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NASA NTRS2014

NASA Tech Briefs, June 2014

Topics include: Real-Time Minimization of Tracking Error for Aircraft Systems; Detecting an Extreme Minority Class in Hyperspectral Data Using Machine Learning; KSC Spaceport Weather Data Archive; Visualizing Acquisition, Processing, and Network Statistics Through Database Queries; Simulating Data Flow via Multiple Secure Connections; Systems and Services for Near-Real-Time Web Access to NPP Data; CCSDS Telemetry Decoder VHDL Core; Thermal Response of a High-Power Switch to Short Pulses; Solar Panel and System Design to Reduce Heating and Optimize Corridors for Lower-Risk Planetary Aerobraking; Low-Cost, Very Large Diamond-Turned Metal Mirror; Very-High-Load-Capacity Air Bearing Spindle for Large Diamond Turning Machines; Elevated-Temperature, Highly Emissive Coating for Energy Dissipation of Large Surfaces; Catalyst for Treatment and Control of Post-Combustion Emissions; Thermally Activated Crack Healing Mechanism for Metallic Materials; Subsurface Imaging of Nanocomposites; Self-Healing Glass Sealants for Solid Oxide Fuel Cells and Electrolyzer Cells; Micromachined Thermopile Arrays with Novel Thermo - electric Materials; Low-Cost, High-Performance MMOD Shielding; Head-Mounted Display Latency Measurement Rig; Workspace-Safe Operation of a Force- or Impedance-Controlled Robot; Cryogenic Mixing Pump with No Moving Parts; Seal Design Feature for Redundancy Verification; Dexterous Humanoid Robot; Tethered Vehicle Control and Tracking System; Lunar Organic Waste Reformer; Digital Laser Frequency Stabilization via Cavity Locking Employing Low-Frequency Direct Modulation; Deep UV Discharge Lamps in Capillary Quartz Tubes with Light Output Coupled to an Optical Fiber; Speech Acquisition and Automatic Speech Recognition for Integrated Spacesuit Audio Systems, Version II; Advanced Sensor Technology for Algal Biotechnology; High-Speed Spectral Mapper; "Ascent - Commemorating Shuttle" - A NASA Film and Multimedia Project DVD; High-Pressure, Reduced-Kinetics Mechanism for N-Hexadecane Oxidation; Method of Error Floor Mitigation in Low-Density Parity-Check Codes; X-Ray Flaw Size Parameter for POD Studies; Large Eddy Simulation Composition Equations for Two-Phase Fully Multicomponent Turbulent Flows; Scheduling Targeted and Mapping Observations with State, Resource, and Timing Constraints;

Source record↗
NASA NTRS2017

Carbon-Carbon Nozzle Extension Development in Support of In-Space and Upper-Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. Due to the large size of such nozzles, and the related engine performance requirements, carbon-carbon (C-C) composite nozzle extensions are being considered to reduce weight impacts. Currently, the state-of-the-art is represented by the metallic and foreign composite nozzle extensions limited to approximately 2000 degrees F. used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles. NASA and industry partners are working towards advancing the domestic supply chain for C-C composite nozzle extensions. These development efforts are primarily being conducted through the NASA Small Business Innovation Research (SBIR) program in addition to other low level internal research efforts. This has allowed for the initial material development and characterization, subscale hardware fabrication, and completion of hot-fire testing in relevant environments. NASA and industry partners have designed, fabricated and hot-fire tested several subscale domestically produced C-C extensions to advance the material and coatings fabrication technology for use with a variety of liquid rocket and scramjet engines. Testing at NASA's Marshall Space Flight Center (MSFC) evaluated heritage and state-of-the-art C-C materials and coatings, demonstrating the initial capabilities of the high temperature materials and their fabrication methods. This paper discusses the initial material development, design and fabrication of the subscale carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work. The follow on work includes the fabrication of ultra-high temperature materials, larger C-C nozzle extensions, material characterization, sub-element testing and hot-fire testing at larger scale.

Gradl, Paul R.↗
NASA NTRSDate not supplied

Toward an IMU-based Space Suit Motion Capture System

Spacesuits are complex engineering systems that sustain human health and enable performance outside of Earth-like environments. These systems must support human mobility and physical workload demands while minimizing injury risk during extravehicular activity (EVA). Future EVA on the lunar surface during the Artemis program is expected to be more frequent and require higher physical workloads than previous EVAs during the ISS, Shuttle, or Apollo programs. Hence it is important to optimize future as well as current spacesuits to be efficient and comfortable for the success of space and planetary missions. To enable this, an efficient method is needed to test these spacesuits on the ground.When testing spacesuits in ground environments, it is often necessary to understand the kinematics of the suit to validate the design against relevant requirements or characterize the physical workload necessary to operate the suit. This is a challenging task for traditional optical motion capture (OMC) approaches: suit-mounted OMC markers are easily occluded by the subject or environment and may become detached during testing. Controlling lighting and reflectivity of objects in the motion capture volume is also difficult. Fixed-position OMC cameras also constrain testing to a small and contrived laboratory environment, disallowing kinematics capture in field environments.One promising alternative is the use of suit-mounted inertial measurement units (IMUs). These sensors are small, unobtrusive, and portable, but come at the cost of increased sensor noise and complexity of the software and mathematics to analyze the collected data. To this end, engineers at NASA are developing the Augmented Suit Inverse Kinematics (ASIK) system, a complete motion capture methodand inverse kinematics solver which relies solely on a network of wireless IMUs attached to the major kinematic segments of the spacesuit. The ASIK modeling language allows for the simple inclusion of probabilistic priors such as suit size and shape or IMU positions and rotations. Furthermore, to increase accuracy and reduce operational overhead to use this motion capture approach, the developed inverse kinematics solver exploits so-called self-calibratingalgorithmic techniques, which reduce the need for precise alignment of the sensors on the segments or scripted functional calibration procedures. The ASIK system was tested in a 7-subject pilot study. Each subject donned NASA’s new prototype exploration spacesuit in the Active Response Gravity Offload System (ARGOS) facility at the NASA Johnson Space Center. The subjects were outfitted with a set of 14 APDM (Portland, OR, USA) Opal IMUs, 12 of which were used in the ASIK model to estimate lower body and trunk kinematics. The subjects were also outfitted with a set of reflective OMC markers and traditional OMC data was collected and processed. Presented results will include characterization of ASIK-derived suit joint angles accuracy against an optical motion capture datum. Discussion of these results, as well as discussion of system calibration and nuances of mathematical observability, will be included.If successful, IMU-based motion capture will enable testing and validation of spacesuits more frequently, with less overhead, in more extreme environments. Future work will apply these techniques to common spacesuit testing tasks, such as gait, mobility, and balance assessment, physical workload characterization, and ergonomics evaluations.

Timothy Mcgrath↗
NASA NTRS2010

Environmental Stress Testing of the Single Sample Cylinder: A Proven Consensus Standard for Internal Gas Analysis (IGA) or Residual Gas Analysis (RGA)

In August 2008, Schuessler Consulting was contracted by NASA GSFC in support of the NASA Electronic Parts and Packaging (NEPP) program to perform two separate studies on moisture laden air in a stainless steel cylinder that had been designed to become a consensus standard for Test Method 1018. This Test Method was originally released for hybrids under Mil. Std. 883 but was quickly utilized on other microelectronic devices under the auspice of Mil. Std. 750. The cylinder had subsequently been fabricated for the 750 community. It was back-filled with moist air and subsequently analyzed over a period of time under a previous NASA contract. It had been shown that moisture in the 4000 - 5000 ppm range could be analyzed rather precisely with a mass spectrometer, commonly referred to as a Residual Gas Analyzer (RGA). The scope of this study was to ascertain if the composition and precision varied as a function of thermal shock at sub-zero temperatures and whether there was consensus when the standard was submitted to other RGA units. It was demonstrated and published that the consensus standard would yield precise RGA data for moisture within +/- 1% when optimized for a given RGA unit. It has been subsequently shown in this study at Oneida Research Services, that sub-zero storage did not affect that precision when a well-defined protocol for the analysis was followed. The consensus standard was taken to a second facility for analysis where it was found that moisture adsorption on the transfer lines caused precision to drop to +/- 12%. The Single Sample Cylinder (SSC) is a one liter stainless steel cylinder with associated sampling valves and has considerable weight and volume. But this considerable size allows for approximately 300 gas samples of the same composition to be delivered to any RGA unit. Lastly, a smaller cylinder, approximately 75 cc, of a second consensus standard was fabricated and tested with a different mix of fixed gases where moisture was kept in the 100 ppm range. This second standard has the potential of providing 30 gaseous samples and can be readily shipped to any analytical facility that desires to generate comparison RGA data. A series of comparison residual gas analyses was performed at the Honeywell Federal Manufacturing & Technologies facility in the National Nuclear Facility Administration s plant in Kansas City to complete this project. It was shown that improvements in the precision of a given RGA unit can be done by controlling the cycle time for each analysis and increasing analysis temperatures to minimize moisture adsorption. It was also found that a "one time event" in the subzero storage of the large SSC did not effect the units ability to continuously supply precise samples of the same chemistry, however the "event" caused a permanent +8% shift in the reported value of the moisture content. Lastly, a set of SSC RGA results was plotted on a common graph with DSCC "correlation study" RGA data. The result demonstrates the ability of the SSC to remove many of the individual variances that single, individual samples introduce. The consensus standards are now in storage at Oneida Research Services, one of the DSCC certified houses that does RGA to Military Standards, where they await future studies. The analytical data and the operational parameters of the instruments used are provided in the following discussion. Limitations and suggested means for improvement of both precision and accuracy are provided.

Schuessler, Philipp WH↗
NASA NTRS1994

Aeroacoustic sensitivity analysis and optimal aeroacoustic design of turbomachinery blades

During the first year of the project, we have developed a theoretical analysis - and wrote a computer code based on this analysis - to compute the sensitivity of unsteady aerodynamic loads acting on airfoils in cascades due to small changes in airfoil geometry. The steady and unsteady flow though a cascade of airfoils is computed using the full potential equation. Once the nominal solutions have been computed, one computes the sensitivity. The analysis takes advantage of the fact that LU decomposition is used to compute the nominal steady and unsteady flow fields. If the LU factors are saved, then the computer time required to compute the sensitivity of both the steady and unsteady flows to changes in airfoil geometry is quite small. The results to date are quite encouraging, and may be summarized as follows: (1) The sensitivity procedure has been validated by comparing the results obtained by 'finite difference' techniques, that is, computing the flow using the nominal flow solver for two slightly different airfoils and differencing the results. The 'analytic' solution computed using the method developed under this grant and the finite difference results are found to be in almost perfect agreement. (2) The present sensitivity analysis is computationally much more efficient than finite difference techniques. We found that using a 129 by 33 node computational grid, the present sensitivity analysis can compute the steady flow sensitivity about ten times more efficiently that the finite difference approach. For the unsteady flow problem, the present sensitivity analysis is about two and one-half times as fast as the finite difference approach. We expect that the relative efficiencies will be even larger for the finer grids which will be used to compute high frequency aeroacoustic solutions. Computational results show that the sensitivity analysis is valid for small to moderate sized design perturbations. (3) We found that the sensitivity analysis provided important insight into how airfoils should be modified to improve their aeroelastic stability. Using this insight, we redesigned an aeroelastically unstable cascade to produce a stable cascade.

Hall, Kenneth C.↗
NASA NTRSDate not supplied

Macro-scale Testing and Micromechanics Modeling of Fracture Behaviors for Boron Carbide Composites with Hierarchical Microstructures

With a unique combination of properties including high hardness, low density, wear and corrosion resistance, thermal stability, high neutron absorption, and semi-conductivity, boron carbide (B4C) is a candidate material for various engineering applications that involve extreme environment. The current applications of boron carbide, however, are limited by its intrinsic brittleness due to its strong covalent bonding. To toughen boron carbide, in this work hierarchical microstructure designs was used to provide multiple toughening mechanisms including crack deflection/bridging, micro-crack toughening, etc. Using field assisted sintering, B4C composites with hierarchical microstructure features including graphite platelets, micron and sub-micron sized TiB2 reinforcements were fabricated. The fracture toughness of fabricated B4C composites were previously measured at micro-scale using micro-indentation followed by post-testing microstructure inspection. However, questions including whether the fracture toughness enhancement measured at micro-scale can translate to macro-scale mechanical properties, and what are the fundamental mechanisms behind observed fracture toughness enhancement, remain to be answered. In this study, the fabricated B4C composites were tested using standardized four-point bending method to obtain fracture toughness at macro-scale. In addition, micromechanics modeling was conducted using MAC/GMC code and crack-band model to study the effect of residual stress and weak interphases on fracture behaviors of B4C composites reinforced with TiB2 particles. Through standardized four-point bending tests, fracture toughness enhancements up to 2.85, 3.32, and 3.65 MPa∙m(exp 1/2) (from 2.38 MPa∙m(exp 1/2)) were achieved for B4C composites with graphite platelets addition (micro/nano B4C), with TiB2 formation (micro B4C-TiB2), and with both graphite and TiB2 addition (micro/nano B4C-TiB2) respectively. Micromechanics modeling indicated that introduction of thermal residual stress and weak interphases caused enhanced micro-cracking behavior and resulted in the observed fracture toughness enhancement. These results furthered understanding about the mechanical behaviors at macro-scale and the mechanisms behind observed fracture toughness enhancement for B4C composites with hierarchical microstructures and can provide reference data for the future design of B4C composites with optimized microstructures for further fracture toughness enhancement.

Boron Carbide↗
NASA NTRS2012

Miniaturized Gas Correlation Radiometer for the Detection of Trace Gases in the Martian Atmosphere

We present a miniaturized and simplified version of a gas correlation radiometer (GCR) capable of simultaneously mapping multiple trace gases and identifying active regions on the Mars surface. Gas correlation radiometry (GCR) has been shown to be a sensitive and versatile method for detecting trace gases in Earth's atmosphere. Reduction of the size and mass of the GCR was achieved by implementing compact, light-weight 1 mm inner diameter hollow-core optical fibers (hollow waveguides) as the gas correlation cells. In a comparison with an Earth orbiting CO2 GCR instrument, exchanging the 10 m multipass cells with hollow waveguide gas correlation cells of equivalent path length reduces the mass from approximately 150 kg to approximately 0.5 kg, and reduces the volume from 1.9 m x 1.3 m x 0.86 m to a small bundle of fiber coils approximately 1 meter in diameter by 0.05 m in height (mass and volume reductions of greater than 99%). A unique feature of this instrument is its stackable module design, with a single module for each trace gas. Each of the modules is self-contained, and fundamentally identical; differing by the bandpass filter wavelength range and gas mixtures inside the hollow-waveguide absorption cells. The current configuration contains four stacked modules for simultaneous measurements of methane (CH4), formaldehyde (H2CO), water vapor (H2O), and deuterated water vapor (HDO) but could easily be expanded to include measurements of additional species of interest including nitrous oxide (N2O), hydrogen sulfide (H2S), methanol (CH3OH), and sulfur dioxide (SO2), as well as carbon dioxide (CO2) for a simultaneous measure of mass balance. Preliminary results indicate that a 1 ppb detection limit is possible for both formaldehyde and methane with one second of averaging. Using non-optimized components, we have demonstrated an instrument sensitivity equivalent to approximately 30 ppb for formaldehyde, and approximately 500 ppb for methane. We expect custom bandpass filters and 6 m long waveguides to significantly improve these promising results. Ongoing testing is being conducted on water vapor and deuterated water vapor.

Melroy, Hilary R.↗
NASA NTRS2017

Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails

State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.

Fernandez, Juan M.↗
NASA NTRSDate not supplied

Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems

Introduction. Alloys such as aluminum, nickel-base, and austenitic stainless steels are susceptible to solidification cracking during welding and 3D printing. Compositional optimization is one method used to effectively mitigate solidification cracking of those alloy systems. With the surge in hypersonic and in-space propulsion activities, refractory metals (Nb, Mo, Ta, W, and Re) and their alloy derivatives are increasing in importance due to their extreme high melting point and retention of high-temperature strength; however, their chemistry was most typically optimized to promote ductility during mechanical operations such as drawing and forming. Welding of such alloys has been a challenge due to a number of issues including solidification cracking, atmospheric contamination (O, C, and N), as well as a shift in ductile-to-brittle transition to higher temperature following grain growth induced by welding. Compositional optimization of refractory alloys for solidification cracking resistance in particular is desirable as their usage increases with the advent of advanced manufacturing methods such as 3D printing. This work evaluates the effect of compositional variation in refractory metal systems on the solidification cracking susceptibility with the goals of optimizing existing alloys and joining process techniques, and formulating new alloys with increased solidification cracking resistance. Experimental Procedures. A python code was developed in a Jupyter notebook environment (Michael and Sowards, 2023) to facilitate the calculation of crack susceptibility index proposed by Kou (2015). Composition is entered as a single point, or as a 1-D or 2-D array. The notebook calls pycalphad (Otis and Liu, 2017 and Bocklund et al, 2020) to calculate the evolution of fraction solid as a function of temperature (under either Scheil or equilibrium assumptions) and then evaluates steepness of the fraction solid curve near the terminal stage of solidification to predict solidification cracking resistance. Open source thermodynamic databases available at online repositories are used (van de Walle). The process is setup in an automated fashion to generate plots that show variation in solidification cracking susceptibility according to composition on 1-D line plots or 2-D contour plots. The Jupyter notebook and crack susceptibility algorithm was also integrated with a widely used commercial CALPHAD code for validation and alloy exploration. Results and Discussion. The crack susceptibility model was first validated against a series of refractory alloy compositions evaluated in past work which utilized a specialized Varestraint test built inside a vacuum chamber environment (Lessman and Gold, 1971). The alloys tested in the Varestraint apparatus included T-111 (Ta-8W-2Hf), ASTAR-811C (Ta-8W-1Re-0.7Hf-0.025C), FS-85 (Nb-27Ta-10W-1Zr), T-222 (Ta-9.6W-2.4Hf-0.01C), Ta-10W, B-66 (Nb-5Mo-5V-1Zr), and SCb-291 (Nb-10W-10Ta). The initial test of the model showed a strong correlation with empirical Varestraint data, i.e., a Spearman rank correlation between model predictions and hot cracking measurements was observed to be greater than 0.8. Following the validation, a set of refractory metal binary mixtures was investigated to evaluate sensitivity of Nb, Mo, W, and Ta to C, N, and O content. A series of plots were produced that suggest ppmw ranges of C, N, and O where solidification cracking increases significantly and reaches a maximum. Also comparative ranking of each primary refractory metal to each interstitial was produced. For example C produces greater cracking response in Mo whereas O produces greater cracking response in Ta and Nb. Such compositional values have utility in setting limits on pickup of these interstitial elements during welding and printing rather than using a one-size-fits-all approach. Furthermore, the results have use in determining additive powder recycling requirements, which is especially pertinent for refractory metal powders due to their high cost compared to conventional alloys. Another application created thousands of hypothetical alloys within the nominal specified composition range of two widely used refractory alloys C103 (Nb-10Hf-1Ti) and TZM (Mo-0.5Ti-0.1Zr). The cracking index was calculated for the alloys and results were fed into machine learning regression techniques including Multiple Linear Regression, Ridge Regression, and Lasso Regression to determine relative potency each alloying element had on computed solidification cracking index. A series of linear equations were produced that relate composition of C103 and TZM to solidification cracking index. The crack susceptibility of C103 for example is described by an equation of the form: cracking index ~ O + 0.667*C + 0.635*N + 0.00037*Ta – 0.0008*Hf (in wt.%) From that equation, it is clear that O has strong propensity to induce solidification cracking. Interestingly, Hf is shown to reduce calculated cracking response. Finally, realizing the potential of this method to discover new refractory alloy formulations across the period table that have low solidification cracking sensitivity, the code was applied to new untested alloy systems including W-Zr-C, W-Ta-C, and others. Conclusions. In summary, an open source numerical method has been developed using Python code to calculate Kou’s crack susceptibility index. The method was applied to refractory metals which are inherently difficult to study from a weldability testing standpoint since inert shielding gas is not sufficient and welding is typically done in vacuum, especially in light of findings presented here where oxygen has profound influence on solidification cracking. This work revealed the effect of compositional variations on a series of refractory metals and showed the framework defined here will be useful in 1) the development of new alloys that have improved weldability and 3D printability, 2) placing compositional limits on existing alloys, and 3) ensuring adequate controls of manufacturing processes such as 3D printing where powder reuse is critical. Keywords. pycalphad; Python; refractory metals; solidification cracking. References. B. Bocklund et. al. (2020) http://doi.org/10.5281/zenodo.3630657. S. Kou. (2015) https://doi.org/10.1016/j.actamat.2015.01.034. G.G. Lessmann and R.E. Gold. Welding Journal, issue 1, pp. 1-s – 8-s (1971). F.N. Michael and J.W. Sowards. NASA/TM-20230002218 (2023). R. Otis and Z.-K. Liu. (2017) http://doi.org/10.5334/jors.140. A. Van de Wallle et. al. (2018) https://doi.org/10.1016/j.calphad.2018.04.003.

pycalphad↗
NASA NTRS2020

Small Lunar Base Camp and in Situ Resource Utilization Oxygen Production Facility Power System Comparison

This report examines the power requirements for operating an in situ resource utilization (ISRU) oxygen production system on the lunar surface and a small six-person base camp. The baseline ISRU system produced 1.63 kg/h for a total day and night production rate of 1,154 kg. It was estimated that this plant would require 25.83 kW of power to operate. The base camp power includes auxiliary equipment as well as a communications system. The required power estimate for the base camp was 28.05 kW. This estimation was used to size a power system and determine its mass for meeting these requirements. Three types of power systems were considered: a solar photovoltaic (PV) array system using batteries for energy storage, a PV array system using a regenerative fuel cell (RFC) for energy storage, and a modular 10-kW electrical output power Kilopower reactor system. Three separate cases were examined: a stand-alone ISRU oxygen production system, a base camp, and a combined ISRU oxygen production system and base camp. For the PV array-based system, the RFC energy storage method had a mass advantage over a battery- based energy storage system. For higher power nighttime power operation for all three cases, the RFC system’s specific energy was just over 830 Wh/kg. For the lower power nighttime “keep-alive” level used as part of the Case 1 analysis, the specific energy for the RFC was 456 Wh/kg. Both of these levels are significantly above the specific energy of 200 Wh/kg for the battery. Because of this higher specific energy, the RFC-based system provided significant mass advantages over the battery-based energy storage system. The baseline reactor system utilized shielding and separation distance to meet the desired maximum radiation dose level of 5 rem/yr for personnel operating within the vicinity of the power loads, base camp, and oxygen production facility. There are methods that could potentially be utilized to reduce the shielding requirements and separation distance. Implementing these would reduce the overall system mass for the reactor. Also, optimizing the reactor output to a specific mission would provide benefits in mass at the expense of modularity. The results of the power system comparison between a solar PV array-based system and a Kilopower reactor-based system has shown that for missions required to operate throughout the lunar night at power levels comparable to those used during the day, the reactor-based system provides a significant mass advantage. However, for applications that can meet their mission requirements while only having to operate during the daytime with minimal power required to survive the nighttime, the PV array-based system provides a mass advantage.

Colozza, Anthony J.↗
NASA NTRS2019

Extreme-Temperature Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

The United States (US) National Aeronautics and Space Administration (NASA) and its US industry partners are developing extreme-temperature composite nozzle extensions for a variety of cryogenic liquid rocket engine propulsion systems. Applications under consideration at the NASA Marshall Space Flight Center (MSFC) include launch vehicle (upper stage), in-space, and lunar lander descent/ascent propulsion systems. Composite material systems of interest include carbon-carbon (C-C) and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Missions addressed include access to low Earth orbit, the lunar surface, and more distant destinations. Cryogenic upper-stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. As a result of the large size of such nozzles, and the related engine performance requirements, composite nozzle extensions are being considered to reduce mass impacts. Currently, metallic and foreign composite nozzle extensions used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles represent the state-of-the-art. Such extensions are limited to use at or slightly above 2000°F (1093°C). Materials under development by MSFC and its industry partners have the potential to operate at temperatures up to (or above) 4250°F (2343°C). Marshall Space Flight Center efforts are aimed at (a) further developing the technology and databases needed to enable the use of composite nozzle extensions on cryogenic liquid rocket engines, (b) developing and demonstrating low-cost capabilities for testing and qualifying such nozzle extensions, and (c) advancing the US domestic supply chain for nozzle extensions. Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs, low-level internal MSFC research projects, and teaming arrangements with domestic industry partners, composite material design, development, hot-fire test, and evaluation efforts are progressing. Hot- fire engine tests of subscale hardware have been conducted using oxygen/hydrogen (LOX/H2), oxygen/methane (LOX/CH4), and oxygen/kerosene (LOX/RP-1) propellants. These engine tests at MSFC have enabled the evaluation of both heritage and state-of-the-art material systems, demonstrating the initial capabilities of the extreme temperature materials and their fabrication methods. Recent, ongoing, and potential future work supporting cryogenic propulsion systems development will be presented. The composite nozzle extension technology and test capabilities being developed are intended to support both NASA and US Department of Defense requirements, as well as those of the broader Commercial Space industry.

Valentine, Peter G.↗
NASA NTRS2002

Quasi-One-Dimensional Modeling of Pulse Detonation Rocket Engines

Pulsed detonation rocket engines (PDREs) have generated considerable research interest in recent years as a chemical propulsion system potentially offering improved performance and reduced complexity compared to conventional rocket engines. The detonative mode of combustion employed by these devices offers a thermodynamic advantage over the constant-pressure deflagrative combustion mode used in conventional rocket engines and gas turbines. However, while this theoretical advantage has spurred a great deal of interest in building PDRE devices, the unsteady blowdown process intrinsic to the PDRE has made realistic estimates of the actual propulsive performance problematic. The recent review article by Kailasanath highlights some of the difficulties in comparing the available experimental measurements with numerical models. In a previous paper by the author, parametric studies of the performance of a single, straight-tube PDRE were reported. A 1-D, unsteady method of characteristics code, employing a constant-gamma assumption behind the detonation front, was developed for that study. Models of this type are computationally inexpensive, and are particularly useful for parametric performance comparisons. For example, a plot showing the specific impulse of various PDRE and steady-state rocket engine (SSRE) configurations as a function of blowdown pressure ratio. The performance curves clearly indicate that a straight-tube PDRE is superior in specific impulse to a SSRE with a sonic nozzle over the entire range of pressure ratios. Note, however, that a straight-tube PDRE in general does not compare favorably to a SSRE fitted with an optimized de Laval supersonic nozzle, particularly at the high pressure ratios typical for boost or in-space rocket applications. However, the calculations also show that if a dynamically optimized, supersonic de Laval nozzle could be could be fitted to a PDRE, then the specific impulse of the device would exceed that of a comparable SSRE. While such a nozzle is a considerable idealization, it is clear that nozzle design and optimization will play a critical role in whether the performance potential of PDREs can be effectively realized in practice. In order to study PDRE nozzle issues with greater accuracy, a quasi-one-dimensional, finite-rate chemistry CFD code has been developed by the author. Comparisons of the code with both the previous MOC model and experimental data from Stanford University are reported. The effect of constant-gamma and finite-rate chemistry assumptions on the flowfield and performance is examined. Parametric studies of the effect of nozzle throat size and expansion ratio, at various blowdown pressure ratios, are reported.

Morris, Christopher I.↗
NASA NTRS2013

Multi-Dimensional Damage Detection for Surfaces and Structures

Current designs for inflatable or semi-rigidized structures for habitats and space applications use a multiple-layer construction, alternating thin layers with thicker, stronger layers, which produces a layered composite structure that is much better at resisting damage. Even though such composite structures or layered systems are robust, they can still be susceptible to penetration damage. The ability to detect damage to surfaces of inflatable or semi-rigid habitat structures is of great interest to NASA. Damage caused by impacts of foreign objects such as micrometeorites can rupture the shell of these structures, causing loss of critical hardware and/or the life of the crew. While not all impacts will have a catastrophic result, it will be very important to identify and locate areas of the exterior shell that have been damaged by impacts so that repairs (or other provisions) can be made to reduce the probability of shell wall rupture. This disclosure describes a system that will provide real-time data regarding the health of the inflatable shell or rigidized structures, and information related to the location and depth of impact damage. The innovation described here is a method of determining the size, location, and direction of damage in a multilayered structure. In the multi-dimensional damage detection system, layers of two-dimensional thin film detection layers are used to form a layered composite, with non-detection layers separating the detection layers. The non-detection layers may be either thicker or thinner than the detection layers. The thin-film damage detection layers are thin films of materials with a conductive grid or striped pattern. The conductive pattern may be applied by several methods, including printing, plating, sputtering, photolithography, and etching, and can include as many detection layers that are necessary for the structure construction or to afford the detection detail level required. The damage is detected using a detector or sensory system, which may include a time domain reflectometer, resistivity monitoring hardware, or other resistance-based systems. To begin, a layered composite consisting of thin-film damage detection layers separated by non-damage detection layers is fabricated. The damage detection layers are attached to a detector that provides details regarding the physical health of each detection layer individually. If damage occurs to any of the detection layers, a change in the electrical properties of the detection layers damaged occurs, and a response is generated. Real-time analysis of these responses will provide details regarding the depth, location, and size estimation of the damage. Multiple damages can be detected, and the extent (depth) of the damage can be used to generate prognostic information related to the expected lifetime of the layered composite system. The detection system can be fabricated very easily using off-the-shelf equipment, and the detection algorithms can be written and updated (as needed) to provide the level of detail needed based on the system being monitored. Connecting to the thin film detection layers is very easy as well. The truly unique feature of the system is its flexibility; the system can be designed to gather as much (or as little) information as the end user feels necessary. Individual detection layers can be turned on or off as necessary, and algorithms can be used to optimize performance. The system can be used to generate both diagnostic and prognostic information related to the health of layer composite structures, which will be essential if such systems are utilized for space exploration. The technology is also applicable to other in-situ health monitoring systems for structure integrity.

Williams, Martha↗
NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗
NASA NTRS1993

Low-gravity electrodeposition and growth of polymer thin films with large third-order optical nonlinearities by electrochemical processes for devices: Thiophene-based polymers

It has been proposed that NLO thin film properties may be improved by low-gravity processing. Strong candidates for NLO thin film applications are the polythiophenes. Polymeric thiophenes are attractive materials due to their ease of preparation, stability, and high X(exp 3). A simple and convenient method for preparation of polythiophenes is electrochemical oxidation. We will apply some of our experience and lessons learned in low-gravity metal, metal/cermet electrode position to improve the quality of polythiophene(s) thin films. In low gravity electrode position of Ni at a high rate on an Au substrate often results in the production of an x-ray non diffracting surface. Cobalt metal deposition does not give this result nor does Ni when deposited similarly on a glassy carbon substrate. Co/Ni alloy composition produced during electrode position is strongly dependent upon the amount of convection. Code position of neutral inert cermets with metals is influenced significantly by the presence of gravity and the size of the cermets. Tracks left in the 1-g surfaces by unsuccessful particle occlusion indicate suspension of the large particles is not the only reason for poor volume percentages of the larger particles in the deposits. All size particles are more homogeneously distributed in the deposits in low-gravity electrocodeposition than in 1-g. Low gravity gives larger volume percentages for the larger particles in the deposits, while 1-g gives larger volume percentages for the smaller particles. Intermediate size particles give mixed results. The experimental cells were constructed with flat electrode end plates such that 1-g bench reference electrode positions could be carried out at various orientations with respect to gravity. A series of bench studies using similar designed cells are suggested so that convection modification can be applied to electrochemical thin film preparation. Convection effects can then be coupled with other parameter variations in current, temperature, concentration, solvent, electrolyte, and anode substrates to optimize the properties of NLO thin films before resorting to low-gravity processing.

Penn, Benjamin G.↗
NASA NTRS2013

Optimal Integration of Departures and Arrivals in Terminal Airspace

Coordination of operations with spatially and temporally shared resources, such as route segments, fixes, and runways, improves the efficiency of terminal airspace management. Problems in this category are, in general, computationally difficult compared to conventional scheduling problems. This paper presents a fast time algorithm formulation using a non-dominated sorting genetic algorithm (NSGA). It was first applied to a test problem introduced in existing literature. An experiment with a test problem showed that new methods can solve the 20 aircraft problem in fast time with a 65% or 440 second delay reduction using shared departure fixes. In order to test its application in a more realistic and complicated problem, the NSGA algorithm was applied to a problem in LAX terminal airspace, where interactions between 28% of LAX arrivals and 10% of LAX departures are resolved by spatial separation in current operations, which may introduce unnecessary delays. In this work, three types of separations - spatial, temporal, and hybrid separations - were formulated using the new algorithm. The hybrid separation combines both temporal and spatial separations. Results showed that although temporal separation achieved less delay than spatial separation with a small uncertainty buffer, spatial separation outperformed temporal separation when the uncertainty buffer was increased. Hybrid separation introduced much less delay than both spatial and temporal approaches. For a total of 15 interacting departures and arrivals, when compared to spatial separation, the delay reduction of hybrid separation varied between 11% or 3.1 minutes and 64% or 10.7 minutes corresponding to an uncertainty buffer from 0 to 60 seconds. Furthermore, as a comparison with the NSGA algorithm, a First-Come-First-Serve based heuristic method was implemented for the hybrid separation. Experiments showed that the results from the NSGA algorithm have 9% to 42% less delay than the heuristic method with varied uncertainty buffer sizes.

terminal airspace↗
NASA NTRS2010

Relating Linear and Volumetric Variables Through Body Scanning to Improve Human Interfaces in Space

Designing space suits and vehicles for the diverse human population present unique challenges for the methods of traditional anthropometry. Space suits are bulky and allow the operator to shift position within the suit and inhibit the ability to identify body landmarks. Limited suit sizing options also cause variability in fit and performance between similarly sized individuals. Space vehicles are restrictive in volume in both the fit and the ability to collect data. NASA's Anthropometric and Biomechanics Facility (ABF) has utilized 3D scanning to shift from traditional linear anthropometry to explore and examine volumetric capabilities to provide anthropometric solutions for design. Overall, the key goals are to improve the human-system performance and develop new processes to aid in the design and evaluation of space systems. Four case studies are presented that illustrate the shift from purely linear analyses to an augmented volumetric toolset to predict and analyze the human within the space suit and vehicle. The first case study involves the calculation of maximal head volume to estimate total free volume in the helmet for proper air exchange. Traditional linear measurements resulted in an inaccurate representation of the head shape, yet limited data exists for the determination of a large head volume. Steps were first taken to identify and classify a maximum head volume and the resulting comparisons to the estimate are presented in this paper. This study illustrates the gap between linear components of anthropometry and the need for overall volume metrics in order to provide solutions. A second case study examines the overlay of the space suit scans and components onto scanned individuals to quantify fit and clearance to aid in sizing the suit to the individual. Restrictions in space suit size availability present unique challenges to optimally fit the individual within a limited sizing range while maintaining performance. Quantification of the clearance and fit between similarly sized individuals is critical in providing a greater understanding of the human body's function within the suit. The third case study presented in this paper explores the development of a conformal seat pan using scanning techniques, and details the challenges of volumetric analyses that were overcome in order to develop a universal seat pan that can be utilized across the entire user population. The final case study explores expanding volumetric capabilities through generation of boundary manikins. Boundary manikins are representative individuals from the population of interest that represent the extremes of the population spectrum. The ABF developed a technique to take three-dimensional scans of individuals and manipulate the scans to reflect the boundary manikins' anthropometry. In essence, this process generates a representative three-dimensional scan of an individual from anthropometry, using another individual's scanned image. The results from this process can be used in design process modeling and initial suit sizing work as a three dimensional, realistic example of individuals from the population, maintaining the variability between and correlation to the relevant dimensions of interest.

Margerum, Sarah E.↗
NASA NTRS2004

Improved Thermoplastic/Iron-Particle Transformer Cores

A method of fabricating improved transformer cores from composites of thermoplastic matrices and iron-particles has been invented. Relative to commercially available laminated-iron-alloy transformer cores, the cores fabricated by this method weigh less and are less expensive. Relative to prior polymer-matrix/ iron-particle composite-material transformer cores, the cores fabricated by this method can be made mechanically stronger and more magnetically permeable. In addition, whereas some prior cores have exhibited significant eddy-current losses, the cores fabricated by this method exhibit very small eddy-current losses. The cores made by this method can be expected to be attractive for use in diverse applications, including high-signal-to-noise transformers, stepping motors, and high-frequency ignition coils. The present method is a product of an experimental study of the relationships among fabrication conditions, final densities of iron particles, and mechanical and electromagnetic properties of fabricated cores. Among the fabrication conditions investigated were molding pressures (83, 104, and 131 MPa), and molding temperatures (250, 300, and 350 C). Each block of core material was made by uniaxial-compression molding, at the applicable pressure/temperature combination, of a mixture of 2 weight percent of LaRC (or equivalent high-temperature soluble thermoplastic adhesive) with 98 weight percent of approximately spherical iron particles having diameters in the micron range. Each molded block was cut into square cross-section rods that were used as core specimens in mechanical and electromagnetic tests. Some of the core specimens were annealed at 900 C and cooled slowly before testing. For comparison, a low-carbon-steel core was also tested. The results of the tests showed that density, hardness, and rupture strength generally increased with molding pressure and temperature, though the correlation was rather weak. The weakness of the correlation was attributed to the pores in the specimens. The maximum relative permeabilities of cores made without annealing ranged from 30 to 110, while those of cores made with annealing ranged from 900 to 1,400. However, the greater permeabilities of the annealed specimens were not associated with noticeably greater densities. The major practical result of the investigation was the discovery of an optimum distribution of iron-particle sizes: It was found that eddy-current losses in the molded cores were minimized by using 100 mesh (corresponding to particles with diameters less than or equal to 100 m) iron particles. The effect of optimization of particle sizes on eddy-current losses is depicted in the figure.

Wincheski, Russell A.↗