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Design and Testing of Non-Toxic RCS Thrusters for Second Generation Reusable Launch Vehicle

The current NASA Space Shuttle auxiliary propulsion system utilizes nitrogen tetroxide (NTO) and monomethylhydrazine (MMH), hypergolic propellants. This use of these propellants has resulted in high levels of maintenance and precautions that contribute to costly launch operations. By employing alternate propellant combinations, those less toxic to humans, the hazards and time required between missions can be significantly reduced. Use of alternate propellants can thereby increase the efficiency and lower the cost in launch operations. In support of NASA's Space Launch Initiative (SLI), TRW proposed a three-phase project structured to significantly increase the technology readiness of a high-performance reaction control subsystem (RCS) thruster using non-toxic propellant for an operationally efficient and reusable auxiliary propulsion system (APS). The project enables the development of an integrated primary/vernier thruster capable of providing dual-thrust levels of both 1000-lbf class thrust and 25-lbf thrust. The intent of the project is to reduce the risk associated with the development of an improved RCS flight design that meets the primary NASA objectives of improved safety and reliability while reducing systems operations and maintenance costs. TRW proposed two non-toxic auxiliary propulsion engine designs, one using liquid oxygen and liquid hydrogen and the other using liquid oxygen and liquid ethanol, as candidates to meet the goals of reliability and affordability at the RCS level. Both of these propellant combinations offer the advantage of a safe environment for maintenance, while at the same time providing adequate to excellent performance for a conventional liquid propulsion systems. The key enabling technology incorporated in both TRW thrusters is the coaxial liquid on liquid pintle injector. This paper will concentrate on only the design and testing of one of the thrusters, the liquid oxygen (LOX) and liquid hydrogen (LH2) thruster. The LOX/LH2 thruster design includes a LOX-centered pintle injector, consisting of two rows of slots that create a radial spoke spray pattern in the combustion chamber. The main fuel injector creates a continuous sheet of LH2 originating upstream of the LOX pintle injector. The two propellants impinge at the pintle slots, where the resulting momentum ratio and spray pattern determines the combustion efficiency and thermal effects on the hardware. Another enabling technology used in the design of this thruster is fuel film cooling through a duct, lining the inner wall of the combustion chamber barrel section. The duct is also acts as a secondary fuel injection point. The variation in the amount of LH2 used for the duct allows for adjustments in the cooling capacity for the thruster. The Non-Toxic LOX-LH2 RCS Workhorse Thruster was tested at the NASA Marshall Space Flight Center's Test Stand 500. Hot-fire tests were conducted between March 08, 2002 and April 05, 2002. All testing during the program base period were performed at sea-level conditions. During the test program, 7 configurations were tested, including 2 combustion chambers, 3 LOX injector pintle tips, and 4 LH2 injector stroke settings. The operating conditions that were surveyed varied thrust levels, mixture ratio and LH2 duct cooling flow. The copper heat sink chamber was used for 16 burns, each burn lasting from 0.4 to 10 seconds, totaling 51.4 seconds, followed by Haynes chamber testing ranging from 0.9 to 120 seconds, totaling 300.9 seconds. The total accumulated burn time for the test program is 352.3 seconds. C* efficiency was calculated and found to be within expectable limits for most operating conditions. The temperature on the Haynes combustion chamber remained below established material limits, with the exception of one localized hot spot. The test results demonstrate that both the coaxial liquid-on-liquid pintle injector design and fuel duct concepts are viable for the intended application. The thruster head-e design maintained cryogenic injection temperatures while firing, which validates the concept for minimal heat soak back. By injecting fuel into the duct, the throat temperatures were manageable, yet the split of fuel through the cooling duct does not compromise the overall combustion efficiency, which indicates that, provided proper design refinement, such a concept can be applied to a high-performance version of the thruster. These hot fire tests demonstrate the robustness of the duct design concept and good capability to withstand off-nominal operating conditions without adversely impacting the thermal response of the engine, a key design feature for a cryogenic thruster.

Calvignac, Jacky↗

Exploration Medical Capability - Technology Watch

The objectives of the Technology Watch process are to identify emerging, high-impact technologies that augment current ExMC development efforts, and to work with academia, industry, and other government agencies to accelerate the development of medical care and research capabilities for the mitigation of potential health issues that could occur during space exploration missions. The establishment of collaborations with these entities is beneficial to technology development, assessment and/or insertion. Such collaborations also further NASA s goal to provide a safe and healthy environment for human exploration. The Tech Watch project addresses requirements and capabilities identified by knowledge and technology gaps that are derived from a discrete set of medical conditions that are most likely to occur on exploration missions. These gaps are addressed through technology readiness level assessments, market surveys, collaborations and distributed innovation opportunities. Ultimately, these gaps need to be closed with respect to exploration missions, and may be achieved through technology development projects. Information management is a key aspect to this process where Tech Watch related meetings, research articles, collaborations and partnerships are tracked by the HRP s Exploration Medical Capabilities (ExMC) Element. In 2011, ExMC will be introducing the Tech Watch external website and evidence wiki that will provide access to ExMC technology and knowledge gaps, technology needs and requirements documents.

Krihak, Michael↗

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

A linear decomposition method for large optimization problems. Blueprint for development

A method is proposed for decomposing large optimization problems encountered in the design of engineering systems such as an aircraft into a number of smaller subproblems. The decomposition is achieved by organizing the problem and the subordinated subproblems in a tree hierarchy and optimizing each subsystem separately. Coupling of the subproblems is accounted for by subsequent optimization of the entire system based on sensitivities of the suboptimization problem solutions at each level of the tree to variables of the next higher level. A formalization of the procedure suitable for computer implementation is developed and the state of readiness of the implementation building blocks is reviewed showing that the ingredients for the development are on the shelf. The decomposition method is also shown to be compatible with the natural human organization of the design process of engineering systems. The method is also examined with respect to the trends in computer hardware and software progress to point out that its efficiency can be amplified by network computing using parallel processors.

Sobieszczanski-Sobieski, J.↗

R2U2: Tool Overview

R2U2 (Realizable, Responsive, Unobtrusive Unit) is an extensible framework for runtime System HealthManagement (SHM) of cyber-physical systems. R2U2 can be run in hardware (e.g., FPGAs), or software; can monitorhardware, software, or a combination of the two; and can analyze a range of different types of system requirementsduring runtime. An R2U2 requirement is specified utilizing a hierarchical combination of building blocks: temporal formula runtime observers (in LTL or MTL), Bayesian networks, sensor filters, and Boolean testers. Importantly, the framework is extensible; it is designed to enable definitions of new building blocks in combination with the core structure. Originally deployed on Unmanned Aerial Systems (UAS), R2U2 is designed to run on a wide range of embedded platforms, from autonomous systems like rovers, satellites, and robots, to human-assistive ground systems and cockpits. R2U2 is named after the requirements it satisfies; while the exact requirements vary by platform and mission, the ability to formally reason about realizability, responsiveness, and unobtrusiveness is necessary for flight certifiability, safety-critical system assurance, and achievement of technology readiness levels for target systems. Realizability ensures that R2U2 is suficiently expressive to encapsulate meaningful runtime requirements while maintaining adaptability to run on different platforms, transition between different mission stages, and update quickly between missions. Responsiveness entails continuously monitoring the system under test, real-time reasoning, reporting intermediate status, and as-early-as-possible requirements evaluations. Unobtrusiveness ensures compliance with the crucial properties of the target architecture: functionality, certifiability, timing, tolerances, cost, or other constraints.

Rozier, Kristin Y.↗

Distant Operational Care Centre: Design Project Report

The goal of this project is to outline the design of the Distant Operational Care Centre (DOCC), a modular medical facility to maintain human health and performance in space, that is adaptable to a range of remote human habitats. The purpose of this project is to outline a design, not to go into a complete technical specification of a medical facility for space. This project involves a process to produce a concise set of requirements, addressing the fundamental problems and issues regarding all aspects of a space medical facility for the future. The ideas presented here are at a high level, based on existing, researched, and hypothetical technologies. Given the long development times for space exploration, the outlined concepts from this project embodies a collection of identified problems, and corresponding proposed solutions and ideas, ready to contribute to future space exploration efforts. In order to provide a solid extrapolation and speculation in the context of the future of space medicine, the extent of this project's vision is roughly within the next two decades. The Distant Operational Care Centre (DOCC) is a modular medical facility for space. That is, its function is to maintain human health and performance in space environments, through prevention, diagnosis, and treatment. Furthermore, the DOCC must be adaptable to meet the environmental requirements of different remote human habitats, and support a high quality of human performance. To meet a diverse range of remote human habitats, the DOCC concentrates on a core medical capability that can then be adapted. Adaptation would make use of the DOCC's functional modularity, providing the ability to replace, add, and modify core functions of the DOCC by updating hardware, operations, and procedures. Some of the challenges to be addressed by this project include what constitutes the core medical capability in terms of hardware, operations, and procedures, and how DOCC can be adapted to different remote habitats.

Source record↗

Application of Analytical Hierarchy Process for Narrowing Down Nep Candidate Reactor Designs

NASA is currently studying the possibility of human exploration of Mars in the late 2030s timeframe using a hybrid nuclear electric propulsion (NEP)/chemical propulsion system. Present analyses indicate such a mission could require a reactor power system in the range of 2 to 6 MWe operating for approximately 3 years. At present, the Technology Readiness Levels (TRL) of key NEP technologies are still low, implying that significant technology development activities must be undertaken prior to making informed design selections for an integrated propulsion system. NASA’s Space Nuclear Propulsion (SNP) project has recently undertaken an in-depth effort to identify NEP candidate technologies and determine the required developmental work to mature these technologies to the point where they could realistically support the design and assembly of a full NEP system. A version of the Analytical Hierarchy Process is being employed to narrow the technology candidates for SNP investment planning. This multi-attribute decision-making process relies on quantified technical inputs and the judgement of Subject Matter Experts (SMEs) to evaluate technology options against key technical and programmatic Figures-of-Merit (FOM) at the subsystem and optimized system level. The process and an example evaluation of nuclear fuel/moderator combinations in a sodium heat pipe honeycomb-geometry reactor concept are described. The evaluation and analysis methodology described in this paper can be employed for pairwise comparisons between reactor concepts and technology choices as new data become available.

Dasari V Rao↗

Are we There Yet? ... Developing In-Situ Fabrication and Repair (ISFR) Technologies to Explore and Live on the Moon and Mars

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Engineers and Scientists at the Marshall Space Flight Center are evaluating current technologies for in situ exploration habitat and fabrication and repair applications. Several technologies to be addressed in this paper have technology readiness levels (TRLs) that are currently mature enough to pursue for exploration purposes. However, many technologies offer promising applications but these must be pulled along by the demands and applications of this great initiative. The In Situ Fabrication and Repair (ISFR) program will supply and push state of the art technologies for applications such as habitat structure development, in situ resource utilization for tool and part fabrication, and repair and replacement of common life support elements. This paper will look at the current and future habitat technology applications such as the implementation of in situ environmental elements such as caves, rilles and lavatubes, the development of lunar regolith concrete and structure design and development, thin film and inflatable technologies. We will address current rapid prototyping technologies, their ISFR applications and near term advancements. We will discuss the anticipated need to utilize in situ resources to produce replacement parts and fabricate repairs to vehicles, habitats, life support and quality of life elements. All ISFR technology developments will incorporate automated deployment and robotic construction and fabrication techniques. The current state of the art for these applications is fascinating, but the future is out of this world.

Bassler, Julie A.↗

2007 Lunar Regolith Simulant Workshop Overview

The National Aeronautics and Space Administration (NASA) vision has as a cornerstone, the establishment of an Outpost on the Moon. This Lunar Outpost will eventually provide the necessary planning, technology development, and training for a manned mission to Mars in the future. As part of the overall activity, NASA is conducting Earth-based research and advancing technologies to a Technology Readiness Level (TRL) 6 maturity under the Exploration Technology Development Program that will be incorporated into the Constellation Project as well as other projects. All aspects of the Lunar environment, including the Lunar regolith and its properties, are important in understanding the long-term impacts to hardware, scientific instruments, and humans prior to returning to the Moon and living on the Moon. With the goal of reducing risk to humans and hardware and increasing mission success on the Lunar surface, it is vital that terrestrial investigations including both development and verification testing have access to Lunar-like environments. The Marshall Space Flight Center (MSFC) is supporting this endeavor by developing, characterizing, and producing Lunar simulants in addition to analyzing existing simulants for appropriate applications. A Lunar Regolith Simulant Workshop was conducted by MSFC in Huntsville, Alabama, in October 2007. The purpose of the Workshop was to bring together simulant developers, simulant users, and program and project managers from ETDP and Constellation with the goals of understanding users' simulant needs and their applications. A status of current simulant developments such as the JSC-1A (Mare Type Simulant) and the NASA/U.S. Geological Survey Lunar Highlands-Type Pilot Simulant (NU-LHT-1 M) was provided. The method for evaluating simulants, performed via Figures of Merit (FoMs) algorithms, was presented and a demonstration was provided. The four FoM properties currently being assessed are: size, shape, density, and composition. Some of the Workshop findings include: simulant developers must understand simulant users' needs and applications; higher fidelity simulants are needed and needed in larger quantities now; simulants must be characterized to allow "apples-to-apples" comparison of test results; simulant users should confer with simulant experts to assist them in the selection of simulants; safety precautions should be taken in the handling and use of simulants; shipping, storing, and preparation of simulants have important implications; and most importantly, close communications among the simulant community must be maintained and will be continued via telecoms, meetings, and an annual Lunar Regolith Simulant Workshop.

McLemore, Carole A.↗

2007 Lunar Regolith Simulant Workshop Overview

The National Aeronautics and Space Administration (NASA) vision has as a cornerstone, the establishment of an Outpost on the Moon. This Lunar Outpost will eventually provide the necessary planning, technology development, and training for a manned mission to Mars in the future. As part of the overall activity, NASA is conducting Earth-based research and advancing technologies to a Technology Readiness Level (TRL) 6 maturity under the Exploration Technology Development Program that will be incorporated into the Constellation Project as well as other projects. All aspects of the Lunar environment, including the Lunar regolith and its properties, are important in understanding the long-term impacts to hardware, scientific instruments, and humans prior to returning to the Moon and living on the Moon. With the goal of reducing risk to humans and hardware and increasing mission success on the Lunar surface, it is vital that terrestrial investigations including both development and verification testing have access to Lunar-like environments. The Marshall Space Flight Center (MSFC) is supporting this endeavor by developing, characterizing, and producing Lunar simulants in addition to analyzing existing simulants for appropriate applications. A Lunar Regolith Simulant Workshop was conducted by MSFC in Huntsville, Alabama, in October 2007. The purpose of the Workshop was to bring together simulant developers, simulant users, and program and project managers from ETDP and Constellation with the goals of understanding users' simulant needs and their applications. A status of current simulant developments such as the JSC-1A (Mare Type Simulant) and the NASA/U.S. Geological Survey Lunar Highlands-Type Pilot Simulant (NU-LHT-1M) was provided. The method for evaluating simulants, performed via Figures of Merit (FoMs) algorithms, was presented and a demonstration was provided. The four FoM properties currently being assessed are: size, shape, density, and composition. Some of the Workshop findings include: simulant developers must understand simulant users' needs and applications; higher fidelity simulants are needed and needed in larger quantities now; simulants must be characterized to allow "apples-to-apples" comparison of test results; simulant users should confer with simulant experts to assist them in the selection of simulants; safety precautions should be taken in the handling and use of simulants; shipping, storing, and preparation of simulants have important implications; and most importantly, close communications among the simulant community must be maintained and will be continued via telecoms, meetings, and an annual Lunar Regolith Simulant Workshop.

McLemore, Carole A.↗

Human Spaceflight Safety for the Next Generation on Orbital Space Systems

The National Aeronautics and Space Administration (NASA) Commercial Crew Program (CCP) has been chartered to facilitate the development of a United States (U.S.) commercial crew space transportation capability with the goal of achieving safe, reliable, and cost effective access to and from low Earth orbit (LEO) and the International Space Station (ISS) as soon as possible. Once the capability is matured and is available to the Government and other customers, NASA expects to purchase commercial services to meet its ISS crew rotation and emergency return objectives. The primary role of the CCP is to enable and ensure safe human spaceflight and processes for the next generation of earth orbital space systems. The architecture of the Program delineates the process for investment performance in safe orbital systems, Crew Transportation System (CTS) certification, and CTS Flight Readiness. A series of six technical documents build up the architecture to address the top-level CTS requirements and standards. They include Design Reference Missions, with the near term focus on ISS crew services, Certification and Service Requirements, Technical Management Processes, and Technical and Operations Standards Evaluation Processes.

Mango, Edward J.↗

Are We There Yet? ... Developing In Situ Fabrication and Repair (ISFR) Technologies to Explore and Live on the Moon and Mars

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Engineers and Scientists at the Marshall Space Flight Center (MSFC) are evaluating current technologies for in situ resource-based exploration fabrication and repair applications. Several technologies to be addressed in this paper have technology readiness levels (TRLs) that are currently mature enough to pursue for exploration purposes. However, many technologies offer promising applications but these must be pulled along by the demands and applications of this great initiative. The In Situ Fabrication and Repair (ISFR) Element will supply and push state of the art technologies for applications such as habitat structure development, in situ resource utilization for tool and part fabrication, and repair and replacement of common life support elements, as well as non-destructive evaluation. This paper will address current rapid prototyping technologies, their ISFR applications and near term advancements. We will discuss the anticipated need to utilize in situ resources to produce replacement parts and fabricate repairs to vehicles, habitats, life support and quality of life elements. Many ISFR technology developments will incorporate automated deployment and robotic construction and fabrication techniques. The current state of the art for these applications is fascinating, but the future is out of this world.

Melanie P. Bodiford↗

GO/NO-GO - When is medical hazard mitigation acceptable for launch?

Medical support of spaceflight missions is composed of complex tasks and decisions that dedicated to maintaining the health and performance of the crew and the completion of mission objectives. Spacecraft represent one of the most complex vehicles built by humans, and are built to very rigorous design specifications. In the course of a Flight Readiness Review (FRR) or a mission itself, the flight surgeon must be able to understand the impact of hazards and risks that may not be completely mitigated by design alone. Some hazards are not mitigated because they are never actually identified. When a hazard is identified, it must be reduced or waivered. Hazards that cannot be designed out of the vehicle or mission, are usually mitigated through other means to bring the residual risk to an acceptable level. This is possible in most engineered systems because failure modes are usually predictable and analysis can include taking these systems to failure. Medical support of space missions is complicated by the inability of flight surgeons to provide "exact" hazard and risk numbers to the NASA engineering community. Taking humans to failure is not an option. Furthermore, medical dogma is mostly comprised of "medical prevention" strategies that mitigate risk by examining the behaviour of a cohort of humans similar to astronauts. Unfortunately, this approach does not lend itself well for predicting the effect of a hazard in the unique environment of space. This presentation will discuss how Medical Operations uses an evidence-based approach to decide if hazard mitigation strategies are adequate to reduce mission risk to acceptable levels. Case studies to be discussed will include: 1. Risk of electrocution risk during EVA 2. Risk of cardiac event risk during long and short duration missions 3. Degraded cabin environmental monitoring on the ISS. Learning Objectives 1.) The audience will understand the challenges of mitigating medical risk caused by nominal and off-nominal mission events. 2.) The audience will understand the process by which medical hazards are identified and mitigated before launch. 3.) The audience will understand the roles and responsibilities of all the other flight control positions in participating in the process of reducing hazards and reducing medical risk to an acceptable level.

Hamilton, Douglas R.↗

In Situ Fabrication and Repair (ISFR) Technologies; New Challenges for Exploration

NASA's human exploration initiative poses great opportunity and great risk for manned missions to the Moon and Mars. Engineers and Scientists at the Marshall Space Flight Center (MSFC) are continuing to evaluate current technologies for in situ resource-based exploration fabrication and repair applications. Several technologies to be addressed in this paper have technology readiness levels (TRLs) that are currently mature enough to pursue for exploration purposes. However, while many technologies offer promising applications, these technologies must be pulled along by the demands and applications of this great initiative. The In Situ Fabrication and Repair (ISFR) Element will supply and push state of the art technologies for applications such as habitat structure development, in situ resource utilization for tool and part fabrication, and repair and non-destructive evaluation W E ) of common life support elements. As an overview of the ISFR Element, this paper will address rapid prototyping technologies, their applications, challenges, and near term advancements. This paper will also discuss the anticipated need to utilize in situ resources to produce replacement parts and fabricate repairs to vehicles, habitats, life support and quality of life elements. Overcoming the challenges of ISFR development will provide the Exploration initiative with state of the art technologies that reduce risk, and enhance supportability.

Bassler, Julie A.↗

An Exploration Perspective of Beamed Energy Propulsion

The Vision for Exploration is currently focused on flying the Space Shuttle safely to complete our Space Station obligations, retiring the Shuttle in 2010, then returning humans to the Moon and learning how to proceed to Mars and beyond. The NASA budget still includes funds for science and aeronautics but the primary focus is on human exploration. Fiscal constraints have led to pursuing exploration vehicles that use heritage hardware, particularly existing boosters and engines, with the minimum modifications necessary to satisfy mission requirements. So, pursuit of immature technologies is not currently affordable by NASA. Beamed energy is one example of an immature technology, from a human exploration perspective, that may eventually provide significant benefits for human exploration of space, but likely not in the near future. Looking to the more distant future, this paper will examine some of the criteria that must be achieved by beamed energy propulsion to eventually contribute to human exploration of the solar system. The analysis focuses on some of the implications of increasing the payload fraction of a launch vehicle, with a quick look at trans-lunar injection. As one would expect, there is potential for benefit, and there are concerns. The analysis concludes with an assessment of the Technology Readiness Level (TRL) for some beamed energy propulsion components, indicating that TRL 2 is close to being completed.

Cole, John W.↗

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Soendker, Erich↗

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Hablitzel, Sam↗