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A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Tamir, David

Next generation: In-space transportation system(s)

The development of the next generation In-Space Transportation System presents a unique challenge to the design of a propulsion system for the Space Exploration Initiative (SEI). Never before have the requirements for long-life, multiple mission use, space basing, high reliability, man-rating, and minimum maintenance come together with performance in one system that must protect the lives of space travelers, support the mission logistics needs, and do so at an acceptable cost. The challenge that is presented is to quantify the bounds of these requirements. The issue is one of degree. The length of acceptable life in space, the time it takes for reuse to pay off, and the degree to which space basing is practical (full, partial, or expended) are the issues that determine the reusable bounds of a design and include dependability, contingency capabilities, resilency, and minimum dependence on a maintenance node in preparation for and during a mission. Missions to planet earth, other non-NASA missions, and planetary missions will provide important but less demanding requirements for the transportation systems of the future. The mission proposed for the SEI require a family of transportation vehicles to meet the requirements for establishing a permanent human presence on the Moon and eventually on Mars. Specialized vehicles are needed to accomplish the different phases of each mission. These large scale missions require assembly in space and will provide the greatest usage of the planned integrated transportation system. The current approach to defining the In-Space Transportation System for the SEI Moon missions with later Mars mission applications is presented. Several system development options, propulsion concepts, current/proposed activities are reviewed, and key propulsion design criteria, issues, and technology challenges for the next generation In-Space Transportation System(s) are outlined.

Huffaker, Fredrick

Moisture loss from graphite structures for the Hubble Space Telescope

The construction and telescope assembly of the NASA's Hubble Space Telescope (HST) is described with particular reference to the features of its construction material. Due to the hygroscopic nature of the graphite-fiber reinforced epoxy, used for much of the structure of the HST, the telescope, when in orbit, suffers losses of water, absorbed during on-ground procedures, accompanied by shrinkage of the epoxy matrix, and needs periodic realignment. Using a combination of analytic, laboratory measured, and in-space measured data, an operational plan for adjusting the alignment of the HST is presented. The refocusing plan must take into account the preceding ground environment, as well as the prelaunch, lift-off, and predeployment environments of the HST-bearing Space Shuttle.

Facey, T. A.

In-space research, technology and engineering experiments and Space Station

The NASA Space Station will serve as a technology research laboratory, a payload-servicing facility, and a large structure fabrication and assembly facility. Space structures research will encompass advanced structural concepts and their dynamics, advanced control concepts, sensors, and actuators. Experiments dealing with fluid management will gather data on such fundamentals as multiphase flow phenomena. As requirements for power systems and thermal management grow, experiments quantifying the performance of energy systems and thermal management concepts will be undertaken, together with expanded efforts in the fields of information systems, automation, and robotics.

Tyson, Richard

Pathfinder: Surface exploration, in-space operations and space transfer

Viewgraphs on the Pathfinder program are presented. Information is given on technology needs, a planetary rover, program management, an autonomous lander, mission applications, orbital assembly, cryogenics, space nuclear reactors, space manufacturing, optical communications, spacecraft propulsion, aerobraking, and orbital transfer vehicles.

Mankins, John

Some test/analysis issues for the space station structural characterization experiment

The Space Station Structural Characterization Experiment (SSSCE) 1,2 is an early space flight experiment that uses the space station as a generic structure to study the dynamic characteristics of Large Space Structures (LSS). On-orbit modal testing will be conducted to determine natural frequencies, mode shapes and damping of dominant structural modes of the space structure assembly. This experiment will utimately support the development of system identification and analytical modeling techniques for Large Space Structures. In order to ensure the success of SSSCE (in-space validation of modeling techniques for LSS), adequate measurement and instrumentation requirements have to be established during the experiment-definition study. Among the issues affecting these requirements, spatial and modal coverages of the modal test data are of particular interest. Topics such as total number of sensors, type of measurements (translation and rotation), optimal sensor locations (measurement degrees-of-freedom), selection of target modes, effects of modal superposition and truncation, separation of global and local modes, etc., are all a fundamental importance and must be investigated.

Chou, Chaur-Ming

In-space construction and dynamics of large space structures

The types of equipment and structures that will be required to construct very large spacecraft in space are discussed. One of the basic issues that must be resolved is the appropriate mix of humans and machines in the construction process. While the use of robots offers the potential for reducing the number of extra-vehicular activity (EVA) hours required for particular construction operations, the availability of humans greatly increases the reliability of complex construction tasks. A hybrid system is described which makes the best use of man and machine to provide a highly reliable and versatile construction approach. Such a system will provide an efficient method for constructing large spacecraft until fully automated, robotic devices can be perfected. Details are given on an extensive ground test program which was designed to evaluate and demonstrate large spacecraft construction. A discussion is presented on the use of the Space Station Freedom, or an appropriate derivative, as a construction facility. Finally, a construction scenario and assembly timelines are presented for constructing a 20-meter-diameter high precision reflector.

Mikulas, Martin M., Jr.

An integrated in-space construction facility for the 21st century

This paper presents preliminary results of studies currently being conducted by NASA for constructing very large spacecraft. The paper discusses the various approaches for constructing spacecraft and their relative merits. As currently planned, Space Station Freedom has incorporated all of the basic design characteristics to permit its growth into an in-space construction facility for very large spacecraft. If disturbances from construction operations are intolerable to other experiments on Space Station Freedom, a co-orbiting construction facility could be built using truss hardware and systems previously for developed Space Station Freedom. The new PATHFINDER research initiative for on-orbit assembly and construction is also discussed. This research effort is aimed at developing construction methods for very large spacecraft and includes the development of a 100-meter-long space crane.

Mikulas, Martin M., Jr.

In-space technology experiments - Prerequisite for missions of the future

Experience with the Shuttle and free-flying satellites as technology test beds has shown the feasibility and desirability of using space assets as facilities for technology development. Thus, with the arrival of the Space Station Freedom era, technologists will be ready for an accessible engineering facility in space, particularly to support technology development for manned space exploration. As the 21st century is approached, virtually every flight to the Space Station Freedom will carry one or more research, technology and engineering experiments. The experiments planned will utilize both the pressurized volume and the external attachment facilities. A unique class of experiments will use the Space Station itself as an experimental test bed. Based upon recent examination of possible Space Station assembly sequences, technology payloads may utilize upwards of 20 percent of available resources.

Harris, Leonard A.

Vented Tank Resupply Experiment (VTRE) for In-space Technology Experiment Program (IN-STEP)

An overview of the Vented Tank Resupply Experiment (VTRE) program is presented in outline and graphical form. The goal of the program is to develop, design, build and provide flight and post flight support for a Shuttle Hitchhiker Experiment to investigate and demonstrate vented tank venting in space. Program schedules and experiment subsystem schematics are presented and specific technical objectives, power requirements, payload assemblies, Hitchhiker canister integration, and orbiter mission approach are addressed.

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Advanced automation for in-space vehicle processing

The primary objective of this 3-year planned study is to assure that the fully evolved Space Station Freedom (SSF) can support automated processing of exploratory mission vehicles. Current study assessments show that required extravehicular activity (EVA) and to some extent intravehicular activity (IVA) manpower requirements for required processing tasks far exceeds the available manpower. Furthermore, many processing tasks are either hazardous operations or they exceed EVA capability. Thus, automation is essential for SSF transportation node functionality. Here, advanced automation represents the replacement of human performed tasks beyond the planned baseline automated tasks. Both physical tasks such as manipulation, assembly and actuation, and cognitive tasks such as visual inspection, monitoring and diagnosis, and task planning are considered. During this first year of activity both the Phobos/Gateway Mars Expedition and Lunar Evolution missions proposed by the Office of Exploration have been evaluated. A methodology for choosing optimal tasks to be automated has been developed. Processing tasks for both missions have been ranked on the basis of automation potential. The underlying concept in evaluating and describing processing tasks has been the use of a common set of 'Primitive' task descriptions. Primitive or standard tasks have been developed both for manual or crew processing and automated machine processing.

Sklar, Michael

Activities of the Center for Space Construction

The Center for Space Construction (CSC) at the University of Colorado at Boulder is one of eight University Space Engineering Research Centers established by NASA in 1988. The mission of the center is to conduct research into space technology and to directly contribute to space engineering education. The center reports to the Department of Aerospace Engineering Sciences and resides in the College of Engineering and Applied Science. The college has a long and successful track record of cultivating multi-disciplinary research and education programs. The Center for Space Construction is prominent evidence of this record. At the inception of CSC, the center was primarily founded on the need for research on in-space construction of large space systems like space stations and interplanetary space vehicles. The scope of CSC's research has now evolved to include the design and construction of all spacecraft, large and small. Within this broadened scope, our research projects seek to impact the underlying technological basis for such spacecraft as remote sensing satellites, communication satellites, and other special purpose spacecraft, as well as the technological basis for large space platforms. The center's research focuses on three areas: spacecraft structures, spacecraft operations and control, and regolith and surface systems. In the area of spacecraft structures, our current emphasis is on concepts and modeling of deployable structures, analysis of inflatable structures, structural damage detection algorithms, and composite materials for lightweight structures. In the area of spacecraft operations and control, we are continuing our previous efforts in process control of in-orbit structural assembly. In addition, we have begun two new efforts in formal approach to spacecraft flight software systems design and adaptive attitude control systems. In the area of regolith and surface systems, we are continuing the work of characterizing the physical properties of lunar regolith, and we are at work on a project on path planning for planetary surface rovers.

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Space Station technology testbed: 2010 deep space transport

A space station in a crew-tended or permanently crewed configuration will provide major R&D opportunities for innovative, technology and materials development and advanced space systems testing. A space station should be designed with the basic infrastructure elements required to grow into a major systems technology testbed. This space-based technology testbed can and should be used to support the development of technologies required to expand our utilization of near-Earth space, the Moon and the Earth-to-Jupiter region of the Solar System. Space station support of advanced technology and materials development will result in new techniques for high priority scientific research and the knowledge and R&D base needed for the development of major, new commercial product thrusts. To illustrate the technology testbed potential of a space station and to point the way to a bold, innovative approach to advanced space systems' development, a hypothetical deep space transport development and test plan is described. Key deep space transport R&D activities are described would lead to the readiness certification of an advanced, reusable interplanetary transport capable of supporting eight crewmembers or more. With the support of a focused and highly motivated, multi-agency ground R&D program, a deep space transport of this type could be assembled and tested by 2010. Key R&D activities on a space station would include: (1) experimental research investigating the microgravity assisted, restructuring of micro-engineered, materials (to develop and verify the in-space and in-situ 'tuning' of materials for use in debris and radiation shielding and other protective systems), (2) exposure of microengineered materials to the space environment for passive and operational performance tests (to develop in-situ maintenance and repair techniques and to support the development, enhancement, and implementation of protective systems, data and bio-processing systems, and virtual reality and telepresence/kinetic processes), (3) subsystem tests of advanced nuclear power, nuclear propulsion and communication systems (using boom extensions, remote station-keeping platforms and mobile EVA crew and robots), and (4) logistics support (crew and equipment) and command and control of deep space transport assembly, maintenance, and refueling (using a station-keeping platform).

Holt, Alan C.

General Public Space Travel and Tourism: Executive Summary - Volume 1

Travel and tourism is one of the world's largest businesses. Its gross revenues exceed $400 billion per year in the U.S. alone, and it is our second largest employer. U.S. private sector business revenues in the space information area now approximate $10 billion per year, and are increasing rapidly. Not so in the human spaceflight area. After spending $100s of billions (1998 dollars) in public funds thereon, and continuing to spend over $5 billion per year, the government is still the only customer for human spaceflight goods and services. Serious and detailed consideration was first given to the possibility of space being opened up to trips by the general public three decades ago, and some initial attempts to do so were made a dozen years ago. But the difficulties were great and the Challenger disaster put an end to them. In recent years professional space tourism studies have been conducted in the United Kingdom, Germany and, especially, Japan. In the U.S., technological progress has been pronounced; we have had nearly a decade's experience in seeing our astronauts travel to-from low Earth orbit (LEO) safely, and we expect to commence assembly of a LEO space station housing a half-dozen people this year. Too, NASA and our space industry now have new and promising space transportation development programs underway, especially the X-33 and X-34 programs, and some related, further generation, basic technology development programs. And five private companies are also working on the design of new surface - LEO vehicles. The first professional space tourism market studies have been conducted in several countries in the past few years, especially in Japan and here. The U.S. study makes it clear that, conceptually, tens of millions of us would like to take a trip to space if we could do so with reasonable safety, comfort and reliability, and at an acceptable price. Initial businesses will address the desires of those willing to pay a greater price and accept a greater risk. A two-year cooperative Space Act agreement study has been conducted by our National Aeronautics and Space Administration and the Space Transportation Association. It was conducted by NASA and STA study leaders drawing upon the competence, experience and hard-nosed imagination of a national Steering Group and scores of attendees at a multi-day Workshop. The study has involved scores of professionals and business people from various areas: astronauts; space booster technology and operations professionals; a hotel architect and a hotel operator; an airline planner; insurance underwriters; space sickness experts; space theme park designers; space and travel and tourism association and business executives; a space-related financier; university tourism and space policy experts; present and former space-responsible government officials; space entrepreneurs; space writers; This study concludes that serious national attention should now be given to activities that would enable the expansion of today's terrestrial space tourism businesses, and the creation of in-space travel and tourism businesses. Indeed, it concludes that, in time, it should become a very important part of our Country's overall commercial and civil space business-program structure.

ONeil, Daniel

In-Space Transportation for Geo Space Solar Satellites

Space solar power satellites have the potential to provide abundant quantities of electricity for use on Earth. One concept, the Sun Tower, can be assembled in geostationary orbit from pieces transferred from Earth. The cost of transportation from Earth is one of the major hurdles to space solar power. This study found that a two-stage rocket launch vehicle with autonomous solar-electric transfer can provide the transportation at prices close to the goal of $800/kg

Martin, James A.

Advanced Technology Lifecycle Analysis System (ATLAS)

Developing credible mass and cost estimates for space exploration and development architectures require multidisciplinary analysis based on physics calculations, and parametric estimates derived from historical systems. Within the National Aeronautics and Space Administration (NASA), concurrent engineering environment (CEE) activities integrate discipline oriented analysis tools through a computer network and accumulate the results of a multidisciplinary analysis team via a centralized database or spreadsheet Each minute of a design and analysis study within a concurrent engineering environment is expensive due the size of the team and supporting equipment The Advanced Technology Lifecycle Analysis System (ATLAS) reduces the cost of architecture analysis by capturing the knowledge of discipline experts into system oriented spreadsheet models. A framework with a user interface presents a library of system models to an architecture analyst. The analyst selects models of launchers, in-space transportation systems, and excursion vehicles, as well as space and surface infrastructure such as propellant depots, habitats, and solar power satellites. After assembling the architecture from the selected models, the analyst can create a campaign comprised of missions spanning several years. The ATLAS controller passes analyst specified parameters to the models and data among the models. An integrator workbook calls a history based parametric analysis cost model to determine the costs. Also, the integrator estimates the flight rates, launched masses, and architecture benefits over the years of the campaign. An accumulator workbook presents the analytical results in a series of bar graphs. In no way does ATLAS compete with a CEE; instead, ATLAS complements a CEE by ensuring that the time of the experts is well spent Using ATLAS, an architecture analyst can perform technology sensitivity analysis, study many scenarios, and see the impact of design decisions. When the analyst is satisfied with the system configurations, technology portfolios, and deployment strategies, he or she can present the concepts to a team, which will conduct a detailed, discipline-oriented analysis within a CEE. An analog to this approach is the music industry where a songwriter creates the lyrics and music before entering a recording studio.

O'Neil, Daniel A.

Next-Generation Ion Propulsion Being Developed

The NASA Glenn Research Center ion-propulsion program addresses the need for high specific-impulse systems and technology across a broad range of mission applications and power levels. One activity is the development of the next-generation ion-propulsion system as a follow-on to the successful Deep Space 1 system. The system is envisioned to incorporate a lightweight ion engine that can operate over 1 to 10 kW, with a 550-kg propellant throughput capacity. The engine concept under development has a 40-cm beam diameter, twice the effective area of the Deep Space 1 engine. It incorporates mechanical features and operating conditions to maximize the design heritage established by the Deep Space 1 engine, while incorporating new technology where warranted to extend the power and throughput capability. Prototype versions of the engine have been fabricated and are under test at NASA, with an engineering model version in manufacturing. Preliminary performance data for the prototype engine have been documented over 1.1- to 7.3-kW input power. At 7.3 kW, the engine efficiency is 0.68, at 3615-sec specific impulse. Critical component temperatures, including those of the discharge cathode assembly and magnets, have been documented and are within established limits, with significant margins relative to the Deep Space 1 engine. The 1- to 10-kW ion thruster approach described here was found to provide the needed power and performance improvement to enable important NASA missions. The Integrated In-Space Transportation Planning (IISTP) studies compared many potential technologies for various NASA, Government, and commercial missions. These studies indicated that a high-power ion propulsion system is the most important technology for development because of its outstanding performance versus perceived development and recurring costs for interplanetary solar electric propulsion missions. One of the best applications of a highpower electric propulsion system was as an integral part of a solar electric propulsion (SEP) stage to send a payload to outer planet targets. The IISTP studies showed that either trip time or launch vehicle class could be significantly reduced when compared with state-of-the-art systems.

Patterson, Michael J.