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NASA NTRS1981

MSFC evaluation of the space fabrication demonstration system (beam builder)

The beam builder, designed and manufactured as a ground demonstration model, is a precursor to a machine for use in the space environment, transportable by the space shuttle. The beam builder has the capability to automatically fabricate triangular truss beams in low Earth orbit with a highly reliable machine that requires a minimum of in-space maintenance and repair. A performance assessment of the beam builder, which was fabricated from commercial hardware is given.

Adams, E. O.↗

NASA NTRS1988

Pathfinder: Surface exploration, in-space operations and space transfer

Viewgraphs on the Pathfinder program are presented. Information is given on technology needs, a planetary rover, program management, an autonomous lander, mission applications, orbital assembly, cryogenics, space nuclear reactors, space manufacturing, optical communications, spacecraft propulsion, aerobraking, and orbital transfer vehicles.

Mankins, John↗

NASA NTRS1995

Prospects for commercialization of SELV-based in-space operations

A workshop was hosted by the Langley Research Center as a part of an activity to assess the commercialization potential of Small Expendible Launch Vehicle-based in-space operations. Representatives of the space launch insurance industry, industrial consultants, producers of spacecraft, launch vehicle manufacturers, and government researchers constituted the participants. The workshop was broken into four sessions: Customers Small Expendible Launch Systems, Representative Missions, and Synthesis-Government role. This publication contains the presentation material, written synopses of the sessions, and conclusions developed at the workshop.

Katzberg, Stephen J.↗

NASA NTRS1995

SPARTNIK: Engineering catalyst for government and industry

Industrial demands for highly motivated and competent technical personnel to carry forward with the technological goals of the US has posed a significant challenge to graduating engineers. While curricula has improved and diversified over time to meet these industry demands, relevant industry experience is not always available to undergraduates. The microsatellite development program at San Jose State University (SJSU) has allowed an entire undergraduate senior class to utilize a broad range of training and education to refine their engineering skills, bringing them closer to becoming engineering professionals. Close interaction with industry mentors and manufacturers on a real world project provides a significant advantage to educators and students alike. With support from companies and government agencies, the students have designed and manufactured a microsatellite, designed to be launched into a low Earth orbit. This satellite will gather telemetry for characterizing the state of the spacecraft. This will enable the students to have a physical check on their predicted value of spacecraft subsystem performance. Additional experiments will also be undertaken during the two year lifetime, including micro-meteorite impact sensing and capturing digital color images of the Earth. This paper will detail the process whereby students designed, prototype and manufactured a small satellite in a large team environment, along with the experiments that will be performed on board. With the project's limited funds, it needed the support of many industry companies to help with technical issues and hardware acquisition. Among the many supporting companies, NASA's space shuttle small payloads program could be used for an affordable launch vehicle for the student project. The paper address these collaborations between the student project and industry support, as well as explaining the benefits to both. The paper draws conclusion on how these types of student projects can be used by industry as a feasible resource for developing small platforms for space based experiments, as well as increasing the practical experience and engineering knowledge of graduating students. These benefits to industry and universities, can lead to a close working relationship between the two. These types of projects can facilitate the development of low-cost space rated parts to be used by the industry and university projects. It can also help with the understanding and use of acceptable risk non-space rated parts reducing the cost of the spacecraft. This will lead to the development of low cost platforms for space based experiments, providing research companies an inexpensive, long duration platform to conduct their in-space experiments, while better preparing engineering undergraduates for their transition into the work force.

Prass, James D.↗

NASA NTRS1998

Status of the Advanced Reusable Technologies Project

The Advanced Reusable Technologies (ART) Project, part of the Advanced Space Transportation Program Office at the NASA's Marshall Space Flight Center in Huntsville, Ala., focuses on future reusable technologies beyond those being pursued by X-33. The prime objective of the project is to dramatically reduce the cost of access to space. In April 1996, an NRA was issued soliciting proposals for tasks focusing on rocket-based combined cycle propulsion system (RBCC). In August of 1996, five contractors were selected for a two year period to design and ground test their RBCC engine concepts. The work on these contracts should be completed by the end of this year. In March of this year, another NRA was issued to solicit inputs for reusable vehicle and propulsion technologies applicable to earth-to-orbit and in-space transportation. The current RBCC effort is the first of three phases leading to a large scale flight demonstrations of the technology for space launch vehicle propulsion. This first phase will provide initial verification of proposed concepts through ground demonstration of combined rocket/air breathing propulsion technologies. Using the most promising concepts identified in the first phase, the second phase will design, manufacture and ground test flight-type engine(s) to demonstrate actual design weights and performance. In the third phase, the first flight of a sub-scale integrated X-vehicle is planned for 2002. This paper describes the current status, plans and progress of the ART Project.

Hueter, Ume↗

NASA NTRS2005

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The fulfillment of the new US. National Vision for Space Exploration requires many new enabling technologies to accomplish the goal of utilizing space for commercial activities and for returning humans to the moon and extraterrestrial environments. Traditionally, flight structures are manufactured as complete systems and require humans to complete the integration and assembly in orbit. These structures are bulky and require the use of heavy launch vehicles to send the units to the desired location, e.g. International Space Station (ISS). This method requires a high degree of safety, numerous space walks and significant cost for the humans to perform the assembly in orbit. For example, for assembly and maintenance of the ISS, 52 Extravehicular Activities (EVA's) have been performed so far with a total EVA time of approximately 322 hours. Sixteen (16) shuttle flights haw been to the ISS to perform these activities with an approximate cost of $450M per mission. For future space missions, costs have to be reduced to reasonably achieve the exploration goals. One concept that has been proposed is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly operations. Assembly is autonomously performed when two components containing onboard electronics join after recognizing that the joint is appropriate and in the precise position and orientation required for assembly. The mechanism only activates when the specifications are correct and m a nominal range. After assembly, local sensors and electronics monitor the integrity of the joint for feedback to a master controller. To achieve this concept will require a shift in the methods for designing space structures. In addition, innovative techniques will be required to perform the assembly autonomously. Monitoring of the assembled joint will be necessary for safety and structural integrity. If a very large structure is to be assembled in orbit, then the number of integrity sensors will be significant. Thus simple, low cost sensors are integral to the success of this concept. This paper will address these issues and will propose a novel concept for assembling space structures autonomously. The paper will present Several autonomous assembly methods. Core technologies required to achieve in space assembly will be discussed and novel techniques for communicating, sensing, docking and assembly will be detailed. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Finally, these technologies can also be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

NASA NTRS2001

Specimens Prepared for Materials International Space Station Experiment

The Materials International Space Station Experiment (MISSE) is a materials flight experiment sponsored by the Materials and Manufacturing Directorate of the Air Force Research Laboratory at Wright-Patterson Air Force Base and the NASA Space Environmental Effects Program at the NASA Marshall Space Flight Center. MISSE is a cooperative effort among the Air Force, several NASA field centers, and industry. The experiment package will be placed on the exterior of the International Space Station in the summer of 2001. Approximately half of the specimens will be exposed to the space environment for 1 year, and the other half will be exposed for 3 years. The Electro-Physics Branch at the NASA Glenn Research Center has prepared and delivered over 150 specimens to be included in MISSE. Specimens include: 1) Double-coated polyimide Kapton to compare mass loss from in-space atomic oxygen undercutting erosion to ground-laboratory atomic oxygen undercutting erosion for predicting in-space durability; 2) Silicones to study changes in surface hardness and optical properties after combined atomic oxygen--ultraviolet radiation exposure for predicting in-space durability; 3) Forty-one different polymers to accurately measure their atomic oxygen erosion yields; 4) Scattering chambers to study atomic oxygen scattering characteristics that are relevant to the degradation found in spacecraft with exterior openings; 5) Thin polymer film disks and tensile specimens to study the effects of radiation on their optical properties and mechanical properties; 6) Lightweight intercalated graphite epoxy composites to study electromagnetic interference shielding performance; and 7) Polymer-based materials utilizing new atomic oxygen protection concepts to study their durability.

Banks, Bruce A.↗

NASA NTRS2001

Next-Generation Ion Propulsion Being Developed

The NASA Glenn Research Center ion-propulsion program addresses the need for high specific-impulse systems and technology across a broad range of mission applications and power levels. One activity is the development of the next-generation ion-propulsion system as a follow-on to the successful Deep Space 1 system. The system is envisioned to incorporate a lightweight ion engine that can operate over 1 to 10 kW, with a 550-kg propellant throughput capacity. The engine concept under development has a 40-cm beam diameter, twice the effective area of the Deep Space 1 engine. It incorporates mechanical features and operating conditions to maximize the design heritage established by the Deep Space 1 engine, while incorporating new technology where warranted to extend the power and throughput capability. Prototype versions of the engine have been fabricated and are under test at NASA, with an engineering model version in manufacturing. Preliminary performance data for the prototype engine have been documented over 1.1- to 7.3-kW input power. At 7.3 kW, the engine efficiency is 0.68, at 3615-sec specific impulse. Critical component temperatures, including those of the discharge cathode assembly and magnets, have been documented and are within established limits, with significant margins relative to the Deep Space 1 engine. The 1- to 10-kW ion thruster approach described here was found to provide the needed power and performance improvement to enable important NASA missions. The Integrated In-Space Transportation Planning (IISTP) studies compared many potential technologies for various NASA, Government, and commercial missions. These studies indicated that a high-power ion propulsion system is the most important technology for development because of its outstanding performance versus perceived development and recurring costs for interplanetary solar electric propulsion missions. One of the best applications of a highpower electric propulsion system was as an integral part of a solar electric propulsion (SEP) stage to send a payload to outer planet targets. The IISTP studies showed that either trip time or launch vehicle class could be significantly reduced when compared with state-of-the-art systems.

Patterson, Michael J.↗

NASA NTRS2005

Novel Space-based Solar Power Technologies and Architectures for Earth and Beyond

Research, development and studies of novel space-based solar power systems, technologies and architectures for Earth and beyond are needed to reduce the cost of clean electrical power for terrestrial use and to provide a stepping stone for providing an abundance of power in space, i.e., manufacturing facilities, tourist facilities, delivery of power between objects in space, and between space and surface sites. The architectures, technologies and systems needed for space to Earth applications may also be used for in-space applications. Advances in key technologies, i.e., power generation, power management and distribution, power beaming and conversion of beamed power are needed to achieve the objectives of both terrestrial and extraterrestrial applications. Power beaming or wireless power transmission (WPT) can involve lasers or microwaves along with the associated power interfaces. Microwave and laser transmission techniques have been studied with several promising approaches to safe and efficient WPT identified. These investigations have included microwave phased array transmitters, as well as laser transmission and associated optics. There is a need to produce "proof-of-concept" validation of critical WPT technologies for both the near-term, as well as far-term applications. Investments may be harvested in near-term beam safe demonstrations of commercial WPT applications. Receiving sites (users) include ground-based stations for terrestrial electrical power, orbital sites to provide power for satellites and other platforms, future space elevator systems, space vehicle propulsion, and space to surface sites. This paper briefly discusses achieving a promising approach to the solar power generation and beamed power conversion. The approach is based on a unique high-power solar concentrator array called Stretched Lens Array (SLA) for both solar power generation and beamed power conversion. Since both versions (solar and laser) of SLA use many identical components (only the photovoltaic cells need to be different), economies of manufacturing and scale may be realized by using SLA on both ends of the laser power beaming system in a space solar power application. Near-term uses of this SLA-laser-SLA system may include terrestrial and space exploration in near Earth space. Later uses may include beamed power for bases or vehicles on Mars.

Howell, Joe T.↗

NASA NTRS2006

Rapid Development of Gossamer Propulsion for NASA Inner Solar System Science Missions

Over a two and one-half year period dating from 2003 through 2005, NASA s In-Space Propulsion Program matured solar sail technology from laboratory components to full systems, demonstrated in as relevant a space environment as could feasibly be simulated on the ground. This paper describes the challenges identified; as well as the approaches taken toward solving a broad set of issues spanning material science, manufacturing technology, and interplanetary trajectory optimization. Revolutionary advances in system structural predictive analysis and characterization testing occurred. Also addressed are the remaining technology challenges that might be resolved with further ground technology research, geared toward reducing technical risks associated with future space validation and science missions.

Young, Roy M.↗

NASA NTRS2006

2006 Status of the Momentum eXchange Electrodynamic Re-Boost (MXER) Tether Development

The MXER Tether technology development is a high-payoff/high-risk investment area within the NASA In-Space Propulsion Technology (ISPT) Program. The ISPT program is managed by the NASA Headquarters Science Mission Directorate and implemented by the Marshall Space Flight Center in Huntsville, Alabama. The MXER concept was identified and competitively ranked within NASA's comprehensive Integrated In-Space Transportation Plan (IISTP); an agency-wide technology assessment activity. The objective of the MXER tether project within ISPT is to advance the technological maturation level for the MXER system, and its subsystems, as well as other space and terrestrial tether applications. Recent hardware efforts have focused on the manufacturability of space-survivable high-strength tether material and coatings, high-current electrodynamic tether, lightweight catch mechanism, high-accuracy propagator/predictor code, and efficient electron collection/current generation. Significant technical progress has been achieved with modest ISPT funding to the extent that MXER has evolved to a well-characterized system with greater capability as the design has been matured. Synergistic efforts in high-current electrodynamic tethers and efficient electron collection/current generation have been made possible through SBIR and STTR support. The entire development endeavor was orchestrated as a collaborative team effort across multiple individual contracts and has established a solid technology resource base, which permits a wide variety of future space cable/tether applications to be realized.

Bonometti, Joseph A.↗

NASA NTRS2006

Advanced Energy Conversion Technologies and Architectures for Earth and Beyond

Research, development and studies of novel space-based solar power systems, technologies and architectures for Earth and beyond are needed to reduce the cost of clean electrical power for terrestrial use and to provide a stepping stone for providing an abundance of power in space, i.e., manufacturing facilities, tourist facilities, delivery of power between objects in space, and between space and surface sites. The architectures, technologies and systems needed for space to Earth applications may also be used for in-space applications. Advances in key technologies, i.e., power generation, power management and distribution, power beaming and conversion of beamed power are needed to achieve the objectives of both terrestrial and extraterrestrial applications. There is a need to produce "proof-ofconcept" validation of critical WPT technologies for both the near-term, as well as far-term applications. Investments may be harvested in near-term beam safe demonstrations of commercial WPT applications. Receiving sites (users) include ground-based stations for terrestrial electrical power, orbital sites to provide power for satellites and other platforms, future space elevator systems, space vehicle propulsion, and space surface sites. Space surface receiving sites of particular interest include the areas of permanent shadow near the moon s North and South poles, where WPT technologies could enable access to ice and other useful resources for human exploration. This paper discusses work addressing a promising approach to solar power generation and beamed power conversion. The approach is based on a unique high-power solar concentrator array called Stretched Lens Array (SLA) applied to both solar power generation and beamed power conversion. Since both versions (solar and laser) of SLA use many identical components (only the photovoltaic cells need to be different), economies of manufacturing and scale may be realized by using SLA on both ends of the laser power beaming system in a space solar power application. Near-term uses of this SLA-laser-SLA system may include terrestrial and space exploration in near Earth space. Later uses may include beamed power for bases or vehicles on Mars. Strategies for developing energy infrastructures in space which utilize this technology are presented. This dual use system produces electrical energy efficiently from either coherent light, such as from a highly coherent laser, or from conventional solar illumination. This allows, for example, supplementing solar energy with energy provided by highly coherent laser illumination during periods of low solar illumination or no illumination. This reduces the need for batteries and alternate sources of power. The capability of using laser illumination in a lowest order Gaussian laser mode provides means for transmitting power optically with maximum efficiency and precision over the long distances characteristic of space. A preliminary receiving system similar to that described here, has been produced and tested under solar and laser illumination. A summary of results is given.

Howell, Joe T.↗

NASA NTRS2007

Electron Beam Freeform Fabrication in the Space Environment

The influence of reduced gravitational forces (in space and on the lunar or Martian surfaces) on manufacturing processes must be understood for effective fabrication and repair of structures and replacement parts during long duration space missions. The electron beam freeform fabrication (EBF3) process uses an electron beam and wire to fabricate metallic structures. The process efficiencies of the electron beam and the solid wire feedstock make the EBF3 process attractive for use in-space. This paper will describe the suitability of the EBF3 process in the space environment and will highlight preliminary testing of the EBF3 process in a zero-gravity environment.

Hafley, Robert A.↗

NASA NTRS2007

Aerocapture Technology Developments from NASA's In-Space Propulsion Technology Program

This paper will explain the investment strategy, the role of detailed systems analysis, and the hardware and modeling developments that have resulted from the past 5 years of work under NASA's In-Space Propulsion Program (ISPT) Aerocapture investment area. The organizations that have been funded by ISPT over that time period received awards from a 2002 NASA Research Announcement. They are: Lockheed Martin Space Systems, Applied Research Associates, Inc., Ball Aerospace, NASA's Ames Research Center, and NASA's Langley Research Center. Their accomplishments include improved understanding of entry aerothermal environments, particularly at Titan, demonstration of aerocapture guidance algorithm robustness at multiple bodies, manufacture and test of a 2-meter Carbon-Carbon "hot structure," development and test of evolutionary, high-temperature structural systems with efficient ablative materials, and development of aerothermal sensors that will fly on the Mars Science Laboratory in 2009. Due in large part to this sustained ISPT support for Aerocapture, the technology is ready to be validated in flight.

Munk, Michelle M.↗

NASA NTRS2008

Aerocapture Technology Development Overview

This paper will explain the investment strategy, the role of detailed systems analysis, and the hardware and modeling developments that have resulted from the past 5 years of work under NASA's In-Space Propulsion Program (ISPT) Aerocapture investment area. The organizations that have been funded by ISPT over that time period received awards from a 2002 NASA Research Announcement. They are: Lockheed Martin Space Systems, Applied Research Associates, Inc., Ball Aerospace, NASA s Ames Research Center, and NASA s Langley Research Center. Their accomplishments include improved understanding of entry aerothermal environments, particularly at Titan, demonstration of aerocapture guidance algorithm robustness at multiple bodies, manufacture and test of a 2-meter Carbon-Carbon "hot structure," development and test of evolutionary, high-temperature structural systems with efficient ablative materials, and development of aerothermal sensors that will fly on the Mars Science Laboratory in 2009. Due in large part to this sustained ISPT support for Aerocapture, the technology is ready to be validated in flight.

Munk, Michelle M.↗

NASA NTRS2008

Plasma Processing of Lunar Regolith Simulant for Diverse Applications

Versatile manufacturing technologies for extracting resources from the moon are needed to support future space missions. Of particular interest is the production of gases and metals from lunar resources for life support, propulsion, and in-space fabrication. Deposits made from lunar regolith could yield highly emissive coatings and near-net shaped parts for replacement or repair of critical components. Equally important is development of high fidelity lunar simulants for ground based validation of potential lunar surface operations. Described herein is an innovative plasma processing technique for insitu production of gases, metals, coatings, and deposits from lunar regolith, and synthesis of high fidelity lunar simulant from NASA issued lunar simulant JSC-1. Initial plasma reduction trials of JSC-1 lunar simulant have indicated production of metallic iron and magnesium. Evolution of carbon monoxide has been detected subsequent to reduction of the simulant using the plasma process. Plasma processing of the simulant has also resulted in glassy phases resembling the volcanic glass and agglutinates found in lunar regolith. Complete and partial glassy phase deposits have been obtained by varying the plasma process variables. Experimental techniques, product characterization, and process gas analysis will be discussed.

Schofield, Elizabeth C.↗

NASA NTRS2006

Solar Sails

The Solar Sail Propulsion investment area has been one of the three highest priorities within the In-Space Propulsion Technology (ISPT) Project. In the fall of 2003, the NASA Headquarters' Science Mission Directorate provided funding and direction to mature the technology as far as possible through ground research and development from TRL 3 to 6 in three years. A group of experts from government, industry, and academia convened in Huntsville, Alabama to define technology gaps between what was needed for science missions to the inner solar system and the current state of the art in ultra1ightweight materials and gossamer structure design. This activity set the roadmap for development. The centerpiece of the development would be the ground demonstration of scalable solar sail systems including masts, sails, deployment mechanisms, and attitude control hardware and software. In addition, new materials would be subjected to anticipated space environments to quantify effects and assure mission life. Also, because solar sails are huge structures, and it is not feasible to validate the technology by ground test at full scale, a multi-discipline effort was established to develop highly reliable analytical models to serve as mission assurance evidence in future flight program decision-making. Two separate contractor teams were chosen to develop the SSP System Ground Demonstrator (SGD). After a three month conceptual mission/system design phase, the teams developed a ten meter diameter pathfinder set of hardware and subjected it to thermal vacuum tests to compare analytically predicted structural behavior with measured characteristics. This process developed manufacturing and handling techniques and refined the basic design. In 2005, both contractor teams delivered 20 meter, four quadrant sail systems to the largest thermal vacuum chamber in the world in Plum Brook, Ohio, and repeated the tests. Also demonstrated was the deployment and articulation of attitude control mechanisms. In conjunction with these tests, the stowed sails were subjected to launch vibration and ascent vent tests. Other investments studied radiation effects on the solar sail materials, investigated spacecraft charging issues, developed shape measuring techniques and instruments, produced advanced trajectory modeling capabilities, and identified and resolved gossamer structure dynamics issues. Technology validation flight and application to a He1iophysics science mission is on the horizon.

Young, Roy↗

NASA NTRS2009

Recent Electric Propulsion Development Activities for NASA Science Missions

(The primary source of electric propulsion development throughout NASA is managed by the In-Space Propulsion Technology Project at the NASA Glenn Research Center for the Science Mission Directorate. The objective of the Electric Propulsion project area is to develop near-term electric propulsion technology to enhance or enable science missions while minimizing risk and cost to the end user. Major hardware tasks include developing NASA s Evolutionary Xenon Thruster (NEXT), developing a long-life High Voltage Hall Accelerator (HIVHAC), developing an advanced feed system, and developing cross-platform components. The objective of the NEXT task is to advance next generation ion propulsion technology readiness. The baseline NEXT system consists of a high-performance, 7-kW ion thruster; a high-efficiency, 7-kW power processor unit (PPU); a highly flexible advanced xenon propellant management system (PMS); a lightweight engine gimbal; and key elements of a digital control interface unit (DCIU) including software algorithms. This design approach was selected to provide future NASA science missions with the greatest value in mission performance benefit at a low total development cost. The objective of the HIVHAC task is to advance the Hall thruster technology readiness for science mission applications. The task seeks to increase specific impulse, throttle-ability and lifetime to make Hall propulsion systems applicable to deep space science missions. The primary application focus for the resulting Hall propulsion system would be cost-capped missions, such as competitively selected, Discovery-class missions. The objective of the advanced xenon feed system task is to demonstrate novel manufacturing techniques that will significantly reduce mass, volume, and footprint size of xenon feed systems over conventional feed systems. This task has focused on the development of a flow control module, which consists of a three-channel flow system based on a piezo-electrically actuated valve concept, as well as a pressure control module, which will regulate pressure from the propellant tank. Cross-platform component standardization and simplification are being investigated through the Standard Architecture task to reduce first user costs for implementing electric propulsion systems. Progress on current hardware development, recent test activities and future plans are discussed.

Pencil, Eric J.↗