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NASA NTRS2016

Investigating the Simulink Auto-Coding Process

Model based program design is the most clear and direct way to develop algorithms and programs for interfacing with hardware. While coding "by hand" results in a more tailored product, the ever-growing size and complexity of modern-day applications can cause the project work load to quickly become unreasonable for one programmer. This has generally been addressed by splitting the product into separate modules to allow multiple developers to work in parallel on the same project, however this introduces new potentials for errors in the process. The fluidity, reliability and robustness of the code relies on the abilities of the programmers to communicate their methods to one another; furthermore, multiple programmers invites multiple potentially differing coding styles into the same product, which can cause a loss of readability or even module incompatibility. Fortunately, Mathworks has implemented an auto-coding feature that allows programmers to design their algorithms through the use of models and diagrams in the graphical programming environment Simulink, allowing the designer to visually determine what the hardware is to do. From here, the auto-coding feature handles converting the project into another programming language. This type of approach allows the designer to clearly see how the software will be directing the hardware without the need to try and interpret large amounts of code. In addition, it speeds up the programming process, minimizing the amount of man-hours spent on a single project, thus reducing the chance of human error as well as project turnover time. One such project that has benefited from the auto-coding procedure is Ramses, a portion of the GNC flight software on-board Orion that has been implemented primarily in Simulink. Currently, however, auto-coding Ramses into C++ requires 5 hours of code generation time. This causes issues if the tool ever needs to be debugged, as this code generation will need to occur with each edit to any part of the program; additionally, this is lost time that could be spent testing and analyzing the code. This is one of the more prominent issues with the auto-coding process, and while much information is available with regard to optimizing Simulink designs to produce efficient and reliable C++ code, not much research has been made public on how to reduce the code generation time. It is of interest to develop some insight as to what causes code generation times to be so significant, and determine if there are architecture guidelines or a desirable auto-coding configuration set to assist in streamlining this step of the design process for particular applications. To address the issue at hand, the Simulink coder was studied at a foundational level. For each different component type made available by the software, the features, auto-code generation time, and the format of the generated code were analyzed and documented. Tools were developed and documented to expedite these studies, particularly in the area of automating sequential builds to ensure accurate data was obtained. Next, the Ramses model was examined in an attempt to determine the composition and the types of technologies used in the model. This enabled the development of a model that uses similar technologies, but takes a fraction of the time to auto-code to reduce the turnaround time for experimentation. Lastly, the model was used to run a wide array of experiments and collect data to obtain knowledge about where to search for bottlenecks in the Ramses model. The resulting contributions of the overall effort consist of an experimental model for further investigation into the subject, as well as several automation tools to assist in analyzing the model, and a reference document offering insight to the auto-coding process, including documentation of the tools used in the model analysis, data illustrating some potential problem areas in the auto-coding process, and recommendations on areas or practices in the current Ramses model that should be further investigated. Several skills were required to be built up over the course of the internship project. First and foremost, my Simulink skills have improved drastically, as much of my experience had been modeling electronic circuits as opposed to software models. Furthermore, I am now comfortable working with the Simulink Auto-coder, a tool I had never used until this summer; this tool also tested my critical thinking and C++ knowledge as I had to interpret the C++ code it was generating and attempt to understand how the Simulink model affected the generated code. I had come into the internship with a solid understanding of Matlab code, but had done very little in using it to automate tasks, particularly Simulink tasks; along the same lines, I had rarely used shell script to automate and interface with programs, which I gained a fair amount of experience with this summer, including how to use regular expression. Lastly, soft-skills are an area everyone can continuously improve on; having never worked with NASA engineers, which to me seem to be a completely different breed than what I am used to (commercial electronic engineers), I learned to utilize the wealth of knowledge present at JSC. I wish I had come into the internship knowing exactly how helpful everyone in my branch would be, as I would have picked up on this sooner. I hope that having gained such a strong foundation in Simulink over this summer will open the opportunity to return to work on this project, or potentially other opportunities within the division. The idea of leaving a project I devoted ten weeks to is a hard one to cope with, so having the chance to pick up where I left off sounds appealing; alternatively, I am interested to see if there are any opening in the future that would allow me to work on a project that is more in-line with my research in estimation algorithms. Regardless, this summer has been a milestone in my professional career, and I hope this has started a long-term relationship between JSC and myself. I really enjoy the thought of building on my experience here over future summers while I work to complete my PhD at Missouri University of Science and Technology.

Gualdoni, Matthew J.↗

NASA NTRS2018

GMI-IPS: Python Processing Software for Aircraft Campaigns

NASA's Atmospheric Tomography Mission (ATom) seeks to understand the impact of anthropogenic air pollution on gases in the Earth's atmosphere. Four flight campaigns are being deployed on a seasonal basis to establish a continuous global-scale data set intended to improve the representation of chemically reactive gases in global atmospheric chemistry models. The Global Modeling Initiative (GMI), is creating chemical transport simulations on a global scale for each of the ATom flight campaigns. To meet the computational demands required to translate the GMI simulation data to grids associated with the flights from the ATom campaigns, the GMI ICARTT Processing Software (GMI-IPS) has been developed and is providing key functionality for data processing and analysis in this ongoing effort. The GMI-IPS is written in Python and provides computational kernels for data interpolation and visualization tasks on GMI simulation data. A key feature of the GMI-IPS, is its ability to read ICARTT files, a text-based file format for airborne instrument data, and extract the required flight information that defines regional and temporal grid parameters associated with an ATom flight. Perhaps most importantly, the GMI-IPS creates ICARTT files containing GMI simulated data, which are used in collaboration with ATom instrument teams and other modeling groups. The initial main task of the GMI-IPS is to interpolate GMI model data to the finer temporal resolution (1-10 seconds) of a given flight. The model data includes basic fields such as temperature and pressure, but the main focus of this effort is to provide species concentrations of chemical gases for ATom flights. The software, which uses parallel computation techniques for data intensive tasks, linearly interpolates each of the model fields to the time resolution of the flight. The temporally interpolated data is then saved to disk, and is used to create additional derived quantities. In order to translate the GMI model data to the spatial grid of the flight path as defined by the pressure, latitude, and longitude points at each flight time record, a weighted average is then calculated from the nearest neighbors in two dimensions (latitude, longitude). Using SciPya's Regular Grid Interpolator, interpolation functions are generated for the GMI model grid and the calculated weighted averages. The flight path points are then extracted from the ATom ICARTT instrument file, and are sent to the multi-dimensional interpolating functions to generate GMI field quantities along the spatial path of the flight. The interpolated field quantities are then written to a ICARTT data file, which is stored for further manipulation. The GMI-IPS is aware of a generic ATom ICARTT header format, containing basic information for all flight campaigns. The GMI-IPS includes logic to edit metadata for the derived field quantities, as well as modify the generic header data such as processing dates and associated instrument files. The ICARTT interpolated data is then appended to the modified header data, and the ICARTT processing is complete for the given flight and ready for collaboration. The output ICARTT data adheres to the ICARTT file format standards V1.1. The visualization component of the GMI-IPS uses Matplotlib extensively and has several functions ranging in complexity. First, it creates a model background curtain for the flight (time versus model eta levels) with the interpolated flight data superimposed on the curtain. Secondly, it creates a time-series plot of the interpolated flight data. Lastly, the visualization component creates averaged 2D model slices (longitude versus latitude) with overlaid flight track circles at key pressure levels. The GMI-IPS consists of a handful of classes and supporting functionality that have been generalized to be compatible with any ICARTT file that adheres to the base class definition. The base class represents a generic ICARTT entry, only defining a single time entry and 3D spatial positioning parameters. Other classes inherit from this base class; several classes for input ICARTT instrument files, which contain the necessary flight positioning information as a basis for data processing, as well as other classes for output ICARTT files, which contain the interpolated model data. Utility classes provide functionality for routine procedures such as: comparing field names among ICARTT files, reading ICARTT entries from a data file and storing them in data structures, and returning a reduced spatial grid based on a collection of ICARTT entries. Although the GMI-IPS is compatible with GMI model data, it can be adapted with reasonable effort for any simulation that creates Hierarchical Data Format (HDF) files. The same can be said of its adaptability to ICARTT files outside of the context of the ATom mission. The GMI-IPS contains just under 30,000 lines of code, eight classes, and a dozen drivers and utility programs. It is maintained with GIT source code management and has been used to deliver processed GMI model data for the ATom campaigns that have taken place to date.

Damon, M. R.↗

NASA NTRS2017

Vacuum Infusion Process Development for Conformal Ablative Thermal Protection System Materials

Conformal ablators are low density composite materials comprised of a flexible carbon felt based fibrous substrate and a high surface area phenolic matrix. These materials are fabricated to near net shape by molding the substrate, placing in a rigid matched mold and infusing with liquid resin through a vacuum assisted process. The open mold process, originally developed for older rigid substrate ablators, such as PICA, wastes a substantial amount of resin. In this work, a vacuum infusion process a type of liquid composite molding where resin is directly injected into a closed mold under vacuum is advanced for conformal ablators. The process reduces waste over the state-of-the-art technique. Small, flat samples of Conformal Phenolic Impregnated Carbon Ablator are infused using the new approach and subjected to a range of curing configurations and conditions. Resulting materials are inspected for quality and compared to material produced using the standard process. Lessons learned inform subsequent plans for process scale up.

TPS↗

NASA NTRS2017

Precomputing Process Noise Covariance for Onboard Sequential Filters

Process noise is often used in estimation filters to account for unmodeled and mismodeled accelerations in the dynamics. The process noise covariance acts to inflate the state covariance over propagation intervals, increasing the uncertainty in the state. In scenarios where the acceleration errors change significantly over time, the standard process noise covariance approach can fail to provide effective representation of the state and its uncertainty. Consider covariance analysis techniques provide a method to precompute a process noise covariance profile along a reference trajectory using known model parameter uncertainties. The process noise covariance profile allows significantly improved state estimation and uncertainty representation over the traditional formulation. As a result, estimation performance on par with the consider filter is achieved for trajectories near the reference trajectory without the additional computational cost of the consider filter. The new formulation also has the potential to significantly reduce the trial-and-error tuning currently required of navigation analysts. A linear estimation problem as described in several previous consider covariance analysis studies is used to demonstrate the effectiveness of the precomputed process noise covariance, as well as a nonlinear descent scenario at the asteroid Bennu with optical navigation.

onboard↗

NASA NTRS2019

Uncertainties in the Geostationary Ocean Color Imager (GOCI) Remote Sensing Reflectance for Assessing Diurnal Variability of Biogeochemical Processes

Short-term (sub-diurnal) biological and biogeochemical processes cannot be fully captured by the current suite of polar-orbiting satellite ocean color sensors, as their temporal resolution is limited to potentially one clear image per day. Geostationary sensors, such as the Geostationary Ocean Color Imager (GOCI) from the Republic of Korea, allow the study of these short-term processes because their orbit permit the collection of multiple images throughout each day for any area within the sensor’s field of regard. Assessing the capability to detect sub-diurnal changes in in-water properties caused by physical and biogeochemical processes characteristic of open ocean and coastal ocean ecosystems, however, requires an understanding of the uncertainties introduced by the instrument and/or geophysical retrieval algorithms. This work presents a study of the uncertainties during the daytime period for an ocean region with characteristically low-productivity with the assumption that only small and undetectable changes occur in the in-water properties due to biogeochemical processes during the daytime period. The complete GOCI mission data were processed using NASA’s SeaDAS/l2gen package. The assumption of homogeneity of the study region was tested using three-day sequences and diurnal statistics. This assumption was found to hold based on the minimal diurnal and day-to-day variability in GOCI data products. Relative differences with respect to the midday value were calculated for each hourly observation of the day in order to investigate what time of the day the variability is greater. Also, the influence of the solar zenith angle in the retrieval of remote sensing reflectances and derived products was examined. Finally, we determined that the uncertainties in water-leaving “remote-sensing” reflectance (Rrs) for the 412,443, 490, 555, 660 and 680 nm bands on GOCI are 8.05 x 10(exp -4), 5.49 x 10(exp -4), 4.48 x 10(exp -4), 2.51 x 10(exp -4), 8.83 x 10(exp -5), and 1.36 x 10(exp -4)/sr, respectively, and 1.09 x 10(exp -2)/cu.mgm for the chlorophyll-a concentration (Chl-a), 2.09 x 10(exp -3)/m for the absorption coefficient of chromophoric dissolved organic matter at 412 nm (a(sub g) (412)), and 3.7 mg/cu.m for particulate organic carbon (POC). These R(sub rs) values can be considered the threshold values for detectable changes of the in-water properties due to biological, physical or biogeochemical processes from GOCI.

Concha, Javier↗

NASA NTRS2020

The Role of Oceanic Processes in the Initiation of Boreal Winter Intraseasonal Oscillations Over the Indian Ocean

Observational analyses and ocean general circulation model experiments were performed to understand the influence of oceanic processes on warm sea surface temperature anomalies (SSTAs) prior to convection initiation of boreal winter intraseasonal oscillations (ISOs), including the Madden‐Julian Oscillation (MJO), in the tropical Indian Ocean. We found 39 strong ISOs that passed over the Indian Ocean Warm Pool (WP) region during the November–April season of the 2001–2012 period. Seventeen of them (44%) initiated over the Seychelles‐Chagos Thermocline Ridge (SCTR) before propagating eastward to the WP and Maritime Continent. Including only global‐scale MJOs, 71% (24%) of the remaining MJO events initiated from the SCTR (WP). Four (seven) SCTR (WP) ISO events were preceded by SSTAs that were strongly influenced by wind stress‐driven oceanic processes; all four (2/7) SCTR (WP) events were MJOs. Composite analyses of the four oceanic process influenced SCTR MJO events showed that wind stress‐driven oceanic processes contributed about 30% (between 0.1 and 0.2 °C) of the preconvection warming in the SCTR, which coincides with the Intertropical Convergence Zone with mean SST > 28 °C. Reduced upwelling and entrainment played a more important role than horizontal advection in elevating the +SSTAs. Case studies revealed that the two ocean process‐influenced primary MJO SCTR events were also associated with oceanic equatorial Rossby waves. Furthermore, results of a linear atmospheric mixed layer model indicated that boundary layer processes related to SSTAs contributed approximately half of the total convergence during MJO initiation, relative to the effect of the free troposphere, for the Rossby wave‐influenced events.

MJO Initiation↗

NASA NTRS2019

Uncertainties in the Geostationary Ocean Color Imager (GOCI) Remote Sensing Reflectance for Assessing Diurnal Variability of Biogeochemical Processes

Short-term (sub-diurnal) biological and biogeochemical processes cannot be fully captured by the current suite of polar-orbiting satellite ocean color sensors, as their temporal resolution is limited to potentially one clear image per day. Geostationary sensors, such as the Geostationary Ocean Color Imager (GOCI) from the Republic of Korea, allow the study of these short-term processes because their orbit permit the collection of multiple images throughout each day for any area within the sensor’s field of regard. Assessing the capability to detect sub-diurnal changes in in-water properties caused by physical and biogeochemical processes characteristic of open ocean and coastal ocean ecosystems, however, requires an understanding of the uncertainties introduced by the instrument and/or geophysical retrieval algorithms. This work presents a study of the uncertainties during the daytime period for an ocean region with characteristically low-productivity with the assumption that only small and undetectable changes occur in the in-water properties due to biogeochemical processes during the daytime period. The complete GOCI mission data were processed using NASA’s SeaDAS/l2gen package. The assumption of homogeneity of the study region was tested using three-day sequences and diurnal statistics. This assumption was found to hold based on the minimal diurnal and day-to-day variability in GOCI data products. Relative differences with respect to the midday value were calculated for each hourly observation of the day in order to investigate what time of the day the variability is greater. Also, the influence of the solar zenith angle in the retrieval of remote sensing reflectances and derived products was examined. Finally, we determined that the uncertainties in water-leaving “remote-sensing” reflectance (Rrs) for the 412, 443, 490, 555, 660 and 680 nm bands on GOCI are 8.05 × 10−4, 5.49 × 10−4, 4.48 × 10−4, 2.51 × 10−4, 8.83 × 10−5, and 1.36 × 10−4 sr−1, respectively, and 1.09 × 10−2 mg m−3 for the chlorophyll-a concentration (Chl-a), 2.09 × 10−3 m−1 for the absorption coefficient of chromophoric dissolved organic matter at 412 nm (ag (412)), and 3.7 mg m−3 for particulate organic carbon (POC). These Rrs values can be considered the threshold values for detectable changes of the in-water properties due to biological, physical or biogeochemical processes from GOCI.

Geostationary Ocean Color Imager (GOCI)↗

NASA NTRSDate not supplied

A Conceptual Model for Integrating Design Thinking and Lean Startup Methods into the Innovation Process

Design thinking is a methodology that comes from the industrial design realm and is centred on culling better insight into needs from users. Another popular methodology is based on gaining insight on the potential of an opportunity through experimentation, testing, and iterating with users. These are commonly referred to as lean startup methods. However, from a research perspective, we still do not know the most effective way to implement these user-focused design methods within the innovation process within organizations, and which aspects of the design process are the most impactful in developing new opportunities. In this research, we propose a high-level conceptual process model on how user-focused design methods such as design thinking and lean startup methods can be integrated into the up-front innovation process within organizations. This is based on a mix of digital ethnography, business historiography, and ethnographic, embedded participant observation of an organization's development of an innovation process. We review the conceptual model, associated activities, and process considerations. The article concludes with thoughts on future research.

Design Innovation↗

NASA NTRSDate not supplied

Effect of Boundary Conditions on Process-Induced Stresses in a Plain Weave Unit Cell

Woven polymer matrix composites (PMCs) are leveraged in aerospace applications for their desirable specific properties, yet they are vulnerable to high residual stresses during manufacturing and their complex geometry makes experimental results difficult to observe. Process modeling is needed to characterize the effects of the curing and predict end stress states. Finite element software can be used to model woven architectures, however accurate representation of processing conditions remains a challenge when it comes to selecting boundary conditions. The effect of BCs on process-induced stress within woven PMCs is studied. The commercial Finite Element Analysis (FEA) software Abaqus is coupled with user-written subroutines in a process modeling framework. A two-dimensionally (2D) woven PMC repeating unit cell (RUC) is modeled with TexGen and Abaqus. Virtual curing is imposed on the bulk matrix. The BC study is conducted with Free, Periodic, Flat, and Flat-Free configurations. Results show that the end stress state is sensitive to the boundary condition assumptions. Flat BC results show great agreement with Periodic BCs. Residual stress results from process modeling are then compared with a linear-elastic thermal cooldown analysis in Abaqus. Cooldown results indicate an overestimation in matrix stresses compared with process modeling.

micromechanics↗

NASA NTRSDate not supplied

Evaluation of a Traditional Regression Model Term Selection Process for Balance Calibration Data Sets

Key elements of a traditional regression model term selection process for the analysis of wind tunnel strain-gage balance calibration data are discussed. The traditional process is sometimes applied when regression models of the gage outputs are needed and an analyst does not have access to a term selection algorithm. In principle, the traditional process identifies supported regression model terms of a gage output by combining an analyst's subject- matter knowledge with a visual examination of selected plots of the calibration loads. Twelve empirical rules are listed that may be used to select regression model terms. Data from the manual calibration of a force balance is used to illustrate the application of the traditional term selection process. The data example shows that the traditional process can become very complex. Its successful application highly depends on an analyst's experience and skills. Therefore, it is suggested to replace the traditional term selection process with an automated term selection algorithm. Then, objective metrics are systematically applied during the term selection that make the identification of the regression model more repeatable and less dependent on an analyst's personal skills.

strain-gage balance↗

NASA NTRSDate not supplied

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

The recently published NASA-STD-6030 defines the Additive Manufacturing (AM) Requirements for Spaceflight Systems. Key aspects of the certification approach include the development of a qualified material process (QMP) and material characterization determined by part classification. Nondestructive evaluation (NDE) of the full surface and volume is required for all part classifications except those with negligible risk. NASA is exploring the use of in-process monitoring data to improve risk posture and supplement post-build inspection for complex parts. Currently, the most challenging obstacle to overcome is linking the indications in the monitoring data to the physics of the process and the final material state of the finished part. NASA is undertaking studies to understand and quantify this relationship for various monitoring methods. The desired goal is to develop a protocol to establish this correlation for any monitoring method. Once this correlation is known, the critical defect size can be linked to a representative indication in the monitoring data, and the capability of the monitoring system can be tested using the 90/95 probability of detection requirement for NDE methods. This would enable the use of in-process monitoring as a defect screening activity for AM part certification. Many high-criticality components built with AM have high complexity and therefore limited inspectability, so using in-process monitoring can help address this certification gap. The use of adaptive, closed-loop monitoring systems that alter the locked process will require a new approach to the QMP.

additive manufacturing↗

NASA NTRSDate not supplied

Role of NDE and In-Situ Process Monitoring in Managing Risk of AM Space Hardware

advanced manufacturing↗

NASA NTRSDate not supplied

First-results from the Perseverance SHERLOC Investigation: Aqueous Alteration Processes and Implications for Organic Geochemistry in Jezero Crater, Mars

The Perseverance rover landed in Jezero crater, a site selected to fulfill the Mars-2020 mission goals of characterizing the geology of habitable environments and searching for signs of life while collecting samples for return to Earth [1]. Jezero hosted an open-basin lake during the late Noachian/early Hesperian (~3.7 Ga) [1-2], has units associated with the largest carbonate deposit identified on Mars [3-4], and has a well-preserved delta with clay and carbonate-bearing sediments, well-suited to preservation of organics [1,3-4]. Investigating the nature of organics and aqueous environments within their geologic con-text allows us to understand important aqueous processes and determine habitability within Jezero crater. Previous in situ landed measurements of organics could not resolve their spatial and mineralogical con-text [5-6]. Although Martian meteorites lack geological context, the spatial distribution of organic compounds in Martian meteorites have allowed recognition of an association between aqueous processes and organics [7-8]. Here, we show for the first time in-situ associations between carbonate-forming ultramafic alteration process, later stage aqueous sulfate and perchlorate formation, and organics on the Martian surface. Methodology and geological context: We use the Perseverance rover’s SHERLOC instrument (Scanning Habitable Environments with Raman and Lumines-ence of Organics and Chemicals), a deep-ultraviolet fluorescence and Raman scattering spectrometer capable of mapping the organic and mineral composition with a spatial resolution of 100 μm resolution to report the presence of organics and aqueously formed minerals at Jezero crater [9]. These spectral detections were compared with co-located images obtained with the autofocus context imager (ACI) and the WATSON camera for textural analysis [9]. As of writing, the Per-severance rover has abraded five targets that were measured with the SHERLOC instrument. The five targets are located in two different orbitally-identified geological units within the floor of Jezero crater; the Crater Floor Fractured Rough unit (CF-Fr) and the Séítah region within the Crater Floor Fractured 1 unit (CF-F1) [10]. In orbital infrared spectroscopic data, the CF-Fr unit is associated with pyroxene spectral signatures and minor alteration, while the Séítah region is associated with olivine and minor Mg-rich carbonates and clays [3-4,10]. Carbonation of ultramafic protolith recorded within Jezero crater: All scans of abraded targets within the Séítah region reveal strong peaks at 1080–1090 cm−1 consistent with carbonate and peak singlets or doublets at 820–840 cm−1 attributed to olivine (Fig. 1), consistent with orbital infrared observations. Our detailed micron-scale petrographic and spectroscopic evidence shows that these carbonates formed through carbonation of an ultramafic protolith. The supporting observations include: (1) Carbonate cation compositions match those of olivine, suggesting mixed Fe- and Mg-olivine gave rise to mixed Fe- and Mg-carbonates, similar to observations of ultramafic systems on Earth and within Martian meteorites [3-4,7-8]. (2) The ob-served carbonates co-occur with hydrated materials, gypsum, and potentially aqueously-formed phases, amorphous silicates and phosphate. (3) The spectral and textural variation of olivine and carbonate dominated zones and olivine-carbonate mixtures within both primary grains and interstitial zones are expected for carbonated ultramafic protoliths. (4) These mineral associations and textures closely resemble those observed within the ALH84001 and Nakhlite meteorites attributed to olivine carbonation on Mars [6-7]. Taken together, micron-scale SHERLOC documentation of these phenomena bridge previous orbital and meteorite observations and demonstrate in-situ regionally extensive (~106 km2) ultramafic alteration resulting in geo-logical deposition of carbonates. Furthermore, we observe that olivine carbonation was involved in preserving and possibly synthesizing organics, which makes this environment potentially habitable, as previously suggested in [1,3-4] (Fig. 1). Late-stage aqueous perchlorate and sulfate in Jezero crater: An abrasion target within the CF-Fr unit contains combinations of high intensity 950-955 cm−1 peaks and minor 1090-1095 cm−1 and 1150-1155 cm−1 peaks that are spectral fits to anhydrous perchlorate (Fig. 1). Some spectra show a combination of 950-955 cm−1 peaks with equally strong 1010-1020 cm−1 peaks, low intensity broad features at 1120 cm−1, and occasional broad 3450 cm−1 hydration (-OH) features, indicating a mixture of Ca-sulfate and perchlorate that is minimally hydrated (Fig. 1). The detections of per-chlorates within Jezero crater differ from previous measurements (e.g. Phoenix lander, Curiosity rover, Tissint meteorite [7,11]) because they are observed to be intimately related to aqueous processes including sulfate formation, they present as a secondary white void-fill occurring within the interior of the rock, and they are found to likely be Na-perchlorate. implications for their formation: Three different types of organics embedded within three different lithologies were observed within the abraded targets. Organics associated with low intensity ~340 nm fluorescence were widespread within targets with no apparent association to particular minerals (Fig. 1). Organics associated with ~305 nm and ~275 nm fluorescence correlated with sulfates within the Bellegarde target in the CF-Fr unit, while organics associated with high intensity ~340 nm fluorescence correlated with carbonate, phosphate, and amorphous silicate mixtures within the Garde target in the Séítah region (Fig. 1). Although assignment of fluorescence signatures to specific organic compounds is not conclusive, ~340 nm fluorescence is generally more consistent with 2-ring aromatic organics, ~275 nm fluorescence is more consistent with 1-ring aromatic organics, and ~305 nm fluorescence can be created by either 2- or 1-ring aromatics [12]. These observations indicate that the strongest fluorescence signatures interpreted as organics were found in materials associated with aqueous processes, i.e. sulfate- and carbonate-bearing materials, suggesting both brines and ultramafic carbonation aqueous environments were capable of preserving organics on ancient Mars. In Martian meteorites, simple aromatic organics proposed to have been synthesized through aqueous processes can be found within minerals associated with olivine carbonation and in spatial association with perchlorate and sulfate materials [7-8], similar to SHERLOC observations. Hence, we advance an abiotic aqueous synthesis origin for the organics although we cannot rule out the presence of organics from meteoritic in-fall or putative organic biosignatures. Detailed analyses will be required upon return of these materials to Earth.

E L Scheller↗

NASA NTRSDate not supplied

Bosch Process Technology Development for Air Revitalization

Closed-loop Environmental Control and Life Support Systems (ECLSS) aim to fully recover resources needed to keep astronauts alive in space– primarily, this means reclaiming oxygen (O2) to breathe and water (H2O) to drink from metabolic products. In air revitalization, this requires reclaiming the oxygen tied up in metabolic carbon dioxide (CO2). The current state of the art for the International Space Station (ISS) uses a Sabatier reaction in a system that has demonstrated a 50% O2 recovery rate. While there are several ongoing projects to improve the recovery of the Sabatier-based process, there are also projects working on an alternative approach centered around the Bosch process. Unlike the Sabatier, which has theoretical limits on maximum O2 recovery, the Bosch process can theoretically recover all of the O2 trapped in metabolic CO2 with only solid carbon (C) as a byproduct. However, the C generated in the process poses a significant challenge, introducing issues with clogging, contamination, and catalyst degradation that ultimately make the Bosch process unfeasible for flight at the current state of development. This poster overviews the promise and challenges of the Bosch process, prior investigations conducted, and current work towards advancing the TRL of Bosch-based O2 recovery systems and dealing with the (C) buildup. It also discusses potential uses of the carbon itself, which could prove to be a useful product in in-situ resource utilization (ISRU) applications.

Lunar↗

NASA NTRSDate not supplied

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗

NASA NTRSDate not supplied

Integrated Bosch Process System Models for In-Situ Oxygen and Carbon Production

In-Situ Resource Utilization (ISRU) technology is a vital component to NASA’s mission of a sustainable presence on the Moon and Mars. Local resources can be leveraged to reduce resupply frequency and mass. Elements of the Bosch process, combined with the carbothermal reduction process, can produce oxygen on the lunar surface with minimal consumables. The Bosch process can also produce oxygen on the Martian surface by using the CO 2 -rich environment. Between both systems, adsorption pump, solar thermal energy, carbon formation reactor, and water recovery subsystems are modeled and integrated to create a functional model in MATLAB software. The model is used to simulate performance of the system and reduce mass, power, and volume requirements. This integrated system model provides a tool to scale ISRU technologies for oxygen and carbon production. The MATLAB model is created by developing a system of independent subsystem models that are solved for their quasi-steady state values which can be integrated with respect to time to determine the change in current states. A flexible time stepping method is used to ensure a high level of accuracy during periods of rapid change while still making use of a simple explicit integration method. The flexible time step is calculated for each independent subsystem and the minimum value from those is used as the overall time step. A flexible time step is calculated by dividing a resolution value, or the maximum change per time step, by the variables current rate of change. The maximum value from all points in space is used for subsystem models that contain multiple values. The process is done for every variable that is being monitored in each subsystem and the global minimum is used as that iteration’s timestep. Several assumptions used in the MATLAB model for fluid flow dynamics, such as 1-D gas flow through the sorption pump, are supported by modeling in Ansys Fluent software. The Lunar oxygen production system is outlined in Fig. 1. The carbothermal reduction subsystem uses solar energy to heat a mixture of lunar regolith and carbon powder to produce carbon monoxide. To begin, the carbon monoxide feeds to the modified Bosch subsystem along with hydrogen gas. The reactants then enter the carbon formation reactor where water and carbon powder are produced. Solar thermal energy is used to add energy to the reactor, but waste heat from the carbothermal process is another potential heat source. The water is collected and electrolyzed to produce hydrogen which reenters the Bosch subsystem, and the oxygen is stored for downstream use. The carbon powder is collected and feeds back into the carbothermal subsystem. The Martian oxygen production system uses the full Bosch process and is outlined in Fig 2. A CO 2 adsorption pump thermally cycles to scrub and pressurize CO 2 from the environment. Along with an initial supply of hydrogen, the reactants enter the Reverse Water Gas Shift Reactor (RWGSR) which produces carbon monoxide and water. Carbon monoxide and unreacted hydrogen enter the carbon formation reactor to produce water and carbon powder. The water is collected from both reactors and electrolyzed to reintroduce hydrogen and store oxygen for propellant production or life support. Carbon is removed from the carbon formation reactor and stored. The adsorption pump utilizes rapid cycle temperature swings within a stack of zeolite coated surfaces. The subsystem model solves 1-D quasi-steady conservation laws of the quasi-steady form, shown in Eq. 1, for the gas stream and heat exchange liquid to predict performance parameters such as breakthrough capacity and optimum cycle time. The source term S is used to capture interactions between the fluid flows and the sorbent. A quasi-steady-state scheme is used where no time derivatives appear in the governing equations, except for those in the source terms. This results in an autonomous system, where ∂F/∂x = ƒ(F). The fluxes F are provided at the inlet, and an explicit method is used to solve for the spatial distribution of F. The heat and mass flows to the sorbent are then extracted from the source terms. These flows are numerically integrated to produce a 1-D solution for the system’s state as a function of both time and space. The body of the adsorption pump is separated into two semi-independent models: the heat exchanger fluid flow and gas flow through the zeolite coated surfaces. Both models are solved using the above-described method to find a 1-D solution as a function of space and interact only once a timestep is taken. The interaction point is the sorbent through which all heat transfer between the two models must occur. Sorbent mass adsorption is calculated using the Lagergren model, shown in Eq. 2, where the transfer coefficient, λ D , is found by solving a system of nondimensionalized equations derived by using the heat and mass transfer analogy for transport phenomena. Using Grade 544 Type 13X zeolite as the sorbent material, the equilibrium concentration, θ eq , is calculated using the k-site Langmuir isotherm and fit parameters. Additionally, the enthalpy of adsorption used in the model is computed by interpolation of available data [1]. The subsystem model was validated using the Rapid Cycle Temperature Swing Adsorption (RC-TSA) pump. The solar thermal energy subsystem focuses on a solar concentrator concept with a heat exchanger to heat the reactants before entering the carbon formation reactor. The subsystem model assumes a fixed solar flux and reflector efficiency to calculate the reactant temperature given the incoming temperature, pressure, and exchanger geometry. The receiver is a custom manufactured series of copper blocks with serpentine channels to increase its surface area and the residence time of the reactants to heat up to 550 °C. The subsystem model was validated using a heat exchanger developed at NASA Glenn Research Center (GRC). The solar thermal energy subsystem focuses on a solar concentrator concept with a heat exchanger to heat the reactants before entering the carbon formation reactor. The subsystem model assumes a fixed solar flux and reflector efficiency to calculate the reactant temperature given the incoming temperature, pressure, and exchanger geometry. The receiver is a custom manufactured series of copper blocks with serpentine channels to increase its surface area and the residence time of the reactants to heat up to 550 °C. The subsystem model was validated using a heat exchanger developed at NASA Glenn Research Center (GRC).

In situ Resource Utilization↗

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Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗

NASA NTRSDate not supplied

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing↗