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NASA NTRS2021

Mass Inferencing Model Creation And Deployment To Lunar Excavation Robot, RASSOR

NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) Excavator is a teleoperated mobile robotic platform with a unique space regolith excavation capability. This research project developed functionality for inferencing regolith mass ingested during RASSOR operation, enhancing RASSOR’s ability to successfully complete ISRU missions. Radio wave propagation time to the Moon and back is ~2.56 seconds. Though teleoperation is possible with this delay, autonomous capability that enables RASSOR to plan and execute excavation missions intelligently and efficiently is preferred. To teleoperate or run autonomously, it is crucial for the quantity of regolith mass ingested by RASSOR to be available as a system state for efficient operation (e.g. knowledge of whether drums are full informs the task of highest priority, whether it be continuing to dig, or returning to a processing plant to offload regolith). A configurable data reduction and analysis pipeline was created to allow for straightforward incorporation of new data, such as that from lunar excavation, to improve model performance in new environments. Four distinct modeling approaches were employed in developing a mass inferencing approach that could work on RASSOR. All four models take in system states and output a mass prediction for each set of the robot’s bucket drums. Initial results from deployment to RASSOR and testing in a simulated lunar environment show that the models have <10% mean error during robot operation. Future work includes refinement of a model that estimates regolith mass in real-time during excavation as well as further testing of the developed models on the hardware.

ROS↗

NASA NTRS2015

Mars ISRU for Production of Mission Critical Consumables - Options, Recent Studies, and Current State of the Art

In 1978, a ground breaking paper titled, "Feasibility of Rocket Propellant Production on Mars" by Ash, Dowler, and Varsi discussed how ascent propellants could be manufactured on the Mars surface from carbon dioxide collected from the atmosphere to reduce launch mass. Since then, the concept of making mission critical consumables such as propellants, fuel cell reactants, and life support consumables from local resources, commonly known as In-Situ Resource Utilization (ISRU), for robotic and human missions to Mars has been studied many times. In the late 1990's, NASA initiated a series of Mars Human Design Reference Missions (DRMs), the first of which was released in 1997. These studies primarily focused on evaluating the impact of making propellants on Mars for crew ascent to Mars orbit, but creating large caches of life support consumables (water & oxygen) as a backup for regenerative life support systems for long-duration surface stays (>500 days) was also considered in Mars DRM 3.0. Until science data from the Mars Odyssey orbiter and subsequent robotic missions revealed that water may be widely accessable across the surface of Mars, prior Mars ISRU studies were limited to processing Mars atmospheric resources (carbon dioxide, nitrogen, argon, oxygen, and water vapor). In December 2007, NASA completed the Mars Human Design Reference Architecture (DRA) 5.0 study which considered water on Mars as a potential resource for the first time in a human mission architecture. While knowledge of both water resources on Mars and the hardware required to excavate and extract the water were very preliminary, the study concluded that a significant reduction in mass and significant enhancements to the mission architecture were possible if Mars water resources were utilized. Two subsequent Mars ISRU studies aimed at reexamining ISRU technologies, processing options, and advancements in the state-of-the-art since 2007 and to better understand the volume and packaging associated with Mars ISRU systems further substantiated the preliminary results from the Mars DRA 5.0 study. This paper will provide an overview of Mars ISRU consumable production options, the analyses, results, and conclusions from the Mars DRA 5.0 (2007), Mars Collaborative (2013), and Mars ISRU Payload for the Supersonic Retro Propulsion (2014) mission studies, and the current state-of-the-art of Mars ISRU technologies and systems. The paper will also briefly discuss the mission architectural implications associated with Mars resource and ISRU processing options.

Sanders, G. B.↗

NASA NTRS2017

A Diagnosis-Prognosis Feedback Loop for Improved Performance Under Uncertainties

The feed-forward relationship between diagnosis and prognosis is the foundation of both aircraft structural health management and the digital twin concept. Measurements of structural response are obtained either in-situ with mounted sensor networks or offline using more traditional techniques (e.g., nondestructive evaluation). Diagnosis algorithms process this information to detect and quantify damage and then feed this data forward to a prognostic framework. A prognosis of the structure's future operational readiness (e.g., remaining useful life or residual strength) is then made and is used to inform mission- critical decision-making. Years of research have been devoted to improving the elements of this process, but the process itself has not changed significantly. Here, a new approach is proposed in which prognosis information is not only fed forward for decision-making, but it is also fed back to the forthcoming diagnosis. In this way, diagnosis algorithms can take advantage of a priori information about the expected state of health, rather than operating in an uninformed condition. As a feasibility test, a diagnosis-prognosis feedback loop of this manner is demonstrated. The approach is applied to a numerical example in which fatigue crack growth is simulated in a simple aluminum alloy test specimen. A prognosis was derived from a set of diagnoses which provided feedback to a subsequent set of diagnoses. Improvements in accuracy and a reduction in uncertainty in the prognosis- informed diagnoses were observed when compared with an uninformed diagnostic approach.

Leser, Patrick E.↗

NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic Composites for Aerospace Applications

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and faster production. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are directly influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Within thermoplastic PMC parts, crystallinity gradients can arise due to variations in part geometry, across part thicknesses, and along bonded joints. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials meet the high demands required for aerospace. Several different analytical techniques exist that can be used to characterize the bulk crystallinity of thermoplastic materials. However, many existing methods lack the specificity required to identify the subtle variations in crystallinity that may play a significant role in the performance and durability of PMC parts. Because of this, a significant amount of work is still required to fully characterize and understand the crystallinity profiles of thermoplastic PMCs and the resulting impact to material properties. This talk discusses the use of multiple techniques such as Differential Scanning Calorimetry, Polarized Light Optical Microscopy, and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in carbon fiber/thermoplastic composites. Samples of different crystallinity profiles were manufactured using various cooling procedures. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in aerospace applications.

Thermoplastics↗

NASA NTRSDate not supplied

Metallic Powder Core Tubular Wire (PCTW) Development for Additive Manufacturing

NASA Langley Research Center (LaRC) in Hampton, VA, and the Center for Welding, Joining, and Coating Research (CWJCR) in the Department of Metallurgical and Materials Engineering at the Colorado School of Mines (CSM) in Golden, CO, have collaborated for nearly fifteen years to develop metallic powder core tubular wire (PCTW) feedstock for additive manufacturing (AM) using electron beam deposition. The motivation for this development was to offset dealloying observed during deposition of titanium and aluminum alloy solid wire feedstock in the LaRC electron beam freeform fabrication (EBF3) system and to explore novel alloy compositions by tailoring the powder fill. EBF3 is a fusion-based AM process that is performed under vacuum and is consequently prone to vaporization loss of low vapor pressure alloying elements. Research spanning four graduate student research projects succeeded in developing the basic methodology to fabricate PCTW, the mass balance equations used to define the powder fill, microstructure control through particulate inoculation, and the feasibility of producing metal matrix composite materials. Metallic PCTW is comprised of a thin foil sheath wrapped around a powder blend. Fabrication of PCTW at CSM was accomplished using a tubular wire mill system to first bend a flat strip into a u-shaped cross section, deposit a powder fill, create a lap joint to seal the wire, and draw to final diameter. Powder management systems were developed to ensure uniform mixing of powder constituents and identify feed rates for optimum fill ratios. Processing parameters were successfully developed for titanium and aluminum alloy sheaths to account for material work hardening during drawing. Mass balance equations were developed to account for compositional contributions of the sheath and powder fill. PCTW composition can be adjusted through selection of the sheath or powder materials. PCTWs were successfully developed to offset Al loss in deposits of Ti-6-4 and Mg loss in Al 6061, resulting in deposits that were within the composition limits for each material. Ti-6-4 deposits were fabricated using PCTW comprised of commercially pure (CP) titanium sheath and a fill of pre-alloyed Ti-6-4 powder with additions of elemental Al and V powders. Additions of both elements were required to account for the CP Ti from the sheath, and Al was further enhanced to offset documented losses in EBF3 deposits. For Al 6061 deposits, composition was modulated through the choice of sheath material. The PCTW was made using an Al 5052 sheath to supplement Mg content and a fill composition of pre-alloyed 6061 powder with additions of Si and Cu.The slower solidification rate of the EBF3 process compared with laser powder bed fusion processes can lead to coarse-grained microstructures and mechanical property anisotropy. EBF3deposits of Ti-6-4 exhibited large epitaxially grown β grains, which result in degraded mechanical properties in the deposition direction. Microstructure refinement was achieved through a combination of electron beam modulation and the use of a PCTW designed for Ti-6-4 deposits and modified by the addition of powder made from Fe and B. Resulting deposits exhibited reductions in β grain size, α phase colony intercept length and lath width, and an increased volume fraction of β phase. The mechanism of microstructure refinement was related to precipitation of boride particles. Hardness testing confirmed that mechanical property anisotropy was reduced and an overall increase in hardness was achieved.Metal matrix composite (MMC) materials offer strength and stiffness benefits over unreinforced materials. Two methods were investigated using PCTW technology for producing Al 6061 basedMMC materials; the direct addition of SiC reinforcing particles and the in-situ generation of reinforcements through reaction synthesis of precursor powders. Al 6061 based MMCs reinforced with SiC exhibited particle clustering and formation of aluminum carbides during deposition. The application of a Ni coating to the SiC particles prior to incorporation into the powder fill eliminated aluminum carbide formation and aided particle distribution during deposition. Modulation of beam focus and power further reduced aluminum carbide formation and aided particle distribution. In reaction synthesis, precursor additions undergo an exothermic reaction during deposition to form new ceramic products, generally of finer scale than the initial precursor components. The product phases provide reinforcement in the MMC and act as nucleation sites during solidification, resulting in grain refinement, improved mechanical properties, and reduced susceptibility to solidification cracking. Higher tensile strength and stiffness were demonstrated in Al 6061 based MMCs with 2 vol% reinforcement. These combined research efforts demonstrate the potential of PCTW technology for customizing of alloy composition and achieving microstructure control. A manufacturing process for titanium- and aluminum-based PCTWs was developed based on iterative design, theoretical calculations, and empirical data. PCTW technology successfully mitigated Al loss from Ti-6-4 and Mg loss in Al 6061, resulted in grain refinement in Ti-6-4, and demonstrated fabrication of Al based MMCs

Marcia S Domack↗

NASA NTRS2012

Long-Lasting Science Returns from the Apollo Heat Flow Experiments

The Apollo astronauts deployed geothermal heat flow instruments at landing sites 15 and 17 as part of the Apollo Lunar Surface Experiments Packages (ALSEP) in July 1971 and December 1972, respectively. These instruments continuously transmitted data to the Earth until September 1977. Four decades later, the data from the two Apollo sites remain the only set of in-situ heat flow measurements obtained on an extra-terrestrial body. Researchers continue to extract additional knowledge from this dataset by utilizing new analytical techniques and by synthesizing it with data from more recent lunar orbital missions such as the Lunar Reconnaissance Orbiter. In addition, lessons learned from the Apollo experiments help contemporary researchers in designing heat flow instruments for future missions to the Moon and other planetary bodies. For example, the data from both Apollo sites showed gradual warming trends in the subsurface from 1971 to 1977. The cause of this warming has been debated in recent years. It may have resulted from fluctuation in insolation associated with the 18.6-year-cycle precession of the Moon, or sudden changes in surface thermal environment/properties resulting from the installation of the instruments and the astronauts' activities. These types of reanalyses of the Apollo data have lead a panel of scientists to recommend that a heat flow probe carried on a future lunar mission reach 3 m into the subsurface, approx 0.6 m deeper than the depths reached by the Apollo 17 experiment. This presentation describes the authors current efforts for (1) restoring a part of the Apollo heat flow data that were left unprocessed by the original investigators and (2) designing a compact heat flow instrument for future robotic missions to the Moon. First, at the conclusion of the ALSEP program in 1977, heat flow data obtained at the two Apollo sites after December 1974 were left unprocessed and not properly archived through NASA. In the following decades, heat flow data from January 1975 through February 1976, as well as the metadata necessary for processing the data (the data reduction algorithm, instrument calibration data, etc.), were somehow lost. In 2010, we located 450 original master archival tapes of unprocessed data from all the ALSEP instruments for a period of April through June 1975 at the Washington National Records Center. We are currently extracting the heat flow data packets from these tapes and processing them. Second, on future lunar missions, heat flow probes will likely be deployed by a network of small robotic landers, as recommended by the latest Decadal Survey of the National Academy of Science. In such a scenario, the heat flow probe must be a compact system, and that precludes use of heavy excavation equipment such as a rotary drill for reaching the 3-m target depth. The new heat flow system under development uses a pneumatically driven penetrator. It utilizes a stem that winds out of a reel and pushes its conical tip into the regolith. Simultaneously, gas jets, emitted from the cone tip, loosen and blow away the soil. Lab experiments have demonstrated its effectiveness in lunar vacuum.

Nagihara, S.↗

NASA NTRS2012

NASA's Robotic Lunar Lander Development Project

Since early 2005, NASA's Robotic Lunar Lander Development (RLLD) office at NASA MSFC, in partnership with the Applied Physics Laboratory (APL), has developed mission concepts and preformed risk-reduction activities to address planetary science and exploration objectives uniquely met with landed missions. The RLLD team developed several concepts for lunar human-exploration precursor missions to demonstrate precision landing and in-situ resource utilization, a multi-node lunar geophysical network mission, either as a stand-alone mission, or as part of the International Lunar Network (ILN), a Lunar Polar Volatiles Explorer and a Mercury lander mission for the Planetary Science decadal survey, and an asteroid rendezvous and landing mission for the Exploration Precursor Robotics Mission (xPRM) office. The RLLD team has conducted an extensive number of risk-reduction activities in areas common to all lander concepts, including thruster testing, propulsion thermal control demonstration, composite deck design and fabrication, and landing leg stability and vibration. In parallel, the team has developed two robotic lander testbeds providing closed-loop, autonomous hover and descent activities for integration and testing of flight-like components and algorithms. A compressed-air test article had its first flight in September 2009 and completed over 150 successful flights. This small test article (107 kg dry/146 kg wet) uses a central throttleable thruster to offset gravity, plus 3 descent thrusters (~37lbf ea) and 6 attitude-control thrusters (~12lbf ea) to emulate the flight system with pulsed operation over approximately 10s of flight time. The test article uses carbon composite honeycomb decks, custom avionics (COTS components assembled in-house), and custom flight and ground software. A larger (206 kg dry/322 kg wet), hydrogen peroxide-propelled vehicle began flight tests in spring 2011 and fly over 30 successful flights to a maximum altitude of 30m. The monoprop testbed also uses a central gravity-canceling thruster and 3 descent thrusters, but has 12 attitude-control thrusters and a maximum flight time of over a minute. The testbed uses aluminum ortho-grid decks, an LN200-1 IMU, Roke Manor Radar Altimeter, Illunis optical cameras, Novatel Pro-Pak GPS truth data system, Pressure transducers & thermocouples for housekeeping, "In-Control" ground system software, and the core Flight Executive (cFE) modular software environment. The peroxide lander testbed is able to accept other sensors and algorithms for testing, both from within NASA and from other customers. Through these activities, the RLLD team has significantly reduced technical risks for all small and medium class robotic landers for the Moon and other airless planetary bodies.

Cohen, Barbara A.↗

NASA NTRS2009

A Landsat-Based Assessment of Mobile Bay Land Use and Land Cover Change from 1974 to 2008

The Mobile Bay region has experienced noteworthy land use and land cover (LULC) change in the latter half of the 20th century. Accompanying this change has been urban expansion and a reduction of rural land uses. Much of this LULC change has reportedly occurred since the landfall of Hurricane Frederic in 1979. The Mobile Bay region provides great economic and ecologic benefits to the Nation, including important coastal habitat for a broad diversity of fisheries and wildlife. Regional urbanization threatens the estuary s water quality and aquatic-habitat dependent biota, including commercial fisheries and avian wildlife. Coastal conservation and urban land use planners require additional information on historical LULC change to support coastal habitat restoration and resiliency management efforts. This presentation discusses results of a Gulf of Mexico Application Pilot project that was conducted in 2008 to quantify and assess LULC change from 1974 to 2008. This project was led by NASA Stennis Space Center and involved multiple Gulf of Mexico Alliance (GOMA) partners, including the Mobile Bay National Estuary Program (NEP), the U.S. Army Corps of Engineers, the National Oceanic and Atmospheric Administration s (NOAA s) National Coastal Data Development Center (NCDDC), and the NOAA Coastal Services Center. Nine Landsat images were employed to compute LULC products because of their availability and suitability for the application. The project also used Landsat-based national LULC products, including coastal LULC products from NOAA s Coastal Change & Analysis Program (C-CAP), available at 5-year intervals since 1995. Our study was initiated in part because C-CAP LULC products were not available to assess the region s urbanization prior to 1995 and subsequent to post Hurricane Katrina in 2006. This project assessed LULC change across the 34-year time frame and at decadal and middecadal scales. The study area included the majority of Mobile and Baldwin counties that encompass Mobile Bay. In doing so, each date of Landsat data was classified using an end-user defined modified Anderson level 1 classification scheme. LULC classifications were refined using a decision rule approach in conjunction with available C-CAP products. Individual dates of LULC classifications were validated by image interpretation of stratified random locations on raw Landsat color composite imagery in combination with higher resolution remote sensing and in-situ reference data. The results indicate that during the 34-year study period, urban areas increased from 96,688 to 150,227 acres, representing a 55.37% increase, or 1.63% per annum. Most of the identified urban expansion results from conversion of rural forest and agriculture to urban cover types. Final LULC mapping and metadata products were produced for the entire study area as well as watersheds of concern within the study area. Final project products, including LULC trend information, were incorporated into the Mobile Bay NEP State of the Bay report. Products and metadata were transferred to NOAA NCDDC to allow free online accessibility and use by GOMA partners and by the public.

Spruce, Joseph↗

NASA NTRSDate not supplied

Case Study for Lunar ISRU Systems Utilizing Polar Water

In-Situ Resource Utilization (ISRU) is key to long term presence at any extraterrestrial destination. Current NASA direction is to achieve a sustainable presence on the lunar surface by 2028. Mission plans currently target the lunar South Pole to leverage the extended periods of solar illumination and allows for potential access to water ice in the permanently shadowed areas around the poles. With water, it is possible to produce both fuel and oxidizer to fully refuel a vehicle. In order to address ISRU infusion into mission planning, a study of an end-to-end ISRU propellant production system was initiated to assess ISRU architectures and obtain mass and power estimates for each. The results of these case studies will be presented. For this study, The ISRU system architecture involved two sites; the mine site in a shadowed crater where water ice is excavated and extracted from the regolith and the propellant production site at an illuminated ridge where the water is processed into liquefied O2 and H2 propellants. Fixed hardware would be emplaced at each site, with two alternating water tankers to transport water between them. Notional lunar sites were identified for this architecture for baseline environmental parameters. Technology solutions for each subsystem were selected based on those with the highest fidelity models or those that have empirical laboratory data to anchor to. While power needs were identified for each location, a power solution was not prescribed, therefore the masses presented do not include surface power systems. The baseline case in this study assumed that 10 mT of oxygen, along with enough hydrogen to support a propulsion mixture ratio of 6, must be produced in 225 days. Therefore 15 mT of water would need to be collected and processed. The baseline solution resulted in a system mass of5 mT and a total required power of 68kW. The majority of the mass was split between the ridge site system and the two water tankers (2.6 mTand 1.8mTrespectively). The majority of the required power was with three subsystems at approximately 20 kW each: hydrogen liquefaction, electrolysis, and the water extractor subsystem. Trades for four key variables are also presented, namely production rate, water concentration, dry overburden depth, and number of water transport trips. This can be compared to a system that targets oxygen from the minerals in the surface regolith material. A carbothermal reduction reactor system was used for this comparison. The use of direct solar thermal energy to process the regolith and the ease of access of the resource resulted in significantly lower values for the oxygen case: approximately 2.7 mT and 11.8 kW. However, the mass trade would favor the water case over successive missions where the hydrogen up-mass of 2 mT per mission will accrue against the oxygen system.1Aerospace Research Engineer, Chemical and Thermal Propulsion Systems Branch, Senior Member.2Mechanical Engineer, Propulsion and Power Division/Energy Conversion Systems, 2101 Nasa Pkwy/Mailcode EP3 Houston, TX 77058, AIAA member.

Lunar↗

NASA NTRS2016

Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA)

The proposed paper will cover ongoing effort named HESTIA (Human Exploration Spacecraft Testbed for Integration and Advancement), led at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) to promote a cross-subsystem approach to developing Mars-enabling technologies with the ultimate goal of integrated system optimization. HESTIA also aims to develop the infrastructure required to rapidly test these highly integrated systems at a low cost. The initial focus is on the common fluids architecture required to enable human exploration of mars, specifically between life support and in-situ resource utilization (ISRU) subsystems. An overview of the advancements in both integrated technologies, in infrastructure, in simulation, and in modeling capabilities will be presented, as well as the results and findings of integrated testing,. Due to the enormous mass gear-ratio required for human exploration beyond low-earth orbit, (for every 1 kg of payload landed on Mars, 226 kg will be required on Earth), minimization of surface hardware and commodities is paramount. Hardware requirements can be minimized by reduction of equipment performing similar functions though for different subsystems. If hardware could be developed which meets the requirements of both life support and ISRU it could result in the reduction of primary hardware and/or reduction in spares. Minimization of commodities to the surface of mars can be achieved through the creation of higher efficiency systems producing little to no undesired waste, such as a closed-loop life support subsystem. Where complete efficiency is impossible or impractical, makeup commodities could be manufactured via ISRU. Although, utilization of ISRU products (oxygen and water) for crew consumption holds great promise of reducing demands on life support hardware, there exist concerns as to the purity and transportation of commodities. To date, ISRU has been focused on production rates and purities for propulsion needs. The meshing of requirements between all potential users, producers, and cleaners of oxygen and water is crucial to guiding the development of technologies which will be used to perform these functions. Various new capabilities are being developed as part of HESTIA, which will enable the integrated testing of these technologies. This includes the upgrading of a 20' diameter habitat chamber to eventually support long duration (90+ day) human-in-the-loop testing of advanced life support systems. Additionally, a 20' diameter vacuum chamber is being modified to create Mars atmospheric pressures and compositions. This chamber, designated the Mars Environment Chamber (MEC), will eventually be upgraded to include a dusty environment and thermal shroud to simulate conditions on the surface of Mars. In view that individual technologies will be in geographically diverse locations across NASA facilities and elsewhere in the world, schedule and funding constraints will likely limit the frequency of physical integration. When this is the case, absent subsystems can be either digitally or physically simulated. Using the Integrated Power Avionics and Software (iPAS) environment, HESTIA is able to bring together data from various subsystems in simulated surroundings, insert faults, errors, time delays, etc., and feed data into computer models or physical systems capable of reproducing the output of the absent subsystems for the consumption of a local subsystems. Although imperfect, this capability provides opportunities to test subsystem integration and interactions at a fraction of the cost. When a subsystem technology is too immature for integrated testing, models can be produced using the General-Use Nodal Network Solver (GUNNS) capability to simulate the overall system performance. In doing so, even technologies not yet on the drawing board can be integrated and overall system performance estimated. Through the integrated development of technologies, as well as of the infrastructure to rapidly and at a low cost, model, simulate, and test subsystem technologies early in their development, HESTIA is pioneering a new way of developing the future of human space exploration.

Banker, Brian F.↗

NASA NTRS2021

Pyrolysis Rate and Yield Strength Reduction Incarbon Fiber and Glass Fiber Composites Underreentry Heating Conditions

The behavior of composite materials, specifically carbon fiber reinforced plastic (CFRP) and glass fiber reinforced plastic (GFRP), under reentry conditions poses a problem for space debris reentry risk modeling. Since these materials pyrolyze rather than melt and their different components demise at different rates, modeling their destruction to determine ground impact risk is complex. Modern spacecraft are using these materials in ever-greater quantities owing to their superior strength-to-weight characteristics, and this has required that the orbital debris community improve its understanding of how these materials demise on reentry. The NASA Orbital Debris Program Office undertook an extensive test campaign to better understand the rate at which several types of GFRP and CFRP materials pyrolyze under reentry heating conditions and how that pyrolysis affects the ultimate strength of the material. GFRP with a polyester resin (G10/FR-4) and CFRP with epoxy, cyanate ester, vinyl ester, and phenolic resins were tested. The test campaign was carried out at the Inductively Coupled Plasma (ICP) Torch Facility at the University of Texas at Austin. Because the ICP facility operates in a shirt-sleeve environment, test samples can be changed within seconds or minutes, allowing many samples to be tested in a short period. Two heat flux rates, 20 W/m2 and 30W/m2, and two oxygen concentration conditions, 0% and 2% of atmospheric, were applied to all five types of material. To measure both the char rate and the effect of pyrolysis on the ultimate material strength, two types of test were carried out for each material: a char rate test on a ~10 mm thick sample of material and an in-situ bending stress test of a ~2 mm thick sample of material. Measurements of the char rate showed very similar average pyrolysis front velocity in epoxy resin CFRP as in G10 at 3.6 mm/min and 3.4 mm/min, respectively. However, the total mass loss rate in theG10 was nearly double that of the CFRP at 3.8 g/min and 2.2 g/min, respectively. This result represented a slow ablation rate of carbon fibers in the CFRP at the temperatures encountered in low Earth orbit reentry and a comparatively rapid removal of the glass fibers in G10 due to melting and spallation. Pyrolysis front velocity was more significantly affected by the type of plastic than the type of fiber, with the cyanate ester CFRP samples displaying an average pyrolysis front velocity of only 1.9 mm/min. Similarly, the effect of thermal exposure on the ultimate strength of the material depended heavily on the type of plastic and very little on the type of fiber in the material. Epoxy, vinyl ester, and polyester resins all behaved very similarly, with complete structural failure at between 400 J/g and 600 J/g of specific absorbed heat. Phenolic and cyanate ester resins, on the other hand, displayed a change in structural properties that was only barely measurable with the current apparatus even after the maximum exposure time tested. These data are being incorporated into a numerical model of the ablation and demise of composite materials that will be used to more accurately calculate the ground casualty risk of future spacecraft.

Benton R. Greene↗

NASA NTRS2026

Prototype Demonstration of Solar Carbothermal System to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Aaron Paz↗

NASA NTRS2026

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

Oxygen from Regolith↗

NASA NTRS2026

Prototype Demonstration of Solar-Carbothermal System to Extract Oxygen From Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment [1]. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Koorosh R Araghi↗

NASA NTRS1993

AASE-2 in-situ tracer correlations of methane, nitrous oxide, and ozone as observed aboard the DC-8

We report in situ stratospheric measurements of CH4, N2O, and O3 obtained aboard the NASA DC-8 during the January-March 1992 Airborne Arctic Stratospheric Expedition 2 field campaign. These data demonstrate a strong linear correlation between N2O and CH4 in the lower stratosphere thus indicating that both species are effective tracers of stratospheric air motion. Measurements of both species on constant geometric height surfaces indicate that significant subsidence of the arctic stratospheric air mass occurred at DC-8 altitudes over the course of the AASE-2 expedition. In addition, a widespread reduction in O3 mixing ratios (up to 20%) relative to these conserved tracers was also observed in the lower stratosphere in March as compared to January and February results.

Collins, J. E., Jr.↗

NASA NTRS1993

AASE-2 In-Situ Tracer Correlations of Methane Nitrous Oxide and Ozone as Observed Aboard the DC-8

We report in situ stratospheric measurements of CH4, N2O, and O3 obtained aboard the NASA DC-8 during the January-March 1992 Airborne Arctic Stratospheric Expedition II field campaign. These data demonstrate a strong linear correlation between N2O and CH4 in the lower stratosphere thus indicating that both species are effective tracers of stratospheric air motion. Measurements of both species on constant geometric height surfaces indicate that significant subsidence of the arctic stratospheric air mass occurred at DC-8 altitudes over the course of the AASE-II expedition. In addition, a widespread reduction in O3 mixing ratios (up to 20%) relative to these conserved tracers was also observed in the lower stratosphere in March a compared to January and February results.

Collins, J. E., Jr.↗

NASA NTRS2002

In-Situ Measurements of HCN and CH3CN In the Pacific Troposphere: Sources, Sinks, and Comparisons with Satellite Observations

A new capillary gas chromatographic method using a Reduction Gas Detector was developed to measure HCN and CH3CN in the remote troposphere. This instrumental configuration was deployed for the very first time in the Trace-P field mission performed during the spring of 2001. The NASA DC-8 aircraft afforded an opportunity to measure HCN and CH3CN in polluted and pristine environments over the Pacific to a maximum altitude of 12 km. These are some of the first in situ measurements of the distribution of HCN and CH3CN over the Pacific. Large background concentrations of both nitriles were found to be present and significant variability was observed. The abundance of HCN and CH3CN was strongly impacted by outflow of pollution from Asia. In general there appeared to be a direct but nonlinear relationship between the mixing ratios of HCN and CH3CN. The vertical structure of these chemicals shows direct evidence of the presence of a significant oceanic sink. These observations will be compared with the column content HCN data from satellites and other available measurements. A large body of data have been collected and are being analyzed, both statistically and with the help of models, to better understand the sources and sinks of these nitriles. These results will be presented.

Singh, Hanwant B.↗

NASA NTRS2007

Oxygen production System Models for Lunar ISRU

In-Situ Resource Utilization (ISRU) seeks to make human space exploration feasible; by using available resources from a planet or the moon to produce consumables, parts, and structures that otherwise would be brought from Earth. Producing these in situ reduces the mass of such that must be launched and doing so allows more payload mass' for each mission. The production of oxygen from lunar regolith, for life support and propellant, is one of the tasks being studied under ISRU. NASA is currently funding three processes that have shown technical merit for the production of oxygen from regolith: Molten Salt Electrolysis, Hydrogen Reduction of Ilmenite, and Carbothermal Reduction. The ISRU program is currently developing system models of, the , abovementioned processes to: (1) help NASA in the evaluation process to select the most cost-effective and efficient process for further prototype development, (2) identify key parameters, (3) optimize the oxygen production process, (4) provide estimates on energy and power requirements, mass and volume.of the system, oxygen production rate, mass of regolith required, mass of consumables, and other important parameters, and (5) integrate into the overall end-to-end ISRU system model, which could be integrated with mission architecture models. The oxygen production system model is divided into modules that represent unit operations (e.g., reactor, water electrolyzer, heat exchanger). Each module is modeled theoretically using Excel and Visual Basic for Applications (VBA), and will be validated using experimental data from on-going laboratory work. This modularity (plug-n-play) feature of each unit operation allows the use of the same model on different oxygen production systems simulations resulting in comparable results. In this presentation, preliminary results for mass, power, volume will be presented along with brief description of the oxygen production system model.

Santiago-Maldonado, Edgardo↗