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DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗
NASA NTRS1992

Progress in multi-dimensional upwind differencing

Multi-dimensional upwind-differencing schemes for the Euler equations are reviewed. On the basis of the first-order upwind scheme for a one-dimensional convection equation, the two approaches to upwind differencing are discussed: the fluctuation approach and the finite-volume approach. The usual extension of the finite-volume method to the multi-dimensional Euler equations is not entirely satisfactory, because the direction of wave propagation is always assumed to be normal to the cell faces. This leads to smearing of shock and shear waves when these are not grid-aligned. Multi-directional methods, in which upwind-biased fluxes are computed in a frame aligned with a dominant wave, overcome this problem, but at the expense of robustness. The same is true for the schemes incorporating a multi-dimensional wave model not based on multi-dimensional data but on an 'educated guess' of what they could be. The fluctuation approach offers the best possibilities for the development of genuinely multi-dimensional upwind schemes. Three building blocks are needed for such schemes: a wave model, a way to achieve conservation, and a compact convection scheme. Recent advances in each of these components are discussed; putting them all together is the present focus of a worldwide research effort. Some numerical results are presented, illustrating the potential of the new multi-dimensional schemes.

Vanleer, Bram↗
DOE OSTI2020

Integrable deformation of $\mathbb{C}$P n and generalised Kähler geometry

We build on the results of [1] for generalised frame fields on generalised quotient spaces and study integrable deformations for CP n . In particular we show how, when the target space of the Principal Chiral Model is a complex projective space, a two-parameter deformation can be introduced in principle. The second parameter can however be removed via a diffeomorphism, which we construct explicitly, in accordance with the results stemming from a thorough integrability analysis we carry out. We also elucidate how the deformed target space can be seen as an instance of generalised Kähler, or equivalently bi-Hermitian, geometry. In this respect, we find the generic form of the pure spinors for CP n and the explicit expression for the generalised Kähler potential for n = 1, 2.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Applying Bayesian inference and deterministic anisotropy to retrieve the molecular structure ∣Ψ(R)∣2 distribution from gas-phase diffraction experiments

Abstract Currently, our general approach to retrieving molecular structures from ultrafast gas-phase diffraction heavily relies on complex ab initio electronic or vibrational excited state simulations to make conclusive interpretations. Without such simulations, inverting this measurement for the structural probability distribution is typically intractable. This creates a so-called inverse problem. Here we address this inverse problem by developing a broadly applicable method that approximates the molecular frame structure ∣Ψ( R , t )∣ 2 distribution independent of these complex simulations. We retrieve the vibronic ground state ∣Ψ( R )∣ 2 for both simulated stretched NO 2 and measured N 2 O. From measured N 2 O, we observe 40 mÅ coordinate-space resolution from 3.75 Å −1 reciprocal space range and poor signal-to-noise, a 50X improvement over traditional Fourier transform methods. In simulated NO 2 diffraction experiments, typical to high signal-to-noise levels predict 100–1000X resolution improvements, down to 0.1 mÅ. By directly measuring the width of ∣Ψ( R )∣ 2 , we open ultrafast gas-phase diffraction capabilities to measurements beyond current analysis approaches. This method has the potential to effectively turn gas-phase ultrafast diffraction into a discovery-oriented technique to probe systems that are prohibitively difficult to simulate.

74 ATOMIC AND MOLECULAR PHYSICS↗
NASA NTRS1996

Validation of bonded composite doubler technology through application oriented structural testing

One of the major thrusts established under the FAA's National Aging Aircraft Research Program is to foster new technologies associated with civil aircraft maintenance. Recent DOD and other government developments in the use of bonded composite patches on metal structures has supported the need for research and validation of such doubler applications on U.S. certificated airplanes. Composite patching is a rapidly maturing technology which shows promise of cost savings on aging aircraft. Sandia Labs is conducting a proof-of-concept project with Delta Air Lines, Lockheed Martin, Textron, and the FAA which seeks to remove any remaining obstacles to the approved use of composite doublers. By focusing on a specific commercial aircraft application - reinforcement of the L-1011 door frame - and encompassing all 'cradle-to-grave' tasks such as design, analysis, installation, and inspection, this program is designed to prove the capabilities of composite doublers. This paper reports on a series of structural tests which have been conducted on coupons and subsize test articles. Tension-tension fatigue and residual strength tests attempted to grow engineered flaws in coupons with composite doublers bonded to aluminum skin. Also, structures which modeled key aspects of the door corner installation were subjected to extreme tension, shear, and bending loads. In this manner it was possible to study strain fields in and around the Lockheed-designed composite doubler using realistic aircraft load scenarios and to assess the potential for interply delaminations and disbonds between the aluminum and the laminate. The data acquired was also used to validate finite element models (FEM) and associated Damage Tolerance Analyses.

Roach, Dennis↗
NASA NTRS2010

Wide-Field-of-View, High-Resolution, Stereoscopic Imager

A device combines video feeds from multiple cameras to provide wide-field-of-view, high-resolution, stereoscopic video to the user. The prototype under development consists of two camera assemblies, one for each eye. One of these assemblies incorporates a mounting structure with multiple cameras attached at offset angles. The video signals from the cameras are fed to a central processing platform where each frame is color processed and mapped into a single contiguous wide-field-of-view image. Because the resolution of most display devices is typically smaller than the processed map, a cropped portion of the video feed is output to the display device. The positioning of the cropped window will likely be controlled through the use of a head tracking device, allowing the user to turn his or her head side-to-side or up and down to view different portions of the captured image. There are multiple options for the display of the stereoscopic image. The use of head mounted displays is one likely implementation. However, the use of 3D projection technologies is another potential technology under consideration, The technology can be adapted in a multitude of ways. The computing platform is scalable, such that the number, resolution, and sensitivity of the cameras can be leveraged to improve image resolution and field of view. Miniaturization efforts can be pursued to shrink the package down for better mobility. Power savings studies can be performed to enable unattended, remote sensing packages. Image compression and transmission technologies can be incorporated to enable an improved telepresence experience.

Prechtl, Eric F.↗
DOE OSTI2023

3D tracking of particles in a dusty plasma by laser sheet tomography

The collective behavior of levitated particles in a weakly ionized plasma (dusty plasma) has raised significant scientific interest. This is due to the complex array of forces acting on the particles and their potential to act as in situ diagnostics of the plasma environment. Ideally, the three-dimensional (3D) motion of many particles should be tracked for long periods of time. Typically, stereoscopic imaging using multiple cameras combined with particle image velocimetry is used to obtain a velocity field of many particles, yet this method is limited by its sample volume and short time scales. Here, we demonstrate a different, high-speed tomographic imaging method capable of tracking individual particles. We use a scanning laser sheet coupled to a single high-speed camera. We are able to identify and track tens of individual particles over centimeter length scales for several minutes, corresponding to more than 10 000 frames.

Physics↗
DOE OSTI2024

Methods of Securing Chemical and Pharmaceutical Knowledge and Recommendations for International Institutions to Enhance Research Integrity

Here, this paper examines strategies for securing chemical and pharmaceutical expertise in a globalized research environment, focusing on safeguarding intellectual property and preventing the misuse of sensitive and potentially dual-use information. The product of collective efforts between Pacific Northwest National Laboratory, Carol Davila University of Medicine and Pharmacy, and New Bulgarian University, highlights the challenges and opportunities posed by cross-border research collaborations, particularly in the context of differing regulatory frameworks and research cultures. It explores current mechanisms to prevent data loss and unauthorized access to sensitive information while assessing the effectiveness of existing security measures, frameworks, and international export control regimes. The approach examines the differing methodologies for promoting transparency, trust-building, and mutual accountability in joint research projects to cultivate secure data-sharing practices and intellectual property. It provides recommendations for international institutions to implement security guidelines in framing research priorities, encourages continual training and education programs, and the integration of processes for monitoring research compliance. This partnership aims to advance scientific innovation while maintaining global stability, ensuring compliance with international norms, and safeguarding valuable intellectual property as measures in chemical and pharmaceutical research security practices continue to expand due to international collaboration and knowledge exchange.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

High-z galaxies with JWST and local analogues – it is not only star formation

ABSTRACT I present an analysis of the JWST NIRSpec data of SMACS 0723 released as Early Release Observations. As part of this three new redshifts are provided, bringing the total of reliable redshifts to 14. I propose a modification to the direct abundance determination method that reduces sensitivity to flux calibration uncertainties by a factor of ∼3 and show that the resulting abundances are in good agreement with Bayesian photoionization models of the rest-frame optical spectrum. I also show that 6355 is most likely a narrow-line active galactic nucleus (AGN) with $M_*\lt 10^9\, \mathrm{M}_\odot$ at z = 7.66 and argue that 10 612 might also have an AGN contribution to its flux through comparison to photoionization models and low-redshift analogues. Under the assumption that the lines come from star formation, I find that the galaxies have gas depletion times of ∼107 yr, comparable to similar galaxies locally. I also identify a population of possibly shock-dominated galaxies at z < 3, whose near-IR emission lines plausibly come nearly all from shocks and discuss their implications. I close with a discussion of the potential for biases in the determination of the mass–metallicity relation using samples defined by detected [O iii]4363 and show using low-z galaxies that this can lead to biases of up to 0.5 dex with a systematic trend with mass.

Brinchmann, Jarle (ORCID:0000000343598797)↗
DOE OSTI2020

Quality Control of Additively Manufactured Metallic Structures with Machine Learning of Thermography Images

Additive manufacturing (AM) of high-strength metals is currently based on the laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Quality control (QC) requires nondestructive evaluation of actual AM structures. Flash thermography is a potentially promising QC technique because it is scalable to arbitrary structure size. However, the detection sensitivity of this method is limited by noise. We investigate separation of signal from noise in thermography images using several machine learning (ML) methods, including new spatial–temporal blind source separation and spatial–temporal sparse dictionary learning methods. Performance of the ML methods is benchmarked using thermography data obtained from imaging stainless steel 316L and Inconel 718 specimens produced by the LPBF method with imprinted calibrated porosity defects. The ML methods are ranked by F-score and execution runtime. Finally, the ML methods with higher accuracy require a longer runtime. However, this runtime is sufficiently short to perform QC within a realistic time frame.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Lower-hybrid drift waves and their interaction with plasmas in a 3D symmetric reconnection simulation with zero guide field

We investigate lower-hybrid drift waves (LHDW) in symmetric magnetic reconnection with zero guide field using three-dimensional particle-in-cell simulations. The long-wavelength mode with kρiρe∼1 develops in the bifurcated electron current layer around the X-line within the width of the electron meandering motion from the mid-plane, where ρi(e) is the ion (electron) gyroradius. The short-wavelength mode with kρe∼1 develops in the separatrix region downstream of the electron outflow jet, producing electron vortices in the background flow frame. Electrons follow the E × B drift with corrections from the diamagnetic drift and are heated inside the vortices with diverging electric fields. In the vortices, ions have comparable E × B and inertia drifts, which together mostly cancel the diamagnetic drift. Toward the center of diverging field vortices, ions are decelerated, leading to a decrease in the perpendicular temperature, while the loss of low-energy ions results in an increase in the parallel temperature. Parallel electric fields exist as a combination of the LHDW wave field projected to the magnetic field direction and the penetration of whistler waves that are mainly outside of the LHDW layer. The magnetic flux tube is twisted in the vortices. The twist may potentially lead to slippage reconnection, as indicated by the non-uniform parallel potential variation across field lines, while the periodic variations of the twisting directions are a limiting factor.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Detection of Defects in Additively Manufactured Metallic Materials with Machine Learning of Pulsed Thermography Images

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Quality control (QC) requires nondestructive evaluation (NDE) of actual AM structures. Pulsed thermography is a potentially promising QC technique because it is scalable to arbitrary structure size. However, detection sensitivity of this method is limited by noises. We investigate separation of signal from noise in thermography images using several machine learning (ML) methods, including new spatio-temporal blind source separation (STBSS) and spatio-temporal sparse dictionary learning (STSDL) methods. Performance of the ML methods is benchmarked using thermography data obtained from imaging stainless steel 316L and Inconel 718 specimens produced LPBF method with imprinted calibrated porosity defects. The ML methods are ranked by F-score and execution runtime. The ML methods with higher accuracy require longer run time. However, this runtime is sufficiently short to perform QC within a realistic time frame.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2000

Electric Plasma Arc-Lamp Combustor Liner Durability Test System Developed

Silicon carbide matrix composites are candidate materials for high-temperature combustor liners. Because through-the-thickness thermal gradients are the primary cause of stress on combustor liners, a unique test facility was developed at the NASA Glenn Research Center at Lewis Field to simulate in-service pure thermal stress distributions in fiber reinforced silicon carbide cylinders. It was developed initially under Phase II of the High- Speed Research Program. This test stand can accommodate 8-in.-long test cylinders that have outer diameters of 4 in. and a wall thickness of about 0.08 to 0.12 in. One cylinder at a time is loaded vertically into the test stand. Water-cooled plates enclose the open ends of the cylinder and provide cooling. Load plates on the exterior side of the water-cooled plates provide support and compression loads. To evaluate a combustor liner material s potential performance, researchers induce thermal gradients with an axisymmetric, direct-current, electric arc within the cylinder while refrigerated air at a rate of 1.5 lb/sec impinges on the outside surface of the cylinder. The achievable through-the-thickness thermal gradient is predicted to be in excess of 200 C. The 8-in. long, 0.5-in.-diameter plasma arc emits full spectrum visible light; radiant intensity exceeds 300 Watts per square centimeters to produce temperatures in excess of 1500 C on materials with emissivity near unity. Because the system does not rely upon the combustion of fuels to achieve the related thermal conditions, ancillary environmental reactions with the sample are eliminated. The system incorporates a standard mechanical test frame, which can impose constant as well cyclical axial stresses up to 2200 lb upon the test piece. Silicon-carbide-fiber reinforced silicon carbide matrix composite cylinders were instrumented with thin-film thermocouples to obtain through-the-thickness thermal flux measurements. Inside wall temperatures reached 1200 C with only 250 A of current. One of the special features of this configuration is the creation of hoop stress states within the cylinder, which up this point have not been obtainable in planar coupon tests. This facility will allow various operational modes, including accelerated tests of thermal transients simulating the effects of repeated engine ignition as well as prescribed thermal and mechanical histories to simulate various duty cycle profiles. Tests can now be performed on thermal-barrier-coated metallic liners and ceramic composite liners that require a combination of high heat flux and controlled mechanical stresses.

Goldsby, Jon C.↗
NASA NTRS2008

Design and Development of an In-Space Deployable Sun Shield for the Atlas Centaur

The Centaur, by virtue of its use of high specific-impulse (Isp) LO2/LH2 propellants, has initial mass-to-orbit launch requirements less than half of those upper stages using storable propellants. That is, for Earth escape or GSO missions the Centaur is half the launch weight of a storable propellant upper stage. A drawback to the use of Liquid oxygen and liquid hydrogen, at 90 K and 20 K respectively, over storable propellants is the necessity of efficient cryogen storage techniques that minimize boil-off from thermal radiation in space. Thermal blankets have been used successfully to shield both the Atlas Centaur and Titan Centaur. These blankets are protected from atmospheric air loads during launch by virtue of the fact that the Centaur is enclosed within the payload fairing. The smaller Atlas V vehicle, the Atlas 400, has the Centaur exposed to the atmosphere during launch, and therefore, to date has not flown with thermal blankets shielding the Centaur. A design and development effort is underway to fly a thermal shield on the Atlas V 400 vehicle that is not put in place until after the payload fairing jettisons. This can be accomplished by the use of an inflatable and deployable thermal blanket referred to as the Centaur Sun Shield (CSS). The CSS design is also scalable for use on a Delta upper stage, and the technology potentially could be used for telescope shades, re-entry shields, solar sails and propellant depots. A Phase I effort took place during 2007 in a partnership between ULA and ILC Dover which resulted in a deployable proof-of-concept Sun Shield being demonstrated at a test facility in Denver. A Phase H effort is underway during 2008 with a partnership between ULA, ILC, NASA Glenn Research Center (GRC) and NASA Kennedy Space Center (KSC) to define requirements, determine materials and fabrication techniques, and to test components in a vacuum chamber at cold temperatures. This paper describes the Sun Shield development work to date, and the future plans leading up to a flight test in the 2011 time frame.

Dew, Michael↗
NASA NTRS2018

Aircraft System Noise Assessment of the NASA D8 Subsonic Transport Concept

Avehicle-level noise assessment has been performed for theNASAD8 concept aircraft (ND8) in the NASA Advanced Air Transport Technology Project portfolio. The NASA research-level Aircraft NOise Prediction Program (ANOPP-Research) was used to predict the noise from each source component on the ND8 to build up a noise estimate for the full aircraft. The propulsion airframe aeroacoustic (PAA) effects of the ND8, namely boundary layer ingestion (BLI) with its influence on fan noise, and the noise shielding, reflection, and diffraction mechanisms of the unconventional airframe, were empirically modeled using experimental data. Noise reduction technologies appropriate to the 2025-2035 time frame were included in this study. Including all technologies and PAA effects, the ND8 is predicted to have a cumulative margin to the Stage 4 certification metric of only 7.4 EPNdB. Boundary layer ingestion is predicted to have a detrimental impact on cumulative noise levels on the order of 15 EPNdB. Fan noise is seen to be the primary noise source at all three certification points, even if the BLI noise impact could be entirely suppressed. The impact of engine noise shielding by the airframe is limited by a lack of aft shielding and the presence of horizontal tail reflections in the aft direction. The physical constraint on engine size by the pi-tail is seen as a potential barrier to engine noise reduction through the corresponding limitation on fan bypass ratio. Mildly reduced climb performance (compared to similar reference aircraft) does not provide any benefit through increased noise propagation distance. If the boundary layer ingestion noise penalty could be suppressed such that BLI would have no effect on noise, the cumulative margin to Stage 4 would increase to 22.4 EPNdB, still below the NASA Mid Term goal of 32-42 EPNdB.

Clark, Ian A.↗
NASA NTRSDate not supplied

Ice Crystal Icing Investigation on a Honeywell Uncertified Research Engine in an Altitude Simulation Icing Facility

A Honeywell Uncertified Research Engine was exposed to various ice crystal conditions in the NASA Glenn Propulsion Systems Laboratory. Simulations using NASA's 1D Icing Risk Analysis tool were used to determine potential inlet conditions that could lead to ice crystal accretion along the inlet of the core flowpath and into the high pressure compressor. These conditions were simulated in the facility to develop baseline conditions. Parameters were then varied to move or change accretion characteristics. Data were acquired at altitudes varying from 5 kft to 45 kft, at nominal ice particle Median Volumetric Diameters from 20 µm to 100 µm, and total water contents of 1 g/m3 to 12 g/m3. Engine and flight parameters such as fan speed, Mach number, and inlet temperature were also varied. The engine was instrumented with total temperature and pressure probes. Static pressure taps were installed at the leading edge of the fan stator, front frame hub, the shroud of the IGV, and first two rotors. Metal temperatures were acquired for vane stators 1-2. In-situ measurements of the particle size distribution were acquired three meters upstream of the engine forward fan flange and one meter downstream of the fan in the bypass in order to study particle break-up behavior. Cameras were installed in the engine to capture ice accretions at the leading edge of the fan stator, splitter lip, and inlet guide vane. Additional measurements acquired but not discussed in this paper include: high speed pressure transducers installed at the trailing edge of the first stage rotor and light extinction probes used to acquire particle concentrations at the fan exit stator plane and at the inlet to the core and bypass. The goal of this study was to understand key parameters of accretion, acquire particle break-up data aft of the fan, and generate a unique icing dataset for model and tool development. This work described in the paper focuses on the effect of particle break-up. It was found that there was significant particle break-up downstream of the fan in the bypass especially with larger initial particle sizes. The metal temperatures on the inlet guide vanes and stators show a temperature increase with increasing MVD. Accretion behavior was very similar across all test cases. However at the inlet guide vanes, the accretion decreased with increasing particle size.

Ashlie B Flegel↗
NASA NTRS2021

Lower-Hybrid Drift Waves and Their Interaction With Plasmas in A 3D Symmetric Reconnection Simulation With Zero Guide Field

We investigate lower-hybrid drift waves (LHDW) in symmetric magnetic reconnection with zero guide field using three-dimensional particle-in-cell simulations. The long-wavelength mode with develops in the bifurcated electron current layer around the X-line within the width of the electron meandering motion from the mid-plane, where is the ion (electron) gyroradius. The short-wavelength mode with develops in the separatrix region downstream of the electron outflow jet, producing electron vortices in the background flow frame. Electrons follow the E × B drift with corrections from the diamagnetic drift and are heated inside the vortices with diverging electric fields. In the vortices, ions have comparable E × B and inertia drifts, which together mostly cancel the diamagnetic drift. Toward the center of diverging field vortices, ions are decelerated, leading to a decrease in the perpendicular temperature, while the loss of low-energy ions results in an increase in the parallel temperature. Parallel electric fields exist as a combination of the LHDW wave field projected to the magnetic field direction and the penetration of whistler waves that are mainly outside of the LHDW layer. The magnetic flux tube is twisted in the vortices. The twist may potentially lead to slippage reconnection, as indicated by the non-uniform parallel potential variation across field lines, while the periodic variations of the twisting directions are a limiting factor.

Shan Wang↗
NASA NTRS2014

Design Concepts for a Small Space-Based GEO Relay Satellite for Missions Between Low Earth and near Earth Orbits

The main purpose of the Small Space-Based Geosynchronous Earth orbiting (GEO) satellite is to provide a space link to the user mission spacecraft for relaying data through ground networks to user Mission Control Centers. The Small Space Based Satellite (SSBS) will provide services comparable to those of a NASA Tracking Data Relay Satellite (TDRS) for the same type of links. The SSBS services will keep the user burden the same or lower than for TDRS and will support the same or higher data rates than those currently supported by TDRS. At present, TDRSS provides links and coverage below GEO; however, SSBS links and coverage capability to above GEO missions are being considered for the future, especially for Human Space Flight Missions (HSF). There is also a rising need for the capability to support high data rate links (exceeding 1 Gbps) for imaging applications. The communication payload on the SSBS will provide S/Ka-band single access links to the mission and a Ku-band link to the ground, with an optical communication payload as an option. To design the communication payload, various link budgets were analyzed and many possible operational scenarios examined. To reduce user burden, using a larger-sized antenna than is currently in use by TDRS was considered. Because of the SSBS design size, it was found that a SpaceX Falcon 9 rocket could deliver three SSBSs to GEO. This will greatly reduce the launch costs per satellite. Using electric propulsion was also evaluated versus using chemical propulsion; the power system size and time to orbit for various power systems were also considered. This paper will describe how the SSBS will meet future service requirements, concept of operations, and the design to meet NASA users' needs for below and above GEO missions. These users' needs not only address the observational mission requirements but also possible HSF missions to the year 2030. We will provide the trade-off analysis of the communication payload design in terms of the number of links looking above and below GEO; the detailed design of a GEO SSBS spacecraft bus and its accommodation of the communication payload, and a summary of the trade study that resulted in the selection of the Falcon 9 launch vehicle to deploy the SSBS and its impact on cost reductions per satellite. ======================================================================== Several initiatives have taken place within NASA1 and international space agencies2 to create a human exploration strategy for expanding human presence into the solar system; these initiatives have been driven by multiple factors to benefit Earth. Of the many elements in the strategy one stands out: to send robotic and human missions to destinations beyond Low Earth Orbit (LEO), including cis-lunar space, Near-Earth Asteroids (NEAs), the Moon, and Mars and its moons.3, 4 The time frame for human exploration to various destinations, based on the public information available,1,4 is shown in Figure 1. Advance planning is needed to define how future space communications services will be provided in the new budget environment to meet future space communications needs. The spacecraft for these missions can be dispersed anywhere from below LEO to beyond GEO, and to various destinations within the solar system. NASA's Space Communications and Navigation (SCaN) program office provides communication and tracking services to space missions during launch, in-orbit testing, and operation phases. Currently, SCaN's space networking relay satellites mainly provide services to users below GEO, at Near Earth Orbit (NEO), below LEO, and in deep space. The potential exists for using a space-based relay satellite, located in the vicinity of various solar system destinations, to provide communication space links to missions both below and above its orbit. Such relays can meet the needs of human exploration missions for maximum connectivity to Earth locations and for reduced latency. In the past, several studies assessed the ability of satellite-based relays working above GEO in conjunction with Earth ground stations. Many of these focused on the trade between space relay and direct-to-Earth station links5,6,7. Several others focused on top-level architecture based on relays at various destinations8,9,10,11,12. Much has changed in terms of microwave and optical technology since the publication of the referenced papers; Ka-band communication systems are being deployed, optical communication is being demonstrated, and spacecraft buses are becoming increasingly more functional and operational. A design concept study was undertaken to access the potential for deploying a Small Space-Based Satellite (SSBS) relay capable of serving missions between LEO and NEO. The needs of future human exploration missions were analyzed, and a notional relay-based architecture concept was generated as shown in Fig. 1. Relay satellites in Earth through cis-Lunar orbits are normally located in stable orbits requiring low fuel consumption. Relay satellites for Mars orbit are normally selected based on the mission requirement and projected fuel consumption. Relay satellites have extreme commonalities of functions between them, differing only in the redundancy and frequencies used; therefore, the relay satellite in GEO was selected for further analysis since it will be the first step in achieving a relay-based architecture for human exploration missions (see Fig.Figure 2). The mission design methodology developed by the Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) team13 was used to produce the satellite relay design and to perform various design trades. At the start of the activity, the team was provided with the detailed concept of the notional architecture and the system and communication payload drivers.

Relay Satellites↗