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Future Aerospace Technology in the Service of the Alliance: Sustained Hypersonic Flight - Volume 3

Sustained Hypersonic Flight capability is envisioned for several future military and civilian applications, such as long range immediate reaction reconnaissance, high speed interception of air targets, long range precision strike against hardened or time critical targets, and access to space. The inherent reduction in time-to-target and low vulnerability will permit new operational tactics. The symposium outlined mission needs and operational scenarios for hypersonic vehicles. Addressed were: Technological issues and challenges in external hypersonic aerodynamics and design, propulsion and engine/airframe integration, military ramjet applications, overall system design including structures and materials development needs, and test facilities. Ground based test facilities cannot provide full simulation at Mach numbers above 5. Therefore, the use of Computational Fluid Dynamics design tools is essential. For routine use of the computational tools in analysis, design and optimization, it is necessary to reduce the time for the entire computational process by two orders of magnitude. Hypersonic boundary layer transition remains a critical design issue because of the important impact on engine drag and on heating, which can affect the choice of materials and thermal protection systems. In addition, reliable prediction of scramjet net thrust is an absolute must in resolving hypersonic air breathing vehicle design issues. Due to current facility and computational shortfalls, the development of future hypersonic flight systems requires research flight tests in the technology areas of boundary layer transition and air-breathing propulsion engine performance. For sustained hypersonic flight beyond Mach 6, the supersonic combustion ramjet (scramjet) engine is the only choice for the near future. Only this air-breathing concept offers a significant promise of large reductions in required propellant fractions, increased payload fractions, and reduced size vehicles, together with a foreseeable technological feasibility. Airframe/engine integration, combustor design and thermal management are the predominant engineering tasks. Fuels, hydrogen or hydrocarbon, must be matched to the operational needs of military or civil use. Experience in existing ramjet propelled missiles capable of speeds up to Mach 4 can support the development effort. The potential mission and cost benefits of sustained hypersonic flight to both military and civil applications are tremendous. From the budget point of view, the possibility of sharing development costs between military and civil programs offers a specific advantage.

Combustion chambers

Initial Test Firing Results for Solid CO/GOX Cryogenic Hybrid Rocket Engine for Mars ISRU Propulsion Applications

ORBITEC is developing methods for producing, testing, and utilizing Mars-based ISRU fuel/oxidizer combinations to support low cost, planetary surface and flight propulsion and power systems. When humans explore Mars we will need to use in situ resources that are available, such as: energy (solar); gases or liquids for life support, ground transportation, and flight to and from other surface locations and Earth; and materials for shielding and building habitats and infrastructure. Probably the easiest use of Martian resources to reduce the cost of human exploration activities is the use of the carbon and oxygen readily available from the CO2 in the Mars atmosphere. ORBITEC has conducted preliminary R&D that will eventually allow us to reliably use these resources. ORBITEC is focusing on the innovative use of solid CO as a fuel. A new advanced cryogenic hybrid rocket propulsion system is suggested that will offer advantages over LCO/LOX propulsion, making it the best option for a Mars sample return vehicle and other flight vehicles. This technology could also greatly support logistics and base operations by providing a reliable and simple way to store solar or nuclear generated energy in the form of chemical energy that can be used for ground transportation (rovers/land vehicles) and planetary surface power generators. This paper describes the overall concept and the test results of the first ever solid carbon monoxide/oxygen rocket engine firing.

Eric E Rice

Space Transportation System Technology Symposium. Volume 2 - Dynamics and Aeroelasticity

The Space Shuttle, being an hybrid – an airplane and a launch vehicle – represents the greatest challenge that the dynamicist and the aeroelastician have faced. Some specific problem areas related to the Space Shuttle are listed on figure 1. Dynamics and aeroelasticity envelop many disciplines, including aerodynamics, vibration, random processes, structures, fluid flow, mechanics, etc., but, of more importance, they involve the interaction and coupling of many of these various disciplines. Fundamentally, we are concerned with structural integrity and safe flight, i.e., trying to ensure that the vehicle will remain structurally intact as well as function properly in the presence of the many faceted dynamic environment. A new area which may have an impact on our task is the effect of the high temperature environment. In the past, we have been able to successfully decouple the temperature effects from our problem formulation. For the Space Shuttle, this problem must be closely reexamined. As has been pointed out in the opening remarks of the Conference, the Dynamics and Aeroelasticity Technology Group comprises one of several technology groups which are attempting to provide the necessary research to support a successful and safe vehicle. The group has members from most of the NASA Centers as well as from the Air Force groups. We meet periodically to review ongoing work, search for new problem areas; and we are constantly updating and revising our program. The group is organized into three panels as shown on figure 2: a panel on Dynamic Loads and Response, one on Aeroelasticity, and one on Flight Dynamics and Environment. The Conference papers accordingly have been grouped in these same three areas, with each Panel Chairman acting as moderator for his particular session.

Harry L Runyan

Distribution of Extraterrestrial Nucleobases, Other N-Heterocycles, and Their Precursors in A Sample From Asteroid Bennu

The recent discovery of all five canonical nucleobases in samples from Bennu provides compelling evidence that some of life’s ingredients were synthesized abiotically in the parent body of this asteroid and/or its precedent components. However, due to the sample availability and the limited method for the analysis, the detailed distribution of nucleobases in the samples remains elusive. Here we report the concentrations of a diverse suite of nitrogen (N)-heterocycles including nucleobases extracted by 2% and 20% hydrochloric acid from a homogenized Bennu sample. The detection of both canonical and non-canonical nucleobase pairs confirms that these biologically important compounds are extraterrestrial. Pyrimidines are more abundant than purines—like the Orgueil meteorite, but unlike the Murchison meteorite and asteroid Ryugu samples—suggesting preferential synthesis in ammonia-rich ices from the outer Solar System. The distribution of other N-heterocycles is consistent with extensive aqueous alteration on the parent body. High concentrations of urea underscore its role in N-heterocycle synthesis. Our findings offer important information on the prebiotic inventory of N-heterocycles in the Solar System.

Yasuhiro Oba

Power and Propulsion Element Steerable High Gain Antenna Lunar Transit Thermal Analysis Tracking Methodology

The Power and Propulsion Element (PPE) is an ion thruster propulsion spacecraft developed as an element of Space Reactor (SR-1) Freedom to provide propulsion, communications and power for the spacecraft. PPE was originally being developed for the use with the lunar orbiting space station Gateway as one of the first two planned elements. PPE was to be launched with the Habitation and Logistics Outpost (HALO) element in a configuration called the Co-Manifested Vehicle (CMV) that would arrive at a Near-Rectilinear Halo Orbit (NRHO) around the Moon via a lunar transit spiral trajectory phase. The PPE communication system is equipped with two Steerable High Gain Antennas (SHGA) each steered by a two-axis gimbal (TAG) mechanism. A thermal analysis was conducted during the near-Earth spiral phase of the mission using Thermal Desktop (TD). This analysis utilized multiple axis Earth tracking articulators in combination with SINDA system internal environmental heating symbols to produce accurate Earth ground station tracking communication system temperatures. This presentation provides an overview of the communication system thermal model and the analysis methodology.

Thermal Analysis

NASA's Advanced Control Law Program for the F-8 Digital Fly-By-Wire Aircraft

This paper briefly describes the NASA F-8 Digital Fly-By-Wire (DFBW) program and Langley Research Center's role in investigating and promoting advanced control laws for possible flight experimentation. The primary purpose of the paper is to provide background material for papers describing some of the F-8 DFBW adaptive control law studies. The paper provides a brief description of the Phase II DFBW F-8 aircraft and its control system, discusses some of the advanced control law study objectives and guidelines, and provides some mathematical models which are useful in the control analysis problem.

Optimal Control

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson

Ares I-X Ground Diagnostic Prototype

The automation of pre-launch diagnostics for launch vehicles offers three potential benefits: improving safety, reducing cost, and reducing launch delays. The Ares I-X Ground Diagnostic Prototype demonstrated anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage Thrust Vector Control and for the associated ground hydraulics while the vehicle was in the Vehicle Assembly Building at Kennedy Space Center (KSC) and while it was on the launch pad. The prototype combines three existing tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool from Qualtech Systems Inc. for fault isolation and diagnostics. The second tool, SHINE (Spacecraft Health Inference Engine), is a rule-based expert system that was developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification, and used the outputs of SHINE as inputs to TEAMS. The third tool, IMS (Inductive Monitoring System), is an anomaly detection tool that was developed at NASA Ames Research Center. The three tools were integrated and deployed to KSC, where they were interfaced with live data. This paper describes how the prototype performed during the period of time before the launch, including accuracy and computer resource usage. The paper concludes with some of the lessons that we learned from the experience of developing and deploying the prototype.

Machine Learning

Optical Telescope Technology

Design optics and technology for large spaceborne astronomical telescopes

Office of Space Science and Applications

Final Report Document: Microgravity Medical Eyewash B

Senior Capstone Design Team 15 has been commissioned by the National Aeronautics and Space Administration (NASA) to redesign the current microgravity eye wash station. The current design exhibits four primary limitations: single-use operation, excessive mass and volume, operational complexity requiring coordination with external systems, and dependence on frequent Earth resupply missions. Our updated eyewash design will be deployed on long-range space missions that could last multiple years. Based on these and other requirements from our customer, we have developed our updated eyewash design. Our compact, single-eye system uses capillary-driven flow and a free-floating water ball. This design allows us to eliminate pumps and bulky tubing, decreasing the mass and volume of the overall system. The containment eyecup is held to the astronaut's face with a strap, and a silicone seal prevents leakage while improving user comfort. Contaminated water is contained within a disposal bag containing wicking material to pull it back out of the eyecup after washing the eye. This system is reusable, efficient, and easy to activate quickly. We evaluated our design through calculations, microfluidic testing, and user try-on testing to verify our requirements. Our work demonstrated that steady-state flow was capable with our capillary framework, achieving 1.31 L/min. The prototype construction confirmed mass and volume reductions, and try-on-testing evaluated the ability to put on the system quickly. Almost all major design requirements were achieved, and water loss could be validated by testing in microgravity. Our design went through a number of iterations to reach the final solution presented in this report. These changes were driven by our testing and collaboration from each member of the team. Updated models optimized tube placement and geometry of the eyecup to better direct flow as it pools across the eye. Changes to our tubing bends improved capillary efficiency and increased the flow rate we were capable of achieving. And improved bracket placements adjusted the fit, comfort, and seal of the eyecup to the astronaut's face. Our capillary-based eyewash system is technically feasible and has been theoretically validated to operate effectively in microgravity conditions. Testing and analysis indicate that it can meet or exceed the required performance metrics, including flow rate and safety constraints. Overall, the design represents a viable alternative to current ISS-dependent eyewash systems for future space missions.

Jeffrey Allen

Chapter 12 - Flight Envelope

The term "flight envelope" is used to refer to the boundaries of aircraft loading and flight conditions within which operation of the aircraft is satisfactory, and beyond which some aspect becomes unacceptable. This flight envelope represents, in fact, the limiting conditions arising from a matrix of inter-related flight envelopes covering the appropriate variables. Thus, for each loading (i.e., external stores configuration and its associated range of weight and center of gravity (c.g.) position) and aircraft configuration (i.e., position of undercarriage (u/c), flaps, slats, etc.), the envelopes of airspeed versus altitude, airspeed versus load factor, angle of attack versus angle of sideslip, etc., must be investigated to establish the limits within which all aspects such as handling qualities, engine behavior, structural loads, etc., remain acceptable. Flight testing of new or derivative aircraft models is carried out with the initial purpose of defining a flight envelope which is, first and foremost, safe and secondarily, which enables the effective use of the vehicle for its intended purpose. Flight testing occurs only after numerous reviews of the design and review of results from ground tests and predictions of flight characteristics in such areas as structures, aerodynamics, stability and control, flight controls (particularly fly-by-wire control systems, propulsion, etc.). Accordingly, opening and expanding the envelope is a task that must be approached cautiously, systematically, and with coordination and cooperation of the many disciplines involved in the design and test of an airplane. (Sections 8 and 10 cover test planning and safety of flight considerations, respectively). The fundamental tenet in establishing a flight envelope via flight test is risk reduction. This is reflected in the typical sequence of events leading to initial flight test - design reviews (both hardware and software), then ground test involving singular disciplines (windtunnel tests for aerodynamics, structurally loading the wing/fuselage/nacelle on a ground test article with loads anticipated to occur in flight, flight control system control law checkout, propulsion test cell runs and/or flying test bed tests, etc.), and then ground tests involving multi-disciplines (See Section 9). Only after these have been accomplished will an initial, limited, low-risk, flight envelope be established. The limited envelope will typically be in the middle of the projected final flight envelope. Subsequent flight tests will then be devoted to expanding the initial envelope by operating the airplane at increasing ranges - representing increasing risk - of engine operation, airspeeds both fast and slow, altitude, load factor both above and below 1g, centers of gravity (fore and aft), and with system/subsystem failures. Whether flight tests are to define a flight envelope on a new model airplane with the attendant new airframe, new engine(s), and new subsystems (hydraulics, pressurization, etc.), or on an airplane involving only a few of these areas such as new engines in an old airframe, the fundamental approach to establishing an envelope is the same.

H Walgemoed

Multifaceted Considerations for Fission Surface Power Radiation Shielding Design

The purpose of the Fission Surface Power (FSP) nuclear system is to provide energy on the Moon and Mars for supporting their exploration and colonization. The FSP design and deployment can leverage the past research and development work in areas, such as reactor design, but such crucial components as radiation shielding and instrumentation still need material and manufacturing studies, modeling, and testing. The shielding components are needed for the protection of humans, electronics, and sensitive components. They are essential system components, but they are often the heaviest components of the system for which each kilogram matters. Different material combinations and layouts are possible. The studies presented were focused on the evaluation of several options. The initial analysis included their performance assessment, initial temperature distribution evaluation and manufacturability considerations. Several feasible shield design options were identified and discussed in this paper, as well.

Fission Surface Power

The NASA Aerospace Battery Safety Handbook

This handbook has been written for the purpose of acquainting those involved with batteries with the information necessary for the safe handling, storage, and disposal of these energy storage devices. Included in the document is a discussion of the cell and battery design considerations and the role of the components within a cell. The cell and battery hazards are related to user- and/or manufacturer-induced causes. The Johnson Space Center (JSC) Payload Safety Guidelines for battery use in Shuttle applications are also provided. The electrochemical systems are divided into zinc anode and lithium anode primaries, secondary cells, and fuel cells. Each system is briefly described, typical applications are given, advantages and disadvantages are tabulated, and most importantly, safety hazards associated with its use are given.

Halpert, Gerald

The Hyperspectral Microwave Photonic Instrument (HyMPI) and its NEDT Performance

This work presents an overview of a hyperspectral microwave-photonic spectrometer and demonstrates the system end-to-end noise equivalent delta temperature (NEDT) performance. The system aims at augmenting the remote sensing capability from space, with a focus on the Earth’s planetary boundary layer (PBL) thermal microwave (MW) spectral region (0-200 GHz). Combining a Photonic Integrated Circuit (PIC) channelizer and an application-specific integrated circuit (ASIC) spectrometer, the PIC & ASIC (PICASIC) module is capable of processing 40 GHz spectra at hyperspectral (4 MHz) resolution. The photonic technology is agnostic to the spectral region and multiple photonic modules can cover the entire 200 GHz spectrum. Measured results of the end-to-end system NEDT agree with predicted values confirming that the NEDT is primarily dominated by the noise figure of the MW front-end, with the optical link adding no significant noise. The data also demonstrate that a single module enables simultaneous super- and hyper-spectral resolution channel analysis across a 40 GHz range.

spectrometer

Next-Generation Hard X-ray Missions: SuperHERO and HEROIX

High-energy X-ray observations have transformed our understanding of astrophysical systems where non-thermal processes dominate, from shock-accelerated particles in supernova remnants to relativistic jets and hot coronae in active galactic nuclei. NuSTAR’s pioneering focusing images of the hard X-ray sky have demonstrated the immense scientific potential of this band, while also highlighting how limited angular resolution constrains our ability to fully characterize complex physical processes in faint extended sources and resolving faint sources in crowded sky regions. In this presentation, I will discuss a pathway to overcome these challenges through NASA Marshall Space Flight Center’s replicated NiCo full-shell X-ray mirror technology. Specifically, I will discuss the SuperHERO hard X-ray telescope to achieve better than 10-arcsecond half-power diameter (HPD) angular resolution on a balloon flight observing the Crab Nebula, and the High EneRgy Observatory for Imaging X-rays (HEROIX) Medium-Class Mission concept to achieve an integrated effective area of 570 cm2 at 30 keV with 5 arcsec HPD angular resolution.

AGN

Characterization of a New Phase and Its Effect on the Work Characteristics of a Near-Stoichiometric Ni30Pt20Ti50 High-Temperature Shape Memory Alloy (HTSMA)

A new phase observed in a nominal Ni 30 Pt 20 Ti 50 (at.%) high temperature shape memory alloy has been characterized using transmission electron microscopy and 3-D atom probe tomography. This phase forms homogenously in the B2 austenite matrix by a nucleation and growth mechanism and results in a concomitant increase in the martensitic transformation temperature of the base alloy. Although the structure of this phase typically contains a high density of faults making characterization difficult, it appears to be trigonal (-3m point group) with a o ~1.28 nm and c o ~1.4 nm. Precipitation of this phase increases the microhardness of the alloy substantially over that of the solution treated and quenched single-phase material. The effect of precipitation strengthening on the work characteristics of the alloy has been explored through load-biased strain-temperature testing in the solution-treated condition and after aging at 500 ºC for times ranging from 1 to 256 hours. Work output was found to increase in the aged alloy as a result of an increase in transformation strain, but was not very sensitive to aging time. The amount of permanent deformation that occurred during thermal cycling under load was small but increased with increasing aging time and stress. Nevertheless, the dimensional stability of the alloy at short aging times (1-4 hours) was still very good making it a potentially useful material for high-temperature actuator applications.

A Garg

Preparation of the Ice Certification of the Dornier 328 Regional Airliner By Numerical Simulation and By Ground Test

The Dornier 328, a new regional airliner, is to be qualified to FAR25/JAR25 requirements for operation into known icing conditions. All lifting surfaces are pneumatically deiced. Impingement limits were determined using a validated computational fluid dynamic (CFD) code. Wind tunnel tests with a model of the whole aircraft and the isolated empennage equipped with artificial ice shapes showed a degradation of handling characteristics due to ice accretion. Extensive two and three dimensional CFD calculations evaluated ice accretion at the deflection elevator horn. Icing tunnel tests were performed with a model of the horizontal tail with icing similitude fulfilled. The Dornier Do328 powerplant air induction system has successfully completed a program of icing tests in support of aircraft certification for operation into known icing conditions. Potential flight icing conditions were extensively analyzed using a CFD potential flow code and 3-D particle tracking routine to identify critical flight icing conditions. The tunnel test program verified the analytically predicted critical ice accretion surfaces of the air induction system, the adequacy of the ice protection provisions and demonstrated compliance with the applicable (JAR25) regulatory material.

D Welte

A Battery Charger and State of Charge Indicator

A battery charger which has a full wave rectifier in series with a transformer isolated 20 kHz dc-dc converter with high frequency switches, which are programmed to actively shape the input dc line current to be a mirror image of the ac line voltage is discussed. The power circuit operates at 2 kW peak and 1 kW average power. The BC/SCI has two major subsystems: (1) the battery charger power electronics with its controls; and (2) a microcomputer subsystem which is used to acquire battery terminal data and exercise the state of charge software programs. The state of charge definition employed is the energy remaining in the battery when extracted at a 10 kW rate divided by the energy capacity of a fully charged new battery. The battery charger circuit is an isolated boost converter operating at an internal frequency of 20 kHz. The switches selected for the battery charger are the single most important item in determining its efficiency. The combination of voltage and current requirements dictate the use of high power NPN Darlington switching transistors. The power circuit topology is a three switch design which utilizes a power FET on the center tap of the isolation transformer and the power Darlingtons on each of the two ends. An analog control system is employed to accomplish active input current waveshaping as well as the necessary regulation.

Latos, T. S.