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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Results of May 2000 field testing of the FIDO prototype Mars rover are summarized. Tests included remote science operations and simulated aspects of the Athena payload for 2003 MER (Mars Exploration Rovers). Additional information is contained in the original extended abstract.
Today's modern machining projects are composed more and more of complicated and intricate structure due to a variety of reasons including the ability to computer model complex surfaces and forms. The cost of producing these forms can be extremely high not only in dollars but in time to complete. Changes are even more difficult to incorporate. The subject blade shown is an excellent example. Its complex form would have required hundreds of hours in fabrication for just a simple prototype. The procurement would have taken in the neighborhood of six weeks to complete. The actual fabrication would have been an equal amount of time to complete. An alternative to this process would have been a wood model. Although cheaper than a metal fabrication, it would be extremely time intensive and require in the neighborhood of a month to produce in-house.
One of the most costly errors committed during the development of an element to be used in the space industry is the lack of communication between design and manufacturing engineers. A very important tool that should be utilized in the development stages by both design and manufacturing disciplines is rapid prototyping. Communication levels are intensified with the injection of functional models that are generated from a drawing. At the Marshall Space Flight Center, this discipline is utilized on a more frequent basis as a manner by which hardware may be tested for design and material compatibility.
We were originally awarded Priority 3 time (approximately 60,000 sec) with Infrared Space Observatory (ISO) to obtain a complete ISOPHOT (PHT32-C200) map of a nearby prototypical giant molecular cloud (GMC). Following the FALL launch and revised estimates for the sensitivity of the ISOPHOT detectors, our program was modified to fit within the time constraints while still carrying out the main science requirements. The revised program requested long strip maps of our FALL target (NGC7538) using sequences of PHT37/38/39 observations with LWS observations of the brightest regions. The large number of AOTs required to cover each GMC required that our observations be spread over four separate proposals (PROP-01, PROP-02, PROP-03, PROP-04) which together comprise a single observing program. Our program was executed in early 1997; nearly 50,000 sec of data were obtained, including all of our requested ISOPHOT C200 observations. None of the LWS data were taken.
The Controlled Ecological Life Support System (CELSS) Antarctic Analog Project (CAAP), is a joint endeavor between the National Science Foundation, Office of Polar Programs (NSF-OPP) and the NASA. The fundamental objective is to develop, deploy, and operate a testbed of advanced life support technologies at the Amundsen-Scott South Pole Station that enable the objectives of both the NSF and NASA. The functions of food production, water purification, and waste treatment, recycle and reduction provided by CAAP will improve the quality of life for the South Pole inhabitants, reduce logistics dependence, enhance safety and minimize environmental impacts associated with human presence on the polar plateau. Because of the analogous technical, scientific, and mission features with Planetary missions such as a mission to Mars, CAAP provides NASA with a method for validating technologies and overall approaches to supporting humans. Prototype systems for sewage treatment, water recycle and crop production are being evaluated at Ames Research Center. The product water from sewage treatment using a Wiped-Film Rotating Disk is suitable for input to the crop production system. The crop production system has provided an enhanced level of performance compared with projected performance for plant-based life support: an approximate 50% increase in productivity per unit area, more than a 65% decrease in power for plant lighting, and more than a 75% decrease in the total power requirement to produce an equivalent mass of edible biomass.
The essence of the KLEM (Kinematic Lightweight Energy Meter) instrument is to directly measure the elemental energy spectra of high-energy cosmic rays by determining the angular distribution of secondary particles produced in a target. The first test of the simple KLEM prototype has been performed at the CERN SPS test-beam with 180 GeV pions during 2001. The results of the first test analysis confirm that, using the KLEM method, the energy of 180 GeV pions can be measured with a relative error of about 67%, which is very close to the results of the simulation (65%).
The Controlled Ecological Life Support System (CELSS) Antarctic Analog Project (CAAP) is a joint endeavor between the National Science Foundation, Office of Polar Programs (NSF-OPP), and the National Aeronautics and Space Administration (NASA). The fundamental objective is to develop, deploy, and operate a testbed of advanced life support technologies at the Amundsen-Scott South Pole Station that enable the objectives of both the NSF and NASA. The functions of food production, water purification, and waste treatment, recycle, and reduction provided by CAAP will improve the quality of life for the South Pole inhabitants, reduce logistics dependence, enhance safety, and minimize environmental impacts associated with human presence on the polar plateau. Because of the analogous technical, scientific, and mission features with Planetary missions, such as a mission to Mars, CAAP provides NASA with a method for validating technologies and overall approaches to supporting humans. Prototype systems for waste treatment, water recycle, resource recovery and crop production are being evaluated in a testbed at Ames Research Center. The combined performance of these biological and physical/chemical systems as an integrated function in support of the human habitat will be discussed. Overall system performance will be emphasized. The effectiveness and efficiency of component technologies will be discussed in the context of energy and mass flow within the system and contribution to achieving a mass and energy conservative system. Critical to the discussion are interfaces with habitat functions outside of the closed-loop life support: the ability of the system to satisfy the life support requirements of the habitat and the ability to define input requirements. The significance of analog functions in relation to future Mars habitats will be discussed.
Javelin, a Lone Peak Engineering Inc. Company has introduced the SteamRoller(TM) System as a commercial product. The system was designed by Javelin during a Phase II NASA funded small commercial product. The purpose of the invention was to allow automated-feed of flexible ceramic tapes to the Laminated Object Manufacturing rapid prototyping equipment. The ceramic material that Javelin was working with during the Phase II project is silicon nitride. This engineered ceramic material is of interest for space-based component.
Thermography and shearography methods of inspection rely on optic based technologies and can reduce the time and cost required to inspect composite tanks or aerostructures. Usually areas identified as suspect in the initial inspection results are reexamined with ultrasonic methods. This combination of techniques results in a rapid and comprehensive inspection of composite structures. Development of useful defect standards will be discussed. Examples of application of this inspection philosophy to prototype, GSE, and flight hardware will be presented. Methods organizing the inspection and evaluating the results will be considered.
This report discusses the design implications for spacecraft radiators made possible by the successful fabrication and proof-of-concept testing of a graphite-fiber-carbon-matrix composite (i.e., carbon-carbon (C-C)) heat pipe. The prototype heat pipe, or space radiator element, consists of a C-C composite shell with integrally woven fins. It has a thin-walled furnace-brazed metallic (Nb-1%Zr) liner with end caps for containment of the potassium working fluid. A short extension of this liner, at increased wall thickness beyond the C-C shell, forms the heat pipe evaporator section which is in thermal contact with the radiator fluid that needs to be cooled. From geometric and thermal transport properties of the C-C composite heat pipe tested, a specific radiator mass of 1.45 kg/sq m can be derived. This is less than one-fourth the specific mass of present day satellite radiators. The report also discusses the advantage of segmented space radiator designs utilizing heat pipe elements, or segments, in their survivability to micrometeoroid damage. This survivability is further raised by the use of condenser sections with attached fins, which also improve the radiation heat transfer rate. Since the problem of heat radiation from a fin does not lend itself to a closed analytical solution, a derivation of the governing differential equation and boundary conditions is given in appendix A, along with solutions for rectangular and parabolic fin profile geometries obtained by use of a finite difference computer code written by the author.
For ceramics to be used as structural components in high temperature applications, their fracture toughness is improved by embedding continuous ceramic fibers. Ceramic matrix composite (CMC) materials allow increasing the overall operating temperature, raising the temperature safety margins, avoiding the need for cooling, and improving the damping capacity, while reducing the weight at the same time. They also need to be reliable and available in large quantities as well. In this paper, an innovative rapid prototyping technique to fabricate continuous fiber reinforced ceramic matrix composites is described. The process is simple, robust and will be widely applicable to a number of high temperature material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The results of mechanical properties and microstructural characterization are presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts at an order of magnitude lower cost than current CVI and PIP processes.
Thermography inspection is an optic based technology that can reduce the time and cost required to inspect propellant tanks or aero structures fabricated from composite materials. Usually areas identified as suspect in the thermography inspection are examined with ultrasonic methods to better define depth, orientation and the nature of the anomaly. This combination of nondestructive evaluation techniques results in a rapid and comprehensive inspection of composite structures. Examples of application of this inspection philosophy to prototype will be presented. Methods organizing the inspection and evaluating the results will be considered.
NASA's Langley Research Center and Johnson Space Center are developing a solid freeform fabrication system utilizing an electron beam energy source and wire feedstock. This system will serve as a testbed for exploring the influence of gravitational acceleration on the deposition process and will be a simplified prototype for future systems that may be deployed during long-duration space missions for assembly, fabrication, and production of structural and mechanical replacement components. Critical attributes for this system are compactness, minimal mass, efficiency in use of feedstock material, energy use efficiency, and safety. The use of a low-voltage (less than 15kV) electron beam energy source will reduce radiation so that massive shielding is not required to protect adjacent personnel. Feedstock efficiency will be optimized by use of wire, and energy use efficiency will be achieved by use of the electron beam energy source. This system will be evaluated in a microgravity environment using the NASA KC-135A aircraft.
This paper presents an overview of an ongoing research and development effort at the NASA Ames Research Center to create an autonomous control system for an internal spacecraft autonomous mobile monitor. It primary functions are to provide crew support and perform intra- vehicular sensing activities by autonomously navigating onboard the International Space Station. We describe the mission roles and high-level functional requirements for an autonomous mobile monitor. The mobile monitor prototypes, of which two are operational and one is actively being designed, physical test facilities used to perform ground testing, including a 3D micro-gravity test facility, and simulators are briefly described. We provide an overview of the autonomy framework and describe each of its components, including those used for automated planning, goal-oriented task execution, diagnosis, and fault recovery. A sample mission test scenario is also described.
Contents include the following: Background and motivation. Grid computing concepts. Advanced data grid (ADG) prototype development. ADG requirements and operations concept. ADG architecture. ADG implementation. ADG test plan. ADG schedule. Summary and status.
For ceramics to be used as structural components in high temperature applications, their fracture toughness is improved by embedding continuous ceramic fibers. Ceramic matrix composite (CMC) materials allow increasing the overall operating temperature, raising the temperature safety margins, avoiding the need for cooling, and improving the damping capacity, while reducing the weight at the same time. They also need to be reliable and available in large quantities as well. In this paper, an innovative rapid prototyping technique to fabricate continuous fiber reinforced ceramic matrix composites is described. The process is simple, robust and will be widely applicable to a number of high temperature material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The results of mechanical properties and microstructural characterization are presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts at an order of magnitude lower cost than current chemical vapor infiltration (CVI) and polymer impregnation and pyrolysis (PIP) processes.
My experience, both first-and second-hand, has been that people have misused prototyping almost as often as they have used it wisely. I will try and cite some of the ways I have seen people abuse the concept.
A full-scale crash test of a prototype composite helicopter was performed at the Impact Dynamics Research Facility at NASA Langley Research Center in 1999 to obtain data for validation of a finite element crash simulation. The helicopter was the flight test article built by Sikorsky Aircraft during the Advanced Composite Airframe Program (ACAP). The composite helicopter was designed to meet the stringent Military Standard (MIL-STD-1290A) crashworthiness criteria and was outfitted with two crew and two troop seats and four anthropomorphic dummies. The test was performed at 38-ft/s vertical and 32.5-ft/s horizontal velocity onto a rigid surface. An existing modal-vibration model of the Sikorsky ACAP helicopter was converted into a model suitable for crash simulation. A two-stage modeling approach was implemented and an external user-defined subroutine was developed to represent the complex landing gear response. The crash simulation was executed with a nonlinear, explicit transient dynamic finite element code. Predictions of structural deformation and failure, the sequence of events, and the dynamic response of the airframe structure were generated and the numerical results were correlated with the experimental data to validate the simulation. The test results, the model development, and the test-analysis correlation are described.