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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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At least 685 records · Page 38

Fabrication of Spherical Reflectors in Outer Space

A process is proposed for fabrication of lightweight spherical reflectors in outer space for telescopes, radio antennas, and light collectors that would be operated there. The process would obviate the relatively massive substrates and frames needed to support such reflectors in normal Earth gravitation. According to the proposal, fabrication of a reflector would begin with blowing of a bubble to the specified reflector radius. Taking advantage of the outer-space vacuum as a suitable environment for evaporative deposition of metal, a metal-evaporation source would be turned on and moved around the bubble to deposit a reflective metal film over the specified reflector area to a thickness of several microns. Then the source would be moved and aimed to deposit more metal around the edge of the reflector area, increasing the thickness there to approximately equal to 100 micron to form a frame. Then the bubble would be deflated and peeled off the metal, leaving a thin-film spherical mirror having an integral frame. The mirror would then be mounted for use. The feasibility of this technology has been proved by fabricating a prototype at JPL. As shown in the figure, a 2-in. (.5-cm) diameter hemispherical prototype reflector was made from a polymer bubble coated with silver, forming a very smooth surface.

Wang, Yu↗

Preparation and evaluation of Apollo 14 composite experiments

An account is given of the work aimed at flight experiments on Apollo 14, in relation to space manufacturing processes. Evaluation of suitable materials, definition of in-flight processing procedures, preparation of preprocessed materials and delivery, and evaluation of the space-processed samples after return from the Apollo 14 flight are presented.

Steurer, W. H.↗

Analysis of launch site processing effectiveness for the Space Shuttle 26R payload

A trend analysis study has been performed on problem reports recorded during the Space Shuttle 26R payload's processing cycle at NASA-Kennedy, using the defect-flow analysis (DFA) methodology; DFA gives attention to the characteristics of the problem-report 'population' as a whole. It is established that the problem reports contain data which distract from pressing problems, and that fully 60 percent of such reports were caused during processing at NASA-Kennedy. The second major cause of problem reports was design defects.

Flores, Carlos A.↗

Toward a space materials systems program

A program implementation model is presented which covers the early stages of space material processing and manufacturing. The model includes descriptions of major program elements, development and experiment requirements in space materials processing and manufacturing, and an integration of the model into NASA's long range plans as well as its evolution from present Materials Processing in Space plans.

Vontiesenhausen, G. F.↗

Oversimplification of Systems Engineering Goals, Processes, and Criteria in NASA Space Life Support

This paper investigates the oversimplification of the inherently complex systems engineering process in space life support. The standard systems engineering process steps are described. The International Space Station (ISS) life support system is explained with its goals and performance criteria. Although it is not usually emphasized, the essential function of developing a hierarchy of systems and subsystems is to simplify the design process. The System Complexity Metric (SCM) shows how this di-vide-and-conquer approach also reduces the system complexity. The complete systems engineering process has many detailed steps. It is often simplified because of the effort required and the human limitations on working memory and decision span. Systems analysis demands slow, logical, and fo-cused thinking but is often bypassed in favor of quick, intuitive, subconscious “gut feel.” A study of 100 system designs found examples of 12 specific mental mistakes, such as ignoring stakeholder needs, and these mistakes are essentially oversimplifications of the systems engineering process. An analysis of space life support goals, options, criteria, and processes found 11 examples of oversimplifications in systems engineering, such as neglecting safety and cost. All these 11 oversimplifications could be traced to one or more of the 12 previously identified mental mistakes or other well-known ones, such as ig-noring sunk costs. Oversimplification of the systems engineering process is rarely noticed but is a common and harmful problem. A study of failures in 50 different space systems found that problems in systems engineering caused failures and often led to errors in design, development, and test that further contributed to failure. It seems that more diligent systems engineering could prevent many project problems and failures, but projects seem to be more guided by “gut feel” based on tradition, authority, and consensus than on the logical, rational systems engineering approach.

Simplified systems engineering↗

Influence of the space environment on some materials processing phenomena

The influence of the space environment on materials processing phenomena is studied by applying the principles of physical similarity to a system E on Earth and a system S in the microgravity environment of space. If these systems can be characterized by a set of dimensionless groups, then they are similar if corresponding members of the set are equal for E and S. Similarity is often impractical or impossible if Q is larger than a few samples. For example, there is a simple law of similarity for an isothermal liquid zone floating between inert solids; however, similarity is lost if the zone becomes nonisothermal. A molten zone during crystal growth is so complex that a complete set cannot be identified with certainty. A second example is double-diffusive convection during unidirectional solidification of a binary alloy. Results show that buoyancy driven fluid dynamical instabilities couple with constitutionally related instabilities quite differently in E and S.

Sekerka, R. F.↗

Certification-Based Process Analysis

Space mission architects are often challenged with knowing which investment in technology infusion will have the highest return. Certification-based analysis (CBA) gives architects and technologists a means to communicate the risks and advantages of infusing technologies at various points in a process. Various alternatives can be compared, and requirements based on supporting streamlining or automation can be derived and levied on candidate technologies. CBA is a technique for analyzing a process and identifying potential areas of improvement. The process and analysis products are used to communicate between technologists and architects. Process means any of the standard representations of a production flow; in this case, any individual steps leading to products, which feed into other steps, until the final product is produced at the end. This sort of process is common for space mission operations, where a set of goals is reduced eventually to a fully vetted command sequence to be sent to the spacecraft. Fully vetting a product is synonymous with certification. For some types of products, this is referred to as verification and validation, and for others it is referred to as checking. Fundamentally, certification is the step in the process where one insures that a product works as intended, and contains no flaws.

Knight, Russell L.↗

RoMPS concept review automatic control of space robot

The Robot operated Material Processing in Space (RoMPS) experiment is being performed to explore the marriage of two emerging space commercialization technologies: materials processing in microgravity and robotics. This concept review presents engineering drawings and limited technical descriptions of the RoMPS programs' electrical and software systems.

Source record↗

Contamination Control and Hardware Processing Solutions at Marshall Space Flight Center

The Contamination Control Team of Marshall Space Flight Center's Materials and Processes Laboratory supports many Programs/ Projects that design, manufacture, and test a wide range of hardware types that are sensitive to contamination and foreign object damage (FOD). Examples where contamination/FOD concerns arise include sensitive structural bondline failure, critical orifice blockage, seal leakage, and reactive fluid compatibility (liquid oxygen, hydrazine) as well as performance degradation of sensitive instruments or spacecraft surfaces such as optical elements and thermal control systems. During the design phase, determination of the sensitivity of a hardware system to different types or levels of contamination/FOD is essential. A contamination control and FOD control plan must then be developed and implemented through all phases of ground processing, and, sometimes, on-orbit use, recovery, and refurbishment. Implementation of proper controls prevents cost and schedule impacts due to hardware damage or rework and helps assure mission success. Current capabilities are being used to support recent and on-going activities for multiple Mission Directorates / Programs such as International Space Station (ISS), James Webb Space Telescope (JWST), Space Launch System (SLS) elements (tanks, engines, booster), etc. The team also advances Green Technology initiatives and addresses materials obsolescence issues for NASA and external customers, most notably in the area of solvent replacement (e.g. aqueous cleaners containing hexavalent chrome, ozone depleting chemicals (CFC s and HCFC's), suspect carcinogens). The team evaluates new surface cleanliness inspection and cleaning technologies (e.g. plasma cleaning), and maintains databases for processing support materials as well as outgassing and optical compatibility test results for spaceflight environments.

Burns, DeWitt H.↗

A Coordinated Initialization Process for the Distributed Space Exploration Simulation (DSES)

This document describes the federate initialization process that was developed at the NASA Johnson Space Center with the HIIA Transfer Vehicle Flight Controller Trainer (HTV FCT) simulations and refined in the Distributed Space Exploration Simulation (DSES). These simulations use the High Level Architecture (HLA) IEEE 1516 to provide the communication and coordination between the distributed parts of the simulation. The purpose of the paper is to describe a generic initialization sequence that can be used to create a federate that can: 1. Properly initialize all HLA objects, object instances, interactions, and time management 2. Check for the presence of all federates 3. Coordinate startup with other federates 4. Robustly initialize and share initial object instance data with other federates.

Phillips, Robert↗

Space Shuttle Systems Engineering Processes for Liftoff Debris Risk Mitigation

This slide presentation reviews the systems engineering process designed to reduce the risk from debris during Space Shuttle Launching. This process begins the day of launch from the tanking to the vehicle tower clearance. Other debris risks (i.e., Ascent, and micrometeoroid orbital debit) are mentioned) but are not the subject of this presentation. The Liftoff debris systems engineering process and an example of how it works are reviewed (i.e.,STS-119 revealed a bolt liberation trend on the Fixed Service Structure (FSS) 275 level elevator room). The process includes preparation of a Certification of Flight Readiness (CoFR) that includes (1) Lift-off debris from previous mission dispositioned, (2) Flight acceptance rationale has been provided for Lift-off debris sources/causes (3) Lift-off debris mission support documentation, processes and tools are in place for the up-coming mission. The process includes a liftoff debris data collection that occurs after each launch. This includes a post launch walkdown, that records each liftoff debris, and the entry of the debris into a database, it also includes a review of the imagery from the launch, and a review of the instrumentation data. There is also a review of the debris transport analysis process, that includes temporal and spatial framework and a computational fluid dynamics (CFD) analysis. which incorporates a debris transport analyses (DTA), debris materials and impact tests, and impact analyses.

Mitchell, Michael↗

Qualification of Bonding Process of Temperature Sensors to Extreme Temperature Deep Space Missions

A process has been explored based on the state-of-the-art technology to bond the platinum resistance thermometer (PRT) on to potential aerospace material such as a flat aluminum surface and a flexible copper tube to simulate coaxial cable for the flight applications. Primarily, PRTs were inserted into a metal plated copper braid to avoid stresses on the sensor while attaching the sensor with braid to the base material for long duration deep space missions. Appropriate pretreatment has been implemented in this study to enhance the adhesion of the PRTs to the base material. NuSil product has been chosen in this research to attach PRT to the base materials. The resistance (approx.1.1 k(Omega)) of PRTs has been electrically monitored continuously during the qualification thermal cycling testing from -150 C to +120 C and -100 C to -35 C. The test hardware has been thermal cycled three times the mission life per JPL design principles for JUNO project. No PRT failures were observed during and after the PRT thermal cycling qualification test for extreme temperature environments. However, there were some failures associated with staking of the PRT pig tails as a result of thermal cycling qualification test.

Extreme temperatures↗

Audio problems in space.

Audio signal processing techniques in future space exploration, discussing channel capacity, speech processing, bandwidth narrowing, etc

SPACE EXPLORATION↗

Space Shuttle data acquisition and processing

The techniques of minimizing the amount of Space Shuttle data processed by using real-time ground data and on board computer to prescreen the data are presented. With the advent of long duration space flight and the large amounts of data generated, it became necessary to limit the amount of data to be processed and also to present data in a manner that highlights the most important data. The Shuttle operational data system with output of 128 kilobits/sec, the developmental flight instrumentation system, and screening of data by the analysts, flight crew, or onboard computers is described, noting that by using these monitoring methods the mission evaluation team can rapidly determine time periods for which postflight data processing is required. Postflight processing systems, batch system output products, data compression techniques, the interactive computer system, and the special telemetry conversion system are discussed, and it is concluded that the combination of Shuttle on board and ground data processing systems enhances the ability to perform a functional evaluation of the Space Shuttle vehicle.

Foster, G. B., Jr.↗

Adaptation of Metal Additive Manufacturing Processes for the International Space Station

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center, in a partnership with the company, Made in Space, has previously investigated 3D printing of polymer materials on-orbit. In recent years, the project has begun exploring the potential for metal additive manufacturing (AM) on future space missions to reduce logistics and enable point-of-use manufacturing for sparing and repair. This presentation will provide an overview of constraints for demonstrating a manufacturing process on the International Space Station (ISS) as well as trades of available metal AM processes and their potential for in-space use. There are currently two processes in development as payloads for an ISS technology demonstration: wire+arc additive manufacturing (the Vulcan payload from Made in Space, Inc.) and bound metal deposition (the Fabrication Laboratory from Techshot, Inc). An update on both of these systems, results to date, and future development efforts will be presented. Relevant modeling work to evaluate operation of certain aspects of the processes in a microgravity environment will also be summarized.

manufacturing↗

Adaptation of Metal Additive Manufacturing Processes for the International Space Station

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center, in a partnership with the company, Made in Space, has previously investigated 3D printing of polymer materials on-orbit. In recent years, the project has begun exploring the potential for metal additive manufacturing (AM) on future space missions to reduce logistics and enable point-of-use manufacturing for sparing and repair. This paper provides an overview of constraints for demonstrating a manufacturing process on the International Space Station (ISS) as well as information on previous trades of available metal AM processes and their potential for in-space use. There are currently two processes in development as payloads for an ISS technology demonstration: wire+arc additive manufacturing (the Vulcan payload from Made in Space, Inc.) and bound metal additive manufacturing (the Fabrication Laboratory from Techshot, Inc). An update on both of these systems, key results to date, and future development efforts will be presented. Relevant modeling work, performed by NASA Ames Research Center, to evaluate operation of certain aspects of the bound metal AM process in a microgravity environment will also be summarized.

in-space manufacturing↗