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Expected antenna utilization and overload

The trade-offs between the number of antennas at Deep Space Network (DSN) Deep-Space Communications Complex and the fraction of continuous coverage provided to a set of hypothetical spacecraft, assuming random placement of the space craft passes during the day. The trade-offs are fairly robust with respect to the randomness assumption. A sample result is that a three-antenna complex provides an average of 82.6 percent utilization of facilities and coverage of nine spacecraft that each have 8-hour passes, whereas perfect phasing of the passes would yield 100 percent utilization and coverage. One key point is that sometimes fewer than three spacecraft are visible, so an antenna is idle, while at other times, there aren't enough antennas, and some spacecraft do without service. This point of view may be useful in helping to size the network or to develop a normalization for a figure of merit of DSN coverage.

Posner, Edward C.↗

Power Management and Distribution Trades Studies for a Deep-Space Mission Scientific Spacecraft

As part of NASA's Project Prometheus, the Nuclear Systems Program, NASA GRC performed trade studies on the various Power Management and Distribution (PMAD) options for a deep-space scientific spacecraft which would have a nominal electrical power requirement of 100 kWe. These options included AC (1000Hz and 1500Hz and DC primary distribution at various voltages. The distribution system efficiency, reliability, mass, thermal, corona, space radiation levels and technology readiness of devices and components were considered. The final proposed system consisted of two independent power distribution channels, sourced by two 3-phase, 110 kVA alternators nominally operating at half-rated power. Each alternator nominally supplies 50kWe to one half of the ion thrusters and science modules but is capable of supplying the total power re3quirements in the event of loss of one alternator. This paper is an introduction to the methodology for the trades done to arrive at the proposed PMAD architecture. Any opinions expressed are those of the author(s) and do not necessarily reflect the views of Project Prometheus.

Kimnach, Greg L.↗

Radiation exposure for human Mars exploration

One major obstacle to human space exploration is the possible limitations imposed by the adverse effects of long-term exposure to the space environment. Even before human space flight began, the potentially brief exposure of astronauts to the very intense random solar energetic particle events was of great concern. A new challenge appears in deep-space exploration from exposure to the low-intensity heavy-ion flux of the galactic cosmic rays since the missions are of long duration, and accumulated exposures can be high. Because cancer induction rates increase behind low to moderate thicknesses of aluminum shielding, according to available biological data on mammalian exposures to galactic cosmic ray-like ions, aluminum shield requirements for a Mars mission may be prohibitively expensive in terms of mission launch costs. Alternative materials for vehicle construction are under investigation to provide lightweight habitat structures with enhanced shielding properties. In the present paper, updated estimates for astronaut exposures on a Mars mission are presented and shielding properties of alternative materials are compared with aluminum.

NASA Center LaRC↗

Aircraft Detection System Ensures Free-Space Laser Safety

As scientists continue to explore our solar system, there are increasing demands to return greater volumes of data from smaller deep-space probes. Accordingly, NASA is studying advanced strategies based on free-space laser transmissions, which offer secure, high-bandwidth communications using smaller subsystems of much lower power and mass than existing ones. These approaches, however, can pose a danger to pilots in the beam path because the lasers may illuminate aircraft and blind them. Researchers thus are investigating systems that will monitor the surrounding airspace for aircraft that could be affected. This paper presents current methods for safe free space laser propagation.

Smithgall, Brian↗

Calibration and Characterization of the NASA EOS Terra and Aqua MODIS Instruments

The Moderate Resolution Imaging Spectroradiometer (MODIS) instrument is operating on both of the Terra and Aqua missions within the NASA Earth Observing System (EOS). The Terra MODIS instrument began taking observations in February 2000 and the Aqua MODIS instrument began taking observations in June of 2002 and both continue to operate successfully up to the present time. The MODIS instrument scans the entire Earth every 24 hours at nominal spatial resolutions between 250 and 1000 meters. It has 36 spectral bands spanning the electromagnetic spectrum from the visible wavelengths mar 400 micrometers to the emissive thermal infrared wavelengths at 15 micrometers. The MODIS instruments produce approximately 40 geophysical products devoted to observing land, ocean, and atmospheric processes and trends. To meet the scientific objectives associated with the NASA Earth sciences efforts the MODIS instruments must be and have been carefully calibrated and the performance characterized to meet specifications and goals such as five percent radiance and two percent relative to the sun accuracy in the twenty bands providing reflected solar radiation observations and one percent radiance accuracy in the sixteen bands observing in the thermal infrared. Over the time spanning instrument development and the pre-launch calibration and characterization of the instrument through the years of operation in space, the performance of the MODIS instruments have changed in multiple ways and appropriate adjustments made in relevant algorithms and look-up tables necessary to produce observations that meet the scientific objectives and requirements. The changes have been quantified and accounted for through careful use of on-board calibration devices such as the Spectro-Radiometric Calibration Assembly (SRCA), the Solar Diffuser (SD) and its companion Solar Diffuser Stability Monitor (SDSM), deep-space and lunar observations, and calibration targets on the Earth's surface. The strictest and most difficult challenges have come in trying to meet the requirements for observing Ocean color and related ocean biology processes over time and space. Overall the MODIS observations have been very successful in providing valuable scientific and applications results. The essential capabilities of MODIS are to be provided in the future by the Visible and Infrared Imaging Radiometer Suite (VIIRS) on the National Polar Orbiting Environmental Satellite Series (NPOESS).

Salomonson, Vincent V.↗

CFD Multiphysics Tool

The recent bold initiatives to expand the human presence in space require innovative approaches to the design of propulsion systems whose underlying technology is not yet mature. The space propulsion community has identified a number of candidate concepts. A short list includes solar sails, high-energy-density chemical propellants, electric and electromagnetic accelerators, solar-thermal and nuclear-thermal expanders. For each of these, the underlying physics are relatively well understood. One could easily cite authoritative texts, addressing both the governing equations, and practical solution methods for, e.g. electromagnetic fields, heat transfer, radiation, thermophysics, structural dynamics, particulate kinematics, nuclear energy, power conversion, and fluid dynamics. One could also easily cite scholarly works in which complete equation sets for any one of these physical processes have been accurately solved relative to complex engineered systems. The Advanced Concepts and Analysis Office (ACAO), Space Transportation Directorate, NASA Marshall Space Flight Center, has recently released the first alpha version of a set of computer utilities for performing the applicable physical analyses relative to candidate deep-space propulsion systems such as those listed above. PARSEC, Preliminary Analysis of Revolutionary in-Space Engineering Concepts, enables rapid iterative calculations using several physics tools developed in-house. A complete cycle of the entire tool set takes about twenty minutes. PARSEC is a level-zero/level-one design tool. For PARSEC s proof-of-concept, and preliminary design decision-making, assumptions that significantly simplify the governing equation sets are necessary. To proceed to level-two, one wishes to retain modeling of the underlying physics as close as practical to known applicable first principles. This report describes results of collaboration between ACAO, and Embry-Riddle Aeronautical University (ERAU), to begin building a set of level-two design tools for PARSEC. The "CFD Multiphysics Tool" will be the propulsive element of the tool set. The name acknowledges that space propulsion performance assessment is primarily a fluid mechanics problem. At the core of the CFD Multiphysics Tool is an open-source CFD code, HYP, under development at ERAU. ERAU is renowned for its undergraduate degree program in Aerospace Engineering the largest in the nation. The strength of the program is its applications-oriented curriculum, which culminates in one of three two-course Engineering Design sequences: Aerospace Propulsion, Spacecraft, or Aircraft. This same philosophy applies to the HYP Project, albeit with fluid physics modeling commensurate with graduate research. HYP s purpose, like the Multiphysics Tool s, is to enable calculations of real (three-dimensional; geometrically complex; intended for hardware development) applications of high speed and propulsive fluid flows.

Perrell, Eric R.↗

Power Actuation and Switching Module Test Results

The X2000 Power System Electronics (PSE) is a Jet Propulsion Laboratory (JPL) task to develop a new generation of power system building blocks for use on future deep-space missions. The effort includes the development of electronic components and modules that can be used as building blocks in the design of generic spacecraft power systems. All X2000 avionics components and modules are designed for use in centralized or distributed spacecraft architectures. The Power Actuation and Switching Module (PASM) has been developed under the X2000 program. This component enables a modular and scalable design approach for power switching applications, which can result in a wide variety of power switching architectures using this simple building block. The PASM is designed to provide most of the necessary power switching functions of spacecraft for various Deep Space missions including future missions to Mars, comets, Jupiter and its moons. It is fabricated using an ASIC process that is tolerant of high radiation. The development included two application specific integrated circuits (ASICs) and support circuitry all packaged using High Density Interconnect (HDI) technology. It can be operated in series or parallel with other PASMs. It can be used as a high-side or low-side switch and it can drive thruster valves, pyrotechnic devices such as NASA standard initiators, bus shunt resistors, and regular spacecraft component loads. Each PASM contains two independent switches with internal current limiting and over-current trip-off functions to protect the power subsystem from load faults. During turnon and turnoff each switch can limit the rate of current change (di/dt) to a value determined by the user. Three-way majority-voted On/Off commandability and full switch status telemetry (both analog and digital) are built into the module. This paper is a follow up to the one presented at he IECEC 2004 conference that will include the lessons learned and test results from the development.

X2000↗

NASA's Decadal Planning Team Mars Mission Analysis Summary

In June 1999 the NASA Administrator chartered an internal NASA task force, termed the Decadal Planning Team, to create new integrated vision and strategy for space exploration. The efforts of the Decadal Planning Team evolved into the Agency-wide team known as the NASA Exploration Team (NEXT). This team was also instructed to identify technology roadmaps to enable the science-driven exploration vision, established a cross-Enterprise, cross-Center systems engineering team with emphasis focused on revolutionary not evolutionary approaches. The strategy of the DPT and NEXT teams was to "Go Anywhere, Anytime" by conquering key exploration hurdles of space transportation, crew health and safety, human/robotic partnerships, affordable abundant power, and advanced space systems performance. Early emphasis was placed on revolutionary exploration concepts such as rail gun and electromagnetic launchers, propellant depots, retrograde trajectories, nano structures, and gas core nuclear rockets to name a few. Many of these revolutionary concepts turned out to be either not feasible for human exploration missions or well beyond expected technology readiness for near-term implementation. During the DPT and NEXT study cycles, several architectures were analyzed including missions to the Earth-Sun Libration Point (L2), the Earth-Moon Gateway and L1, the lunar surface, Mars (both short and long stays), one-year round trip Mars, and near-Earth asteroids. Common emphasis of these studies included utilization of the Earth-Moon Libration Point (L1) as a staging point for exploration activities, current (Shuttle) and near-term launch capabilities (EELV), advanced propulsion, and robust space power. Although there was much emphasis placed on utilization of existing launch capabilities, the team concluded that missions in near-Earth space are only marginally feasible and human missions to Mars were not feasible without a heavy lift launch capability. In addition, the team concluded that missions in Earth s neighborhood, such as to the Moon, can serve as stepping-stones toward further deep-space missions in terms of proving systems, technologies, and operational concepts. The material contained in this presentation was compiled to capture the work performed by the Mars Sub-Team of the DPT NEXT efforts in the late 1999-2001 timeframe.

Drake, Bret G.↗

Generation of Data-Rate Profiles of Ka-Band Deep-Space Links

A short report discusses a methodology for designing Ka-band Deep-Space-to- Earth radio-communication links. This methodology is oriented toward minimizing the effects of weather on the Ka-band telecommunication link by maximizing the expected data return subject to minimum link availability and a limited number of data rates. This methodology differs from the current standard practices in which a link is designed according to a margin policy for a given link availability at 10 elevation. In this methodology, one chooses a data-rate profile that will maximize the average data return over a pass while satisfying a minimum-availability requirement for the pass, subject to mission operational limitations expressed in terms of the number of data rates used during the pass. The methodology is implemented in an intelligent search algorithm that first finds the allowable data-rate profiles from the mission constraints, spacecraft-to-Earth distance, spacecraft EIRP (effective isotropic radiated power), and the applicable zenith atmospheric noise temperature distribution, and then selects the best data rate in terms of maximum average data return from the set of allowable data-rate profiles.

Shambayati, Shervin↗

Pointing-Vector and Velocity Based Frequency Predicts for Deep-Space Uplink Array Applications

Uplink array technology is currently being developed for NASA's Deep Space Network (DSN) to provide greater range and data throughput for future NASA missions, including manned missions to Mars and exploratory missions to the outer planets, the Kuiper belt, and beyond. Here we describe a novel technique for generating the frequency predicts that are used to compensate for relative Doppler, derived from interpolated earth position and spacecraft ephemerides. The method described here guarantees velocity and range estimates that are consistent with each other, hence one can always be recovered from the other. Experimental results have recently proven that these frequency predicts are accurate enough to maintain the phase of a three element array at the EPOXI spacecraft for three hours. Previous methods derive frequency predicts directly from interpolated relative velocities. However, these velocities were found to be inconsistent with the corresponding spacecraft range, meaning that range could not always be recovered accurately from the velocity predicts, and vice versa. Nevertheless, velocity-based predicts are also capable of maintaining uplink array phase calibration for extended periods, as demonstrated with the EPOXI spacecraft, however with these predicts important range and phase information may be lost. A comparison of the steering-vector method with velocity-based techniques for generating precise frequency predicts specifically for uplink array applications is provided in the following sections.

uplink arraying↗

Experimental Evaluation of the "Polished Panel Optical Receiver" Concept on the Deep Space Network's 34 Meter Antenna

The potential development of large aperture ground-based "photon bucket" optical receivers for deep space communications has received considerable attention recently. One approach currently under investigation proposes to polish the aluminum reflector panels of 34-meter microwave antennas to high reflectance, and accept the relatively large spotsize generated by even state-of-the-art polished aluminum panels. Here we describe the experimental effort currently underway at the Deep Space Network (DSN) Goldstone Communications Complex in California, to test and verify these concepts in a realistic operational environment. A custom designed aluminum panel has been mounted on the 34 meter research antenna at Deep-Space Station 13 (DSS-13), and a remotely controlled CCD camera with a large CCD sensor in a weather-proof container has been installed next to the subreflector, pointed directly at the custom polished panel. Using the planet Jupiter as the optical point-source, the point-spread function (PSF) generated by the polished panel has been characterized, the array data processed to determine the center of the intensity distribution, and expected communications performance of the proposed polished panel optical receiver has been evaluated.

photon counting detection↗

Biosentinel: Developing a Space Radiation Biosensor

Ionizing radiation presents a major challenge to human exploration and long-term residence in space. The deep-space radiation spectrum includes highly energetic particles that generate double strand breaks (DSBs), deleterious DNA lesions that are usually repaired without errors via homologous recombination (HR), a conserved pathway in all eukaryotes. While progress identifying and characterizing biological radiation effects using Earth-based facilities has been significant, no terrestrial source duplicates the unique space radiation environment.We are developing a biosensor-based nanosatellite to fly aboard NASAs Space Launch System Exploration Mission 1, expected to launch in 2017 and reach a 1AU (astronomic unit) heliocentric orbit. Our biosensor (called BioSentinel) uses the yeast S. cerevisiae to measure DSBs in response to ambient space radiation. The BioSentinel strain contains engineered genetic defects that prevent growth until and unless a radiation-induced DSB near a reporter gene activates the yeasts HR repair mechanisms. Thus, culture growth and metabolic activity directly indicate a successful DSB-and-repair event. In parallel, HR-defective and wild type strains will provide survival data. Desiccated cells will be carried within independent culture microwells, built into 96-well microfluidic cards. Each microwell set will be activated by media addition at different time points over 18 months, and cell growth will be tracked continuously via optical density. One reserve set will be activated only in the occurrence of a solar particle event. Biological measurements will be compared to data provided by onboard physical dosimeters and to Earth-based experiments.BioSentinel will conduct the first study of biological response to space radiation outside Low Earth Orbit in over 40 years. BioSentinel will thus address strategic knowledge gaps related to the biological effects of space radiation and will provide an adaptable platform to perform human-relevant measurements in multiple space environments. We hope that it can therefore be used on the ISS, on and around other planetary bodies as well as other exploration platforms as a self-contained system that will allow us to compare and calibrate different radiation environments.BioSentinels results will be critical for improving interpretation of the effects of space radiation exposure, and for reducing the risk associated with long-term human exploration.

space radiation↗

Delay-Throughput Performance of the Deep-Space Ka-band Link

In this paper, performance of a first-in, first-out (FIFO), selective retransmission scheme for the deep-space Ka-band link is presented and compared to the performance of a comparable X-band link. In this analysis, 16 months of water vapor radiometer (WVR) and advanced water vapor radiometer (AWVR) data from the three Deep Space Network (DSN) Communication Complexes (DSCC) were used to emulate weather effects on X-band and Ka-band links from Mars. Mars Reconnaissance Orbiter (MRO) X-band and Ka-band telecommunications parameters were used for spacecraft telecommunications capabilities. One pass per week per complex was selected from MRO's Deep Space Network (DSN) schedule from April 1, 2006 to August 31, 2007 for a total of 207 passes (69 passes per complex) for this analysis. For each pass both X-band and Ka-band links were designed using at most two data rates so that the expected pass capacity would be maximized subject to a minimum availability requirement (MAR). In conjunction with the WVR/AWVR data, elevation profiles of the selected passes and models for the performance of the antennas in the DSN were used to emulate the performance of both links. It was assumed that the retransmission of the data takes place not on the same pass as the original transmission but during subsequent passes. The data collected before a pass was assumed to be a fraction of the expected capacity of the pass as calculated through the link design process. Infinite spacecraft storage was assumed to obtain an upper bound on the spacecraft storage requirement. The independent parameters of this analysis were MAR and the ratio of data collected before a pass to the expected pass capacity. Since the selected passes did not occur at regular intervals, the delay in this analysis was measured in terms of number of passes. The throughput was measured in terms of number of bits received successfully on the ground. The results indicate that reasonable delay performance could be achieved with very high throughput for relatively low MAR values for data collection to expected pass capacity ratio of around 97% for Ka-band. The results indicate that, except for very low average delay requirements, the Ka-band link provides more than twice the throughput of the X-band link for the same amount of power consumed by the spacecraft. In addition, the results indicate that the required storage onboard the spacecraft is not prohibitive and good performance could be achieved by using a buffer size less than three times the maximum amount of data collected before a pass.

Shambayati, Shervin↗

Delay-Throughput Performance the Deep-Space Ka-Band Link

In this paper, performance of a first-in, first-out (FIFO), selective retransmission scheme for the deep-space Ka-band link is presented and compared to the performance of a comparable X-band link. In this analysis, 16 months of water vapor radiometer (WVR) and advanced water vapor radiometer (AWVR) data from the three Deep Space Network (DSN) Communication Complexes (DSCC) were used to emulate weather effects on X-band and Ka-band links from Mars. Mars Reconnaissance Orbiter (MRO) X-band and Ka-band telecommunications parameters were used for spacecraft telecommunications capabilities. One pass per week per complex was selected from MRO's Deep Space Network (DSN) schedule from April 1, 2006 to August 31, 2007 for a total of 207 passes (69 passes per complex) for this analysis. For each pass both X-band and Ka-band links were designed using at most two data rates so that the expected pass capacity would be maximized subject to a minimum availability requirement (MAR). In conjunction with the WVR/AWVR data, elevation profiles of the selected passes and models for the performance of the antennas in the DSN were used to emulate the performance of both links. It was assumed that the retransmission of the data takes place not on the same pass as the original transmission but during subsequent passes. The data collected before a pass was assumed to be a fraction of the expected capacity of the pass as calculated through the link design process. Infinite spacecraft storage was assumed to obtain an upper bound on the spacecraft storage requirement. The independent parameters of this analysis were MAR and the ratio of data collected before a pass to the expected pass capacity. Since the selected passes did not occur at regular intervals, the delay in this analysis was measured in terms of number of passes. The throughput was measured in terms of number of bits received successfully on the ground. The results indicate that reasonable delay performance could be achieved with very high throughput for relatively low MAR values for data collection to expected pass capacity ratio of around 97% for Ka-band. The results indicate that, except for very low average delay requirements, the Ka-band link provides more than twice the throughput of the X-band link for the same amount of power consumed by the spacecraft. In addition, the results indicate that the required storage onboard the spacecraft is not prohibitive and good performance could be achieved by using a buffer size less than three times the maximum amount of data collected before a pass.

Shambayati, Shervin↗

BioSentinel: Biosensors for Deep-Space Radiation Study

The BioSentinel mission will be deployed on NASA's Exploration Mission 1 (EM-1) in 2018. We will use the budding yeast, Saccharomyces cerevisiae, as a biosensor to study the effect of deep-space radiation on living cells. The BioSentinel mission will be the first investigation of a biological response to space radiation outside Low Earth Orbit (LEO) in over 40 years. Radiation can cause damage such as double stand breaks (DSBs) on DNA. The yeast cell was chosen for this mission because it is genetically controllable, shares homology with human cells in its DNA repair pathways, and can be stored in a desiccated state for long durations. Three yeast strains will be stored dry in multiple microfluidic cards: a wild type control strain, a mutant defective strain that cannot repair DSBs, and a biosensor strain that can only grow if it gets DSB-and-repair events occurring near a specific gene. Growth and metabolic activity of each strain will be measured by a 3-color LED optical detection system. Parallel experiments will be done on the International Space Station and on Earth so that we can compare the results to that of deep space. One of our main objectives is to characterize the microfluidic card activation sequence before the mission. To increase the sensitivity of yeast cells as biosensors, desiccated yeast in each card will be resuspended in a rehydration buffer. After several weeks, the rehydration buffer will be exchanged with a growth medium in order to measure yeast growth and metabolic activity. We are currently working on a time-course experiment to better understand the effects of the rehydration buffer on the response to ionizing radiation. We will resuspend the dried yeast in our rehydration medium over a period of time; then each week, we will measure the viability and ionizing radiation sensitivity of different yeast strains taken from this rehydration buffer. The data obtained in this study will be useful in finalizing the card activation sequence for this mission.

Yeast↗

Comparison of Atmospheric Delay Statistics from Deep Space Network Arrays and Nearby Test Interferometers

Several techniques have been explored and demonstrated that allow for greater data return on space-to-ground links. Among these techniques, arraying several smaller diameter dish antennas together is one method used in several arenas. These arrays can achieve larger effective area and gain than are available from a single larger antenna. This technique is routinely used by the NASA Deep Space Network (DSN) at 8.4 GHz where the incoming signals are much weaker than those experienced by the near-Earth satellite community. When considering arraying at much higher frequencies such as 32 GHz deep-space Ka-band, the phase alignment of the individual antenna signals is significantly disrupted by atmospheric turbulence. Since 2012, several downlink array demonstrations have been conducted using 32 GHz carrier signals emitted by the deep space probes Cassini and Kepler. Site test interferometers (STIs) that receive signals from geostationary satellites have been deployed at all three DSN tracking complexes for long-term monitoring of atmospheric delay fluctuations. In a previous DSN array demonstration study involving the Cassini spacecraft, it was shown that statistics of the adjusted STI phase fluctuations matched the statistics of concurrent array demonstration phase fluctuations. These adjustments accounted for differences in antenna separation, elevation angle and spacecraft frequencies. The STI antenna separations were about 200 m and the DSN antenna separations were about 300 m. These adjustments made use of the thick-layer turbulence model that was applicable to the Goldstone desert climate during the summer months for which the data were acquired. In this paper, we report on the results of additional array demonstrations involving the Kepler spacecraft and compare the adjusted STI phase fluctuations with those seen by a nearby two-element array of 34 m diameter antennas tracking Kepler’s 32 GHz signal at the Goldstone, California and Madrid, Spain DSN sites. We also discuss results from a demonstration using an array over a longer 12.5 km baseline. The Cassini and Kepler array demonstrations were found to validate the long term statistics acquired from several years of STI data as well as the models used to adjust the statistics for the conditions of an array. These statistics represent reliable estimates of the phase fluctuations that would be seen by an array tracking a deep space signal after applying appropriate adjustments for a given array configuration, elevation angle profile and observing frequency.

Morabito, David D.↗

Spacecraft in the Shot: A Platform for Deep-Space Cinematography

Spacecraft In The Shot (SITS) is a breakthrough cross-disciplinary initiative that stands at the intersection of advanced technology and strategic storytelling. It aims to enhance humanity’s connection to robotic space exploration by capturing high-definition footage of heroic spacecraft along their journey through deep space. The SITS Imaging Instrument, a self-contained, highly autonomous instrument package can be included in any typical mission payload. The Instrument stores and deploys SITS imagers, or camera-carrying nanosats. As a mission approaches a key milestone in the trajectory, the SITS Instrument deploys one or more imagers that fly pre-programmed, autonomous trajectories around the host spacecraft. After the footage has been collected and downlinked to the host, the Imagers get decommissioned and left behind as the host spacecraft continues into the depths of space until the next photo opportunity.

Smith, Jonathon↗

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗