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NASA NTRS2004

Information Technology Support in the 8000 Directorate

My summer internship was spent supporting various projects within the Environmental Management Office and Glenn Safety Office. Mentored by Eli Abumeri, I was trained in areas of Information Technology such as: Servers, printers, scanners, CAD systems, Web, Programming, and Database Management, ODIN (networking, computers, and phones). I worked closely with the Chemical Sampling and Analysis Team (CSAT) to redesign a database to more efficiently manage and maintain data collected for the Drinking Water Program. This Program has been established for over fifteen years here at the Glenn Research Center. It involves the continued testing and retesting of all drinking water dispensers. The quality of the drinking water is of great importance and is determined by comparing the concentration of contaminants in the water with specifications set forth by the Environmental Protection Agency (EPA) in the Safe Drinking Water Act (SDWA) and its 1986 and 1991 amendments. The Drinking Water Program consists of periodic testing of all drinking water fountains and sinks. Each is tested at least once every 2 years for contaminants and naturally occurring species. The EPA's protocol is to collect an initial and a 5 minute draw from each dispenser. The 5 minute draw is what is used for the maximum contaminant level. However, the CS&AT has added a 30 second draw since most individuals do not run the water 5 minutes prior to drinking. This data is then entered into a relational Microsoft Access database. The database allows for the quick retrieval of any test@) done on any dispenser. The data can be queried by building number, date or test type, and test results are documented in an analytical report for employees to read. To aid with the tracking of recycled materials within the lab, my help was enlisted to create a database that could make this process less cumbersome and more efficient. The date of pickup, type of material, weight received, and unit cost per recyclable. This information could then calculate the dollar amount generated by the recycling of certain materials. This database will ultimately prove useful in determining the amounts of materials consumed by the lab and will help serve as an indicator potential overuse.

FROM↗
NASA NTRS2007

Launching to the Moon, Mars, and Beyond

America is returning to the Moon in preparation for the first human footprint on Mars, guided by the U.S. Vision for Space Exploration. This presentation will discuss NASA's mission today, the reasons for returning to the Moon and going to Mars, and how NASA will accomplish that mission. The primary goals of the Vision for Space Exploration are to finish the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return people to the Moon and go to Mars. Unlike the Apollo program of the 1960s, this phase of exploration will be a journey, not a race. In 1966, the NASA's budget was 4 percent of federal spending. Today, with 6/10 of 1 percent of the budget, NASA must incrementally develop the vehicles, infrastructure, technology, and organization to accomplish this goal. Fortunately, our knowledge and experience are greater than they were 40 years ago. NASA's goal is a return to the Moon by 2020. The Moon is the first step to America's exploration of Mars. Many questions about the Moon's history and how its history is linked to that of Earth remain even after the brief Apollo explorations of the 1960s and 1970s. This new venture will carry more explorers to more diverse landing sites with more capable tools and equipment. The Moon also will serve as a training ground in several respects before embarking on the longer, more perilous trip to Mars. The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, the Ares V Cargo Launch Vehicle, the Orion Crew Exploration Vehicle, and the Lunar Surface Access Module. The architecture for the lunar missions will use one launch to ferry the crew into orbit on the Ares I and a second launch to orbit the lunar lander and the Earth Departure Stage to send the lander and crew vehicle to the Moon. In order to reach the Moon and Mars within a lifetime and within budget, NASA is building on proven hardware and decades of experience derived from the Apollo Saturn, Space Shuttle, and contemporary commercial launch vehicle programs. Less than one year after the Exploration Launch Projects Office was formed at NASA's Marshall Space Flight Center, engineers are testing engine components, firing test rocket motors, refining vehicle designs in wind tunnel tests, and building hardware for the first flight test of Ares I, scheduled for spring 2009. The Vision for Exploration will require this nation to develop tools, machines, materials, and processes never before invented, technologies and capabilities that can be turned over to the private sector to benefit nearly all aspects of life on Earth. This new pioneering venture, as did the Apollo Program before it, will contribute to America's economic leadership, national security, and technological global competitiveness and serve as an inspiration for all its citizens.

Sumrall, John P.↗
NASA NTRS2009

Expedition Earth and Beyond: Using NASA Data Resources and Integrated Educational Strategies to Promote Authentic Research in the Classroom

Teachers in today s classrooms are bound by state required skills, education standards, and high stakes testing. How can they gain skills and confidence to replace units or individual activities with curriculum that incorporates project and inquiry-based learning and promotes authentic research in the classroom? The key to promoting classroom authentic research experiences lies in educator professional development that is structured around teacher needs. The Expedition Earth and Beyond Program is a new geosciences program based at the NASA Johnson Space Center designed to engage, inspire and educate teachers and students in grades 5-14. The program promotes authentic research experiences for classrooms and uses strategies that will help NASA reach its education goals while still allowing educators to teach required standards. Teachers will have access to experts in terrestrial and planetary remote sensing and geoscience; this will enhance their use of content, structure, and relevant experiences to gain the confidence and skills they need to actively engage students in authentic research experiences. Integrated and powerful educational strategies are used to build skills and confidence in teachers. The strategies are as follows: 1) creating Standards-aligned, inquiry-based curricular resources as ready-to-use materials that can be modified by teachers to fit their unique classroom situation; 2) providing ongoing professional development opportunities that focus on active experiences using curricular materials, inquiry-based techniques and expanding content knowledge; 3) connecting science experts to classrooms to deepen content knowledge and provide relevance to classroom activities and real world applications; 4) facilitating students sharing research with their peers and scientists reinforcing their active participation and contributions to research. These components of the Expedition Earth and Beyond Education Program will be enhanced by providing exciting and diverse research opportunities that are inspired by views of Earth from space taken by astronauts on board the International Space Station. The interest and connection to viewing our home planet from space will inevitably spark questions that will drive students to pursue their research investigations, as well as forming a basis for comparisons to the exploration of other planetary bodies in our solar system.

Graffi, Paige Valderrama↗
NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗
NASA NTRS2019

Radar Cross Section of Orbital Debris Objects

This discussion is concerned with the radar-data analysis and usage involved in the building of model orbital debris (OD) populations in the near-Earth environment, focusing on radar cross section (RCS). While varying with radar wavelength, physical dimension, material composition, overall shape and structure, the RCS of an irregular object is also strongly dependent on its spatial orientation. The historical records of observed RCSs for cataloged OD objects in the Space Surveillance Network are usually distributed over an RCS range, forming respective characteristic patterns. The National Aeronautics and Space Administration (NASA) Size Estimation Model provides an empirical probability-density function of RCS as a function of “effective diameter” (or “characteristic length”), which makes it feasible to predict possible RCS distributions for a given model OD population and to link data with model from a statistical perspective. The discussion also includes application of the widely used method of moments (MoM) and the Generalized Multi-particle Mie-solution (GMM) in the prediction of the RCS of arbitrarily shaped objects. Theoretical calculation results for an aluminum cube are compared with corresponding experimental measurements.

Xu, Yu-Lin↗
NASA NTRSDate not supplied

Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars

A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.

Click Chemistry↗
NASA NTRSDate not supplied

ASTM International Conference on Additive Manufacturing – 2022

The In-Situ Project: Correlating In-situ monitoring data and Non-Destructive Evaluation (NDE) methods to characterize defect populations in Laser Powder Bed Fusion (L-PBF) material NDE is critical to enable the safe use of additive manufactured (AM) parts in aerospace applications. However, traditional NDE methods are not fully adaptable to complex AM geometries to appropriately screen for critical defects, and L-PBF processes inherently generate defects. In-situ monitoring techniques can give information about the quality of the build process and indicate process variations that could potentially create defects. Proven, causal correlations between in-situ monitoring indications and resulting defects are needed to inform about the final quality of the part. Thus, the development of a new approach is necessary. NASA started a two-phase study that would investigate techniques for characterizing defect populations in L-PBF material, first in material with induced defects, then in a nominal L-PBF process, by correlating in-situ, NDE, and serial sectioning data. Objectives also include the evaluation of seeded defect methodologies for realistic defect creation, creating a baseline of defect populations in a Qualified Material Process (QMP), characterizing the effect of heat treatment, and correlating defect populations with tensile and fatigue properties. By comparing computed tomography images, in-situ monitoring images, and metallography images, the team has been able to draw preliminary conclusions. They include a better understanding of the limitation of the NDE tools, learning about the “healing” of the samples observed during layer building and a comparison study on different laser power variation samples. Those preliminary conclusions will help dictate the follow-up work that will be presented at the conference.

additive manufacturing↗
NASA NTRS2022

Nickel Accounting for the Psyche Spacecraft

(16) Psyche is a metallic asteroid located in the asteroid belt between Mars and Jupiter. The composition of Psyche is unknown, but the scientific community believes it is composed primarily of iron, nickel, and silicates. The Psyche mission will be the first space mission to study this asteroid in close proximity, and as such, determining the elemental composition of the asteroid is one of the primary objectives of this mission. The spacecraft measures this elemental composition using the Gamma Ray Spectrometer (GRS), which detects cosmic-ray induced gamma rays from Psyche’s surface. In addition to gamma rays from Psyche, the GRS will also detect background gamma rays from spacecraft material nearby the GRS. Because Ni is such a key element for achieving the mission science objectives, a special effort has been made to minimize background gamma rays from Ni, thus maximizing sensitivity to the Ni gamma rays from Psyche. The Psyche mission approached this potential Ni background issue with two methods, locating the GRS away from the spacecraft/source of Ni and setting a threshold requirement against the total Ni mass of the spacecraft. Verifying that the total amount of Ni on the spacecraft is within this threshold is thus a key part of ensuring the GRS can meet its science objectives. Ni alloys are commonly used on spacecraft, but the mass and location of elemental Ni is not typically accounted for. Ni can be found in many materials all over the spacecraft – in fasteners, optical assemblies, magnetic shields, electromagnetic interference (EMI) tape, under gold plating, in connectors, and so on. The task proved further challenging because of the distributed nature of the build of this spacecraft and the use of vendors external to JPL. While the analysis was atypical and source information difficult to cull, the approach described in this paper used tools and data available to the project in some form to achieve this goal. For Psyche, current analysis shows there is margin in meeting the Ni mass requirement. This paper explains the systematic approach used to accurately and precisely record Ni content on the Psyche spacecraft. While this approach was defined for Ni on the Psyche mission, it can be used for any future project with the need to accurately estimate the total mass of a single element or material on a spacecraft.

Cullinan, Joe↗
NASA NTRS2022

Nickel Accounting for the Psyche Spacecraft

(16) Psyche is a metallic asteroid located in the asteroid belt between Mars and Jupiter. The composition of Psyche is unknown, but the scientific community believes it is composed primarily of iron, nickel, and silicates. The Psyche mission will be the first space mission to study this asteroid in close proximity, and as such, determining the elemental composition of the asteroid is one of the primary objectives of this mission. The spacecraft measures this elemental composition using the Gamma Ray Spectrometer (GRS), which detects cosmic-ray induced gamma rays from Psyche’s surface. In addition to gamma rays from Psyche, the GRS will also detect background gamma rays from spacecraft material nearby the GRS. Because Ni is such a key element for achieving the mission science objectives, a special effort has been made to minimize background gamma rays from Ni, thus maximizing sensitivity to the Ni gamma rays from Psyche. The Psyche mission approached this potential Ni background issue with two methods, locating the GRS away from the spacecraft/source of Ni and setting a threshold requirement against the total Ni mass of the spacecraft. Verifying that the total amount of Ni on the spacecraft is within this threshold is thus a key part of ensuring the GRS can meet its science objectives. Ni alloys are commonly used on spacecraft, but the mass and location of elemental Ni is not typically accounted for. Ni can be found in many materials all over the spacecraft – in fasteners, optical assemblies, magnetic shields, electromagnetic interference (EMI) tape, under gold plating, in connectors, and so on. The task proved further challenging because of the distributed nature of the build of this spacecraft and the use of vendors external to JPL. While the analysis was atypical and source information difficult to cull, the approach described in this paper used tools and data available to the project in some form to achieve this goal. For Psyche, current analysis shows there is margin in meeting the Ni mass requirement. This paper explains the systematic approach used to accurately and precisely record Ni content on the Psyche spacecraft. While this approach was defined for Ni on the Psyche mission, it can be used for any future project with the need to accurately estimate the total mass of a single element or material on a spacecraft.

Cullinan, Joe↗
NASA NTRS2016

In-Space Recycler Technology Demonstration

In 2014, a 3D printer was installed and used successfully on the International Space Station (ISS), creating the first additively manufactured part in space. While additive manufacturing is a game changing technology for exploration missions, the process still requires raw feedstock material to fabricate parts. Without a recycling capability, a large supply of feedstock would need to be stored onboard, which negates the logistical benefits of these capabilities. Tethers Unlimited, Inc. (TUI), received a Small Business Innovation Research (SBIR) award to design and build the first In-space Recycler for demonstration aboard the ISS in 2017. To fully test this technology in microgravity, parts will be 3D printed, recycled into reusable filament, and then reprinted into new parts. Recycling scrap into printer filament is quite challenging in that a recycler must be able to handle a large variety of possible scrap configurations and densities. New challenges include: dealing with inevitable contamination of the scrap material, minimizing damage to the molecular structure of the plastic during reprocessing, managing a larger volume of hot liquid plastic, and exercising greater control over the cooling/resolidification of the material. TUI has developed an architecture that addresses these challenges by combining standard, proven technologies with novel, patented processes developed through this effort. Results show that the filament diameter achieved is more consistent than commercial filament, with only minimal degradation of material properties over recycling steps. In May 2016, TUI completed fabrication of a flight prototype, which will ultimately progress to the demonstration unit for the ISS as a testbed for future exploration missions. This capability will provide significant cost savings by reducing the launch mass and volume required for printer feedstock as well as reduce waste that must be stored or disposed.

Recycling↗
NASA NTRS1975

Design considerations in the creation and maintenance of electrostatic cleanliness for solar electrically propelled spacecraft

Charge build-up on spacecraft surfaces and resulting zones of electrostatic contamination have been examined for electrically active and electrically passive spacecraft with both conducting and dielectric surface materials, illuminated and nonilluminated surface conditions, and for both inclusion and neglect of free charge effects from photocurrents and ambient space plasma particles. Techniques for measurement and reduction of electrostatic contamination zone extent have been developed for spacecraft with charge release capability. Indicated limitations for contamination cleanup are about 1 volt potential variation from spacecraft to ambient plasma. Bandwidths of electrostatic monitoring and clamping devices extend to several hundred kilohertz for both DC and 'broadband' AC electrostatic cleanliness.

Sellen, J. M., Jr.↗
NASA NTRS1981

Effective constitutive relations for large repetitive frame-like structures

Effective mechanical properties for large repetitive framelike structures are derived using combinations of strength of material and orthogonal transformation techniques. Symmetry considerations are used in order to identify independent property constants. The actual values of these constants are constructed according to a building block format which is carried out in the three consecutive steps: (1) all basic planar lattices are identified; (2) effective continuum properties are derived for each of these planar basic grids using matrix structural analysis methods; and (3) orthogonal transformations are used to determine the contribution of each basic set to the overall effective continuum properties of the structure.

Nayfeh, A. H.↗
NASA NTRS1999

Using Experiments to Build a Body of Knowledge

Experimentation in software engineering is important but difficult. One reason it is so difficult is that there are a large number of context variables, and so creating a cohesive understanding of experimental results requires a mechanism for motivating studies and integrating results. This paper argues for the necessity of a framework for organizing sets of related studies. With such a framework, experiments can be viewed as part of common families of studies, rather than being isolated events. Common families of studies can contribute to important and relevant hypotheses that may not be suggested by individual experiments. A framework also facilitates building knowledge in an incremental manner through the replication of experiments within families of studies. Building knowledge in this way requires a community of researchers that can replicate studies, vary context variables, and build abstract models that represent the common observations about the discipline. This paper also presents guidelines for lab packages, meant to encourage and support replications, that encapsulate materials, methods, and experiences concerning software engineering experiments.

Basili, Victor↗
NASA NTRS1999

Crack Growth Prediction Methodology for Multi-Site Damage: Layered Analysis and Growth During Plasticity

A finite element program has been developed to perform quasi-static, elastic-plastic crack growth simulations. The model provides a general framework for mixed-mode I/II elastic-plastic fracture analysis using small strain assumptions and plane stress, plane strain, and axisymmetric finite elements. Cracks are modeled explicitly in the mesh. As the cracks propagate, automatic remeshing algorithms delete the mesh local to the crack tip, extend the crack, and build a new mesh around the new tip. State variable mapping algorithms transfer stresses and displacements from the old mesh to the new mesh. The von Mises material model is implemented in the context of a non-linear Newton solution scheme. The fracture criterion is the critical crack tip opening displacement, and crack direction is predicted by the maximum tensile stress criterion at the crack tip. The implementation can accommodate multiple curving and interacting cracks. An additional fracture algorithm based on nodal release can be used to simulate fracture along a horizontal plane of symmetry. A core of plane strain elements can be used with the nodal release algorithm to simulate the triaxial state of stress near the crack tip. Verification and validation studies compare analysis results with experimental data and published three-dimensional analysis results. Fracture predictions using nodal release for compact tension, middle-crack tension, and multi-site damage test specimens produced accurate results for residual strength and link-up loads. Curving crack predictions using remeshing/mapping were compared with experimental data for an Arcan mixed-mode specimen. Loading angles from 0 degrees to 90 degrees were analyzed. The maximum tensile stress criterion was able to predict the crack direction and path for all loading angles in which the material failed in tension. Residual strength was also accurately predicted for these cases.

James, Mark Anthony↗
NASA NTRS2012

Determination of Survivable Fires

At NASA, there exists no standardized design or testing protocol for spacecraft fire suppression systems (either handheld or total flooding designs). An extinguisher's efficacy in safely suppressing any reasonable or conceivable fire is the primary benchmark. That concept, however, leads to the question of what a reasonable or conceivable fire is. While there exists the temptation to over-size' the fire extinguisher, weight and volume considerations on spacecraft will always (justifiably) push for the minimum size extinguisher required. This paper attempts to address the question of extinguisher size by examining how large a fire a crew member could successfully survive and extinguish in the confines of a spacecraft. The hazards to the crew and equipment during an accidental fire include excessive pressure rise resulting in a catastrophic rupture of the vehicle skin, excessive temperatures that burn or incapacitate the crew (due to hyperthermia), carbon dioxide build-up or other accumulation of other combustion products (e.g. carbon monoxide). Estimates of these quantities are determined as a function of fire size and mass of material burned. This then becomes the basis for determining the maximum size of a target fire for future fire extinguisher testing.

Dietrich, D. L.↗
NASA NTRS2013

Composite Crew Module (CCM) Permeability Characterization

In January 2007, the NASA Administrator chartered the NASA Engineering and Safety Center (NESC) to form an Agency team to design and build a composite crew module in 18 months in order to gain hands-on experience in anticipation that future exploration systems may be made of composite materials. One of the conclusions from this Composite Crew Module Primary Structure assessment was that there was a lack of understanding regarding the ability for composite pressure shells to contain consumable gases, which posed a technical risk relative to the use of a metallic design. After the completion of the Composite Crew Module test program, the test article was used in a new program to assess the overall leakage/permeability and identify specific features associated with high leak rates. This document contains the outcome of the leakage assessment.

Kirsch, Michael T.↗
NASA NTRS2019

Building Foundations for International Collaboration Through Educational Outreach Initiatives

As human space exploration pursues journeying to the Moon and Mars, international and intercultural collaboration is key for the success of such ambitious goals. Since 2014, NASA's Johnson Space Center (JSC) Hispanic Employee Resource Group (HERG) has established relationships and participated in outreach events with emerging space organizations in Latin America with educational and public outreach as a common goal. Such efforts align with strategic goals to empower the next generation of innovators and explorers and to champion the development of space exploration capabilities. This paper discusses the partnerships developed to introduce Spanish speaking populations to science, space technology, aeronautics, research and development through television, webcasts and social media. The authors share accomplishments, challenges, and lessons learned to build foundations for international collaboration to ignite research and innovation and propel human space exploration. The methodology makes use of Space Act Agreements to leverage existing outreach materials and programs and translate the content into Spanish for the benefit of students, educational organizations and the public in general. The plan is to apply the same model in other regions and countries to create a Latin American network of language translation and diffusion of science and space technology content targeting emerging space sectors. This model could be used to reach out to other international communities to provide cultural and educational outreach for space exploration and research.

Fontanot, Carlos↗