to estimate how much of the total known radiation from the source would actually be collected by the antenna if it were 100-percent efficient. The resulting estimate, leading to a source-size correction factor, introduces another degree of uncertainty to the measurements. OTF mapping can remove this uncertainty

Rochblatt, David↗

The Evolution of Technology in the Deep Space Network: A History of the Advanced Systems Program

The Deep Space Network (DSN) of 1995 might be described as the evolutionary result of 45 years of deep space communication and navigation, together with the synergistic activities of radio science and radar and radio astronomy. But the evolution of the DSN did not just happen - it was carefully planned and created. The evolution of the DSN has been an ongoing engineering activity, and engineering is a process of problem solving under constraints, one of which is technology. In turn, technology is the knowledge base providing the capability and experience for practical application of various areas of science, when needed. The best engineering solutions result from optimization under the fewest constraints, and if technology needs are well anticipated (ready when needed), then the most effective engineering solution is possible. Throughout the history of the DSN it has been the goal and function of DSN advanced technology development (designated the DSN Advanced Systems Program from 1963 through 1994) to supply the technology needs of the DSN when needed, and thus to minimize this constraint on DSN engineering. Technology often takes considerable time to develop, and when that happens, it is important to have anticipated engineering needs; at times, this anticipation has been by as much as 15 years. Also, on a number of occasions, mission malfunctions or emergencies have resulted in unplanned needs for technology that has, in fact, been available from the reservoir of advanced technology provided by the DSN Advanced Systems Program. Sometimes, even DSN engineering personnel fail to realize that the organization of JPL permits an overlap of DSN advanced technology activities with subsequent engineering activities. This can result in the flow of advanced technology into DSN engineering in a natural and sometimes almost unnoticed way. In the following pages, we will explore some of the many contributions of the DSN Advanced Systems Program that were provided to DSN Engineering and Implementation. These contributions are, for the most part, unique capabilities that have met the requirements of flight projects for 45 years. These unique capabilities include not only the world's best deep-space communications system, but also outstanding competency in the fields of radio metric measurement, radar and radio astronomy, and radio science.

Layland, J. W.↗

Enhanced Multi-Modal Access to Planetary Exploration

Tomorrow's Interplanetary Network (IPN) will evolve from JPL's Deep-Space Network (DSN) and provide key capabilities to future investigators, such as simplified acquisition of higher-quality science at remote sites and enriched access to these sites. These capabilities could also be used to foster public interest, e.g., by making it possible for students to explore these environments personally, eventually perhaps interacting with a virtual world whose models could be populated by data obtained continuously from the IPN. Our paper looks at JPL's approach to making this evolution happen, starting from improved communications. Evolving space protocols (e.g., today's CCSDS proximity and file-transfer protocols) will provide the underpinning of such communications in the next decades, just as today's rich web was enabled by progress in Internet Protocols starting from the early 1970's (ARPAnet research). A key architectural thrust of this effort is to deploy persistent infrastructure incrementally, using a layered service model, where later higher-layer capabilities (such as adaptive science planning) are enabled by earlier lower-layer services (such as automated routing of object-based messages). In practice, there is also a mind shift needed from an engineering culture raised on point-to-point single-function communications (command uplink, telemetry downlink), to one in which assets are only indirectly accessed, via well-defined interfaces. We are aiming to foster a 'community of access' both among space assets and the humans who control them. This enables appropriate (perhaps eventually optimized) sharing of services and resources to the greater benefit of all participants. We envision such usage to be as automated in the future as using a cell phone is today - with all the steps in creating the real-time link being automated.

interplanetary network (IPN)↗

VISUAL CONTROL OF RENDEZVOUS

Space rendezvous involving human occupants will be required in many phases of space flight. In order that rendezvous capability be concurrent with other phases of manned space flight to insure that such tasks as the rotation and addition of crews for manned space station, supply of stations and launching complexes for deep-space probes, and the emergency rescue of personnel may be carried out, it is desirable to determine the ability of a human pilot to control the rendezvous maneuver. The National Aeronautics and Space Administration has conducted a study program to determine vehicle requirements and control techniques for a number of proposed methods for performing piloted space rendezvous. The final step in each phase of the rendezvous study program has been a simulation of the man-machine combination to test its feasibility. Initially, an analytical study was conducted to determine a range of conditions that would exist at the beginning of the terminal phase of rendezvous (ref. 1). Piloted systems were investigated for rendezvous control using these initial conditions. One such study of piloted rendezvous in which all the required control information was displayed to the simulator pilot on instruments is presented in reference 2. While the control of the rendezvous maneuver by use of the instrument display was shown to be feasible, the sufficiently accurate measurement of the necessary information to operate the instrument was realized to be a difficult problem. Consideration was therefore given to the possibility of maneuvering range and range rate required for the control of the rendezvous from visual sightings made during the initial control application. To provide this capability, an analytical study was made. This analytical study, presented in reference 3, derived three techniques for obtaining range and range rate visually and conducted a simplified preliminary situation to test the three analytical techniques. The study reported herein is a continuation of the simulation work begun in reference 3, and is aimed at determining the ability of a pilot to use visual information to reduce or eliminate the need for some or all of the data that would normally be displayed on instruments.

Rendezvous↗

Propagation anisotropies of solar flare protons and electrons at low energies in interplanetary space.

Flux anisotropies in interplanetary space were investigated for protons with E greater than 0.66 MeV and electrons with E greater than 400 keV. Data were taken from the University of Chicago charged-particle telescope aboard the deep-space probe Pioneer 7 and from the Goddard Space Flight Center magnetometer aboard the same spacecraft. Flux anisotropies lying to the east of the average interplanetary magnetic field direction were first reported by McCracken et al. (1971), late in a solar particle event, for proton energies greater than 7.5 MeV. This work extends this investigation to much lower proton energies, studies the proton and electron anisotropies during both early and late phases of a particle event, and makes use of detailed magnetic field data. The investigation consists of two parts, a study of many periods taken at random during solar events, for both protons and electrons, and a detailed analysis of one period, early in an event, during which the magnetic field was near the solar direction.

Pyle, K. R.↗

TAU as Tao

This paper discusses the feasibility of building and launching a truly deep-space spacecraft mission that will penetrate near interstellar space to a depth of one thousand astronomical units (TAU) within a flight time of 50 years. Particular attention is given to the mission profile and to its communications system, power system, and propulsion system. Results of experimental studies indicate that, with advanced technology, reasonable trip times can be achieved and adequate science information can be brought to earth.

Lyman, P. T.↗

Expected antenna utilization and overload

The trade-offs between the number of antennas at Deep Space Network (DSN) Deep-Space Communications Complex and the fraction of continuous coverage provided to a set of hypothetical spacecraft, assuming random placement of the space craft passes during the day. The trade-offs are fairly robust with respect to the randomness assumption. A sample result is that a three-antenna complex provides an average of 82.6 percent utilization of facilities and coverage of nine spacecraft that each have 8-hour passes, whereas perfect phasing of the passes would yield 100 percent utilization and coverage. One key point is that sometimes fewer than three spacecraft are visible, so an antenna is idle, while at other times, there aren't enough antennas, and some spacecraft do without service. This point of view may be useful in helping to size the network or to develop a normalization for a figure of merit of DSN coverage.

Posner, Edward C.↗

Power Management and Distribution Trades Studies for a Deep-Space Mission Scientific Spacecraft

As part of NASA's Project Prometheus, the Nuclear Systems Program, NASA GRC performed trade studies on the various Power Management and Distribution (PMAD) options for a deep-space scientific spacecraft which would have a nominal electrical power requirement of 100 kWe. These options included AC (1000Hz and 1500Hz and DC primary distribution at various voltages. The distribution system efficiency, reliability, mass, thermal, corona, space radiation levels and technology readiness of devices and components were considered. The final proposed system consisted of two independent power distribution channels, sourced by two 3-phase, 110 kVA alternators nominally operating at half-rated power. Each alternator nominally supplies 50kWe to one half of the ion thrusters and science modules but is capable of supplying the total power re3quirements in the event of loss of one alternator. This paper is an introduction to the methodology for the trades done to arrive at the proposed PMAD architecture. Any opinions expressed are those of the author(s) and do not necessarily reflect the views of Project Prometheus.

Kimnach, Greg L.↗

Radiation exposure for human Mars exploration

One major obstacle to human space exploration is the possible limitations imposed by the adverse effects of long-term exposure to the space environment. Even before human space flight began, the potentially brief exposure of astronauts to the very intense random solar energetic particle events was of great concern. A new challenge appears in deep-space exploration from exposure to the low-intensity heavy-ion flux of the galactic cosmic rays since the missions are of long duration, and accumulated exposures can be high. Because cancer induction rates increase behind low to moderate thicknesses of aluminum shielding, according to available biological data on mammalian exposures to galactic cosmic ray-like ions, aluminum shield requirements for a Mars mission may be prohibitively expensive in terms of mission launch costs. Alternative materials for vehicle construction are under investigation to provide lightweight habitat structures with enhanced shielding properties. In the present paper, updated estimates for astronaut exposures on a Mars mission are presented and shielding properties of alternative materials are compared with aluminum.

NASA Center LaRC↗

Aircraft Detection System Ensures Free-Space Laser Safety

As scientists continue to explore our solar system, there are increasing demands to return greater volumes of data from smaller deep-space probes. Accordingly, NASA is studying advanced strategies based on free-space laser transmissions, which offer secure, high-bandwidth communications using smaller subsystems of much lower power and mass than existing ones. These approaches, however, can pose a danger to pilots in the beam path because the lasers may illuminate aircraft and blind them. Researchers thus are investigating systems that will monitor the surrounding airspace for aircraft that could be affected. This paper presents current methods for safe free space laser propagation.

Smithgall, Brian↗

Calibration and Characterization of the NASA EOS Terra and Aqua MODIS Instruments

The Moderate Resolution Imaging Spectroradiometer (MODIS) instrument is operating on both of the Terra and Aqua missions within the NASA Earth Observing System (EOS). The Terra MODIS instrument began taking observations in February 2000 and the Aqua MODIS instrument began taking observations in June of 2002 and both continue to operate successfully up to the present time. The MODIS instrument scans the entire Earth every 24 hours at nominal spatial resolutions between 250 and 1000 meters. It has 36 spectral bands spanning the electromagnetic spectrum from the visible wavelengths mar 400 micrometers to the emissive thermal infrared wavelengths at 15 micrometers. The MODIS instruments produce approximately 40 geophysical products devoted to observing land, ocean, and atmospheric processes and trends. To meet the scientific objectives associated with the NASA Earth sciences efforts the MODIS instruments must be and have been carefully calibrated and the performance characterized to meet specifications and goals such as five percent radiance and two percent relative to the sun accuracy in the twenty bands providing reflected solar radiation observations and one percent radiance accuracy in the sixteen bands observing in the thermal infrared. Over the time spanning instrument development and the pre-launch calibration and characterization of the instrument through the years of operation in space, the performance of the MODIS instruments have changed in multiple ways and appropriate adjustments made in relevant algorithms and look-up tables necessary to produce observations that meet the scientific objectives and requirements. The changes have been quantified and accounted for through careful use of on-board calibration devices such as the Spectro-Radiometric Calibration Assembly (SRCA), the Solar Diffuser (SD) and its companion Solar Diffuser Stability Monitor (SDSM), deep-space and lunar observations, and calibration targets on the Earth's surface. The strictest and most difficult challenges have come in trying to meet the requirements for observing Ocean color and related ocean biology processes over time and space. Overall the MODIS observations have been very successful in providing valuable scientific and applications results. The essential capabilities of MODIS are to be provided in the future by the Visible and Infrared Imaging Radiometer Suite (VIIRS) on the National Polar Orbiting Environmental Satellite Series (NPOESS).

Salomonson, Vincent V.↗

CFD Multiphysics Tool

The recent bold initiatives to expand the human presence in space require innovative approaches to the design of propulsion systems whose underlying technology is not yet mature. The space propulsion community has identified a number of candidate concepts. A short list includes solar sails, high-energy-density chemical propellants, electric and electromagnetic accelerators, solar-thermal and nuclear-thermal expanders. For each of these, the underlying physics are relatively well understood. One could easily cite authoritative texts, addressing both the governing equations, and practical solution methods for, e.g. electromagnetic fields, heat transfer, radiation, thermophysics, structural dynamics, particulate kinematics, nuclear energy, power conversion, and fluid dynamics. One could also easily cite scholarly works in which complete equation sets for any one of these physical processes have been accurately solved relative to complex engineered systems. The Advanced Concepts and Analysis Office (ACAO), Space Transportation Directorate, NASA Marshall Space Flight Center, has recently released the first alpha version of a set of computer utilities for performing the applicable physical analyses relative to candidate deep-space propulsion systems such as those listed above. PARSEC, Preliminary Analysis of Revolutionary in-Space Engineering Concepts, enables rapid iterative calculations using several physics tools developed in-house. A complete cycle of the entire tool set takes about twenty minutes. PARSEC is a level-zero/level-one design tool. For PARSEC s proof-of-concept, and preliminary design decision-making, assumptions that significantly simplify the governing equation sets are necessary. To proceed to level-two, one wishes to retain modeling of the underlying physics as close as practical to known applicable first principles. This report describes results of collaboration between ACAO, and Embry-Riddle Aeronautical University (ERAU), to begin building a set of level-two design tools for PARSEC. The "CFD Multiphysics Tool" will be the propulsive element of the tool set. The name acknowledges that space propulsion performance assessment is primarily a fluid mechanics problem. At the core of the CFD Multiphysics Tool is an open-source CFD code, HYP, under development at ERAU. ERAU is renowned for its undergraduate degree program in Aerospace Engineering the largest in the nation. The strength of the program is its applications-oriented curriculum, which culminates in one of three two-course Engineering Design sequences: Aerospace Propulsion, Spacecraft, or Aircraft. This same philosophy applies to the HYP Project, albeit with fluid physics modeling commensurate with graduate research. HYP s purpose, like the Multiphysics Tool s, is to enable calculations of real (three-dimensional; geometrically complex; intended for hardware development) applications of high speed and propulsive fluid flows.

Perrell, Eric R.↗

Power Actuation and Switching Module Test Results

The X2000 Power System Electronics (PSE) is a Jet Propulsion Laboratory (JPL) task to develop a new generation of power system building blocks for use on future deep-space missions. The effort includes the development of electronic components and modules that can be used as building blocks in the design of generic spacecraft power systems. All X2000 avionics components and modules are designed for use in centralized or distributed spacecraft architectures. The Power Actuation and Switching Module (PASM) has been developed under the X2000 program. This component enables a modular and scalable design approach for power switching applications, which can result in a wide variety of power switching architectures using this simple building block. The PASM is designed to provide most of the necessary power switching functions of spacecraft for various Deep Space missions including future missions to Mars, comets, Jupiter and its moons. It is fabricated using an ASIC process that is tolerant of high radiation. The development included two application specific integrated circuits (ASICs) and support circuitry all packaged using High Density Interconnect (HDI) technology. It can be operated in series or parallel with other PASMs. It can be used as a high-side or low-side switch and it can drive thruster valves, pyrotechnic devices such as NASA standard initiators, bus shunt resistors, and regular spacecraft component loads. Each PASM contains two independent switches with internal current limiting and over-current trip-off functions to protect the power subsystem from load faults. During turnon and turnoff each switch can limit the rate of current change (di/dt) to a value determined by the user. Three-way majority-voted On/Off commandability and full switch status telemetry (both analog and digital) are built into the module. This paper is a follow up to the one presented at he IECEC 2004 conference that will include the lessons learned and test results from the development.

X2000↗

NASA's Decadal Planning Team Mars Mission Analysis Summary

In June 1999 the NASA Administrator chartered an internal NASA task force, termed the Decadal Planning Team, to create new integrated vision and strategy for space exploration. The efforts of the Decadal Planning Team evolved into the Agency-wide team known as the NASA Exploration Team (NEXT). This team was also instructed to identify technology roadmaps to enable the science-driven exploration vision, established a cross-Enterprise, cross-Center systems engineering team with emphasis focused on revolutionary not evolutionary approaches. The strategy of the DPT and NEXT teams was to "Go Anywhere, Anytime" by conquering key exploration hurdles of space transportation, crew health and safety, human/robotic partnerships, affordable abundant power, and advanced space systems performance. Early emphasis was placed on revolutionary exploration concepts such as rail gun and electromagnetic launchers, propellant depots, retrograde trajectories, nano structures, and gas core nuclear rockets to name a few. Many of these revolutionary concepts turned out to be either not feasible for human exploration missions or well beyond expected technology readiness for near-term implementation. During the DPT and NEXT study cycles, several architectures were analyzed including missions to the Earth-Sun Libration Point (L2), the Earth-Moon Gateway and L1, the lunar surface, Mars (both short and long stays), one-year round trip Mars, and near-Earth asteroids. Common emphasis of these studies included utilization of the Earth-Moon Libration Point (L1) as a staging point for exploration activities, current (Shuttle) and near-term launch capabilities (EELV), advanced propulsion, and robust space power. Although there was much emphasis placed on utilization of existing launch capabilities, the team concluded that missions in near-Earth space are only marginally feasible and human missions to Mars were not feasible without a heavy lift launch capability. In addition, the team concluded that missions in Earth s neighborhood, such as to the Moon, can serve as stepping-stones toward further deep-space missions in terms of proving systems, technologies, and operational concepts. The material contained in this presentation was compiled to capture the work performed by the Mars Sub-Team of the DPT NEXT efforts in the late 1999-2001 timeframe.

Drake, Bret G.↗

Generation of Data-Rate Profiles of Ka-Band Deep-Space Links

A short report discusses a methodology for designing Ka-band Deep-Space-to- Earth radio-communication links. This methodology is oriented toward minimizing the effects of weather on the Ka-band telecommunication link by maximizing the expected data return subject to minimum link availability and a limited number of data rates. This methodology differs from the current standard practices in which a link is designed according to a margin policy for a given link availability at 10 elevation. In this methodology, one chooses a data-rate profile that will maximize the average data return over a pass while satisfying a minimum-availability requirement for the pass, subject to mission operational limitations expressed in terms of the number of data rates used during the pass. The methodology is implemented in an intelligent search algorithm that first finds the allowable data-rate profiles from the mission constraints, spacecraft-to-Earth distance, spacecraft EIRP (effective isotropic radiated power), and the applicable zenith atmospheric noise temperature distribution, and then selects the best data rate in terms of maximum average data return from the set of allowable data-rate profiles.

Shambayati, Shervin↗

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗