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At least 91 records · Page 5

Orion Multi Purpose Crew Vehicle Environmental Control and Life Support Development Status

The Orion Multi Purpose Crew Vehicle (MPCV) is the first crew transport vehicle to be developed by the National Aeronautics and Space Administration (NASA) in the last thirty years. Orion is currently being developed to transport the crew safely from the Earth beyond Earth orbit. This year, the vehicle focused on building the Exploration Flight Test 1 (EFT1) vehicle to be launched in 2014. The development of the Orion Environmental Control and Life Support (ECLS) System, focused on the components which are on EFT1 which includes pressure control and active thermal control systems, is progressing through the design stage into manufacturing. Additional development work was done to keep the remaining component progressing towards implementation for a flight tests in 2017 and in 2020. This paper covers the Orion ECLS development from April 2011 to April 2012.

Lewis, John F.↗

Electron Beam Freeform Fabrication of Titanium Alloy Gradient Structures

Historically, the structural optimization of aerospace components has been done through geometric methods. A monolithic material is chosen based on the best compromise between the competing design limiting criteria. Then the structure is geometrically optimized to give the best overall performance using the single material chosen. Functionally graded materials offer the potential to further improve structural efficiency by allowing the material composition and/or microstructural features to spatially vary within a single structure. Thus, local properties could be tailored to the local design limiting criteria. Additive manufacturing techniques enable the fabrication of such graded materials and structures. This paper presents the results of a graded material study using two titanium alloys processed using electron beam freeform fabrication, an additive manufacturing process. The results show that the two alloys uniformly mix at various ratios and the resultant static tensile properties of the mixed alloys behave according to rule-of-mixtures. Additionally, the crack growth behavior across an abrupt change from one alloy to the other shows no discontinuity and the crack smoothly transitions from one crack growth regime into another.

Brice, Craig A.↗

Feasibility Study to Dissolve Additively Manufactured Inconel 718 Support Structures

Additive manufacture (AM) component design face constrains due to support structure removal. Interior passages or delicate geometries require supports yet cannot be removed without compromising the design or complicating post-processing. A process was developed to dissolve metal AM supports where a sensitizing agent is applied post-build. During stress relief the sensitizing agent diffuses into the surface and alters the chemical composition of the top 100 to 200 μm. During an electrochemical dissolution process the sensitized region is susceptible to corrosion/dissolution and the etching reaction self-terminates once the sensitized region is dissolved. Support thickness varies from 80 to 200 μm, resulting in total dissolution or sufficiently weakened to facilitate removal. The objective of this project was to demonstrate a support structure dissolution process for IN718 components built using AM and to characterize the impact on mechanical properties, microstructure, and surface finish.

Omar R Mireles↗

Mars Ecopoiesis Testbed

Mars surface conditions where liquid water is absent were simulated for the purposes of laboratory research. A pressure-temperature (P-T) profile was maintained in which no combination of pressure or temperature corresponds to the liquid region of the water phase diagram. The triple point of pure water occurs at T = 0.1oC and P(H2O) = 6.01 mbar; therefore all temperatures and pressures must be kept below these values, respectively. A 35-day test was performed in a commercial planetary simulation system (Techshot, Inc., Greenville, IN) in which the minimum night-time temperature was -80oC, the maximum daytime temperature was +26oC, the simulated day-night light cycle in earth hours was 12-on and 12-off, and the total pressure of the pure CO2 atmosphere was maintained below 11 mbar. Any water present was allowed to equilibrate with the changing temperature and pressure. The gas phase was sampled into a CR1-A condensation-mirror low-pressure hygrometer, which uses liquid nitrogen (down to 77oK) to determine the dew point (Buck Technologies, Boulder, CO). Dew point was measured once every hour and recorded on a data logger, along with the varying temperature in the chamber, from which the partial pressure of water was calculated. The resulting calculated daily cycles were tracked on the water P-T diagram, and no points were found to fall within the liquid-phase region of the diagram. It is concluded that there was no liquid water present throughout the test except during the initial pump-down period when aqueous specimens were introduced on the first day (less than 1 hour). Mars regolith simulant was present during this test, and further investigation is needed to determine whether liquid water could have been present or absent in the regolith in the form of brine. Biological samples consisting of Cyanobacteria: Anabena sp., Chroococcidiopsis CCMEE171, Plectonema boryanum; Eubacteria: Bacillus subtilis, Pseudomonas aeruginosa, and Eukaryota: Chlorella ellipsoidia were maintained in the simulator under the above-described conditions. The exposed specimens were tested for intracellular esterase activity, chlorophyll content (where appropriate) and reproductive survival. All tests yielded low-level positive results in all cases. In parallel to these terrestrial studies a planned design study was undertaken for the proposed test bed. Design requirements include compact assembly for transport and installation on the planetary surface (multiple units per mission would be expected), protective internal package for the release of organisms, a means of atmosphere exchange, access to sunlight, a means of penetrating the planetary surface, and most importantly a means of acquiring regolith while meeting the requirements of planetary protection. In consultation with advisers a design was created, and a large-scale mock-up of this design was fabricated by additive manufacturing at Techshot, Inc. with moving parts that simulated the components of the design. The mock-up assembly has been demonstrated to interested parties. A means of detecting live metabolism will also be included in the test bed. Several options were reviewed, and it is concluded that, by the time the ecopoiesis test bed is ready for testing the optimum instrument will be the equivalent of a hand-held mass spectrometer for metabolic gas analysis. This will maximize versatility and reveal much more information than could a detector of a single product (such as molecular oxygen), and the

Ecopoiesis↗

Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping, and Interface

The honeybee’s nest has inspired the design of engineering honeycomb core that primarily abstract the hexagonal cell shape and exploit its mass minimizing properties to construct lightweight panels. This work explored three additional design features that are part of the natural honeybee comb but have not been traditionally considered as design features of interest in honeycomb design: the radius at the corner of each cell, the coping at the top of the cell walls, and the interface between cell arrays. These features were first characterized in natural honeycomb using optical and X-ray techniques, and then incorporated into honeycomb core design, and fabricated using an additive manufacturing process. The honeycomb cores were then tested in out-of-plane compression and bending, and since all three design features added mass to the overall structure, all metrics were examined per unit mass to assess performance gains. The study concluded that the addition of an interface increases specific flexural modulus but has little benefit in out-of-plane compression; coping radius positively impacts specific flexural strength; but that the corner radius has no significant effect in bending, and actually is slightly detrimental for out-of-plane compression testing.

honeycomb↗

Overview of Additively Manufactured TPS Proposed Flight Test and Earth Re-Entry Capsule Design

A flight mechanics overview is presented of an Earth flight test designed to investigate a novel, 3D printed thermal protection system (TPS) that is currently in development at NASA as part of the Additive Manufacturing of Thermal Protection Systems project. The project is pioneering a method to print a thermal protection system onto an entry vehicle forebody one layer at a time. This method reduces labor and complexity as compared to traditional manufacturing methods while increasing mission-dependent customization of through-depth materials properties. The flight test has three objectives. First, subject the forebody stagnation point of a capsule equipped with additively manufactured TPS (AMTPS) material to peak heat fluxes in excess of 100 $W/cm^2$. Second, capture in-flight data to enable flight reconstruction and AMTPS material thermal response model improvement. Third, recover the capsule with data storage and forebody AMTPS intact to enable post-flight inspection and analysis of AMTPS performance. The flight test trajectory is designed to achieve a peak stagnation point, cold-wall, entry heat flux of 135~$W/cm^2$. Flight mechanics simulations are performed using the Program to Optimize Simulated Trajectories II (POST2) and Monte-Carlo analysis yields statistical percentiles on vehicle performance at key points along the trajectory. Based on the flight mechanics analysis presented in this paper, a prototype capsule was designed, partially fabricated, and underwent preliminary component stress testing in preparation for fabrication of the flight unit capsule. The capsule outer mold line is a modified version of the heritage Mars Microprobe geometry. The capsule has a 0.356~m diameter, a 30~kg mass, and a hypersonic ballistic coefficient of 300~$kg/m^2$. Sensor selection is guided by flight dynamics simulations with the goal of resolving the re-entry heating pulse. On-board instrumentation include forebody and aftbody pressure sensors and thermocouples, a 9-axis IMU, a GPS receiver, and an Iridium satellite modem, all of which collect and store data throughout flight via on-board avionics systems. A two-stage parachute system is designed to decelerate the capsule to touchdown velocities that will not result in significant fracture or deformation of the charred AMTPS material at ground impact.

Flight Mechanics↗

ED1: Design and Prototype of a 3D Printed Wind Tunnel Model with Integrated Force Measurement

Wind tunnel testing using conventionally manufactured force measurement systems (balances) is able to yield precise and accurate results. These balances are delicate, complex instruments. Due to the nature of this high-precision complexity, balances are expensive and time-consuming to produce. These factors can limit the design potential of the model because using conventionally manufactured balances generally means that the model is designed to accommodate balances that already exist. Ideally, engineers would be able to design a measurement system that is tailored to fit the needs of the model, rather than the other way around. The goal of this research project was to determine if it is possible to overcome these drawbacks by designing a wind tunnel model with a modifiable integrated force measurement system that leverages additive manufacturing. This was undertaken by utilizing the existing UT-63 wind tunnel balance (measurement system), integrating it with a model based on the existing AGARD-B model, and performing stress analysis to optimize the design. Due to time constraints, the result of this endeavor is currently incomplete. Continued analysis and optimization are required to have a thorough understanding of the success or failure of the attempted design. As additive manufacturing technology evolves, the ability for it to become the primary method of fabrication for sensitive measurement systems increases. This project contributes to this by providing one method for design, a framework for optimizing existing balances for additive manufacturing, and resources for performing necessary stress analysis.

Callie Ellsworth↗

Development of an Additively Manufactured Capacitive Humidity Sensor for the International Space Station

The ability to measure humidity on the International Space Station and other long-duration spaceflight missions is a crucial part of the onboard systems. For example, the Environmental Control and Life Support System (ECLSS) needs to know the amount of humidity in the air to make decisions about whether it should spend power to run the dehumidifier systems to attempt to reclaim that water. Other issues can arise if the humidity reaches too high of levels and condensation builds up on electrical components. With that in mind, it is vital that the spacecraft keeps spare sensors on board or has the ability to manufacture new sensors on demand. An additively manufactured sensor would be additionally beneficial because it would save space onboard that would normally be taken up by spares, save money from costly resupply missions, and allow the sensor to be constantly updated with the most effective design. This Technical Memorandum outlines a development process carried out to design, manufacture, and test an additively manufactured humidity sensor.

Chang, K. T.↗

Tailored Wingbox Structures through Additive Manufacturing: A Summary of Ongoing Research at NASA LaRC

The use of wingbox structural design for improved performance (i.e., fuel burn reduction) of subsonic transports is driven by two trends: reduced structural weight and increased wingspan. These two trends are in direct competition, as the increased span will exacerbate the structural reaction to aerodynamic loading, and the reduced structural weight will nominally weaken the aircraft’s ability to handle this response. Novel structural configurations, enabled by recent improvements in manufacturing, may be critical toward bridging this gap.This paper summarizes pertinent activities at the NASA Langley Research Center in terms of additive manufacturing of metallic wing structures and substructures. Numerical design optimization activities are summarized as well, in order to understand where on a wingbox an additively-manufactured part may be useful and the way in which that part beneficially impacts the flight physics. The paper concludes with a discussion of how these two research paths may be better married in order to fully integrate both the benefits and realistic limitations of additive manufacturing and numerical structural design.

Stanford, Bret. K.↗

Design of P-3 Nadir Port

This project details the design and analysis of a structure to replace the interface of the P-3B nadir port with an optimized interface for science installations. A new nadir port plug has been designed to replace the OEM (Original Equipment Manufacturer) plug (Lockheed PN 910169) currently used in Nadir ports 1 and 2 on the NASA P-3B aircraft. The plug consists of a milled frame that can be outfitted with customizable flat plates to meet a broad range of science needs. The frame slides into place using the existing P-3B rail system using a lever and tie-rod assembly. The seal interface will contact the Fuselage skin of the aircraft and consists of a bulb E-seal that is riveted around the perimeter of the frame. The flat plate (20 inches x 31 inches) provides a large profile that can be outfitted based on science mission goals and requirements to attach multiple instruments. This is a significant increase to the aircraft capability. Previously, the OEM plug had to be modified to hold very small plates, windows, or instruments limiting the use of the ports.There were several challenges for this project that included a constrained schedule, lack of historical references, and reverse engineering. The unusually tight schedule for design, manufacture, and install limited potential approaches. In addition, design of a new interface to replace the existing plug, on an aircraft designed in the 1960's by Lockheed for the Navy with little to no documentation, required substantial reverse engineering. In order to accomplish this, a suitable method to determine interface requirements with the aircraft had to be solved. After several iterations, the solution was to implement laser scanning techniques to scan the aircraft and the OEM plug and generate a 3D model to capture the design envelope. The structure is designed to maintain a positive margin of safety when subjected to the inertial, pressure, and aerodynamic load requirements for an external installation on the P-3B, as described in the Wallops' P-3B Design Requirements 548-RQMT-0001 Rev. A . A finite element model is created in FEMAP (Finite Element Modeling And Postprocessing) and is run through NX Nastran solver to analyze the structure. After several iterations of analysis, the structure was enveloped to hold 115 pounds evenly distributed on the plate.

Chance, Monica↗

In-Space Manufacturing and Reclamation

The goal of this interdisciplinary senior design project is to develop a self-contained additive manufacturing machine with an integrated part recycler. The system is designed to be a sustainable manufacturing system on long-duration space flights with minimal interaction from on-board astronauts. Following a systems engineering approach, a commercially available and opensource 3D printer and recycler will be modified, integrated, and automated to satisfy the project goal. System components and subcomponents will be verified to meet requirements and risks will be assessed and mitigated.

Stephen Hawes↗

Lessons Learned from a Deployment Mechanism for a Ka-band Deployable Antenna for CubeSats

The Ka-band parabolic deployable antenna (KaPDA) is a 0.5 meter diameter antenna which fits in a tiny, CubeSat compatible 10 cm by 10 cm by 16 cm volume. The design evolved from a rough concept in an R&D proposal to a fully flight qualified design, scheduled for launch in May of 2018, in a timeframe of just 4 years. This paper focuses on key lessons learned on maintaining precision through structural depth, use of fixtures and additive manufacturing for fabrication, the design of robust, deterministic mechanisms, and the dangers of friction and press fits

Thomson, Mark↗

Tribology of Polymer Matrix Composites (PMCs) Fabricated by Additive Manufacturing (AM)

The integral process of depositing thin layers of material, one after another, until the designed component is created is collectively referred to as Additive Manufacturing (AM). Fused deposition process (FDP) is a type of AM where feedstock is extruded into filaments which then are deposited by 3D printing, and the solidification occurs during cooling of the melt. Currently, complex structures are being fabricated by commercial and open source desktop 3D printers. Recently, metal powder containing composite filaments based on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) have emerged, which could be utilized for multifunctional applications. For further deployment in the field, especially for aerospace and ground-based applications, it is critical to understand the tribological behavior of 3D printed materials. In this presentation, we will report the tribological behavior of different polymer matrix composites fabricated by fused deposition process. These results will be compared with the base polymer systems. During this study, the tribological behavior of all the samples will be evaluated with tab-on-disc method and compared for different metallic powder reinforcements.

additive manufacturing↗

Additive Component Manufacturing

State-of-the-art technology like additive manufacturing has not yet been thoroughly applied to fluid control valves. Many valve manufacturing issues such as flow passage machining, deep hole boring, and bi-metallic joining could successfully be addressed with this new technology. The goal of this project was to apply additive manufacturing technology specifically to the problems that fluid control valves present. In order to properly apply additive manufacturing processes to the design of control valves, the plan was to manufacture samples using metals compatible with low temperature, high pressure oxygen service and then tested. While vetting this project with manufacturers, it was determined that the materials chosen were not ideal for additive manufacturing due to their high reflectivity. Therefore, materials for this project were currently undergoing reevaluation and materials that are better suited for additive manufacturing may be substituted. During FY20, additional alloys were selected that would be both appropriate for high pressure oxygen environments as well appropriate for additive manufacturing processes. However, final bid for manufacturing was six times larger than the available funding for this project. Based on previous additive manufacturing projects, the scope and funding for this project were appropriate, but a suitable manufacturer willing to provide a reasonable proposal, was not found. Therefore, funds were de-obligated for this project, and then re-obligated to augment another FY20 CIF project.

Jonathan Dickey↗

Design and Testing of a Hall Effect Thruster with 3D Printed Channel and Propellant Distributor

The UAH-78AM is a low-power Hall effect thruster developed at the University of Alabama in Huntsville with channel walls and a propellant distributor manufactured using 3D printing. The goal of this project is to assess the feasibility of using unconventional materials to produce a low-cost functioning Hall effect thruster and consider how additive manufacturing can expand the design space and provide other benefits. A version of the thruster was tested at NASA Glenn Research Center to obtain performance metrics and to validate the ability of the thruster to produce thrust and sustain a discharge. An overview of the thruster design and transient performance measurements are presented here. Measured thrust ranged from 17.2 millinewtons to 30.4 millinewtons over a discharge power of 280 watts to 520 watts with an anode I (sub SP)(Specific Impulse) range of 870 seconds to 1450 seconds. Temperature limitations of materials used for the channel walls and propellant distributor limit the ability to run the thruster at thermal steady-state.

Hall thrusters↗

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗

A 3D Printable Alloy Designed for Extreme Environments

Multiprincipal-element alloys are an enabling class of materials owing to their impressive mechanical and oxidation-resistant properties, especially in extreme environments. Here we develop a new oxide-dispersion-strengthened NiCoCr-based alloy using a model-driven alloy design approach and laser-based additive manufacturing. This oxide-dispersion-strengthened alloy, called GRX-810, uses laser powder bed fusion to disperse nanoscale Y 2 O 3 particles throughout the microstructure without the use of resource-intensive processing steps such as mechanical or in situ alloying. We show the successful incorporation and dispersion of nanoscale oxides throughout the GRX-810 build volume via high-resolution characterization of its microstructure. The mechanical results of GRX-810 show a twofold improvement in strength, over 1,000-fold better creep performance and twofold improvement in oxidation resistance compared with the traditional polycrystalline wrought Ni-based alloys used extensively in additive manufacturing at 1,093 °C. The success of this alloy highlights how model-driven alloy designs can provide superior compositions using far fewer resources compared with the ‘trial-and-error’ methods of the past. These results showcase how future alloy development that leverages dispersion strengthening combined with additive manufacturing processing can accelerate the discovery of revolutionary materials.

Timothy M. Smith↗

Design and fabrication of an autonomous rendezvous and docking sensor using off-the-shelf hardware

NASA Marshall Space Flight Center (MSFC) has developed and tested an engineering model of an automated rendezvous and docking sensor system composed of a video camera ringed with laser diodes at two wavelengths and a standard remote manipulator system target that has been modified with retro-reflective tape and 830 and 780 mm optical filters. TRW has provided additional engineering analysis, design, and manufacturing support, resulting in a robust, low cost, automated rendezvous and docking sensor design. We have addressed the issue of space qualification using off-the-shelf hardware components. We have also addressed the performance problems of increased signal to noise ratio, increased range, increased frame rate, graceful degradation through component redundancy, and improved range calibration. Next year, we will build a breadboard of this sensor. The phenomenology of the background scene of a target vehicle as viewed against earth and space backgrounds under various lighting conditions will be simulated using the TRW Dynamic Scene Generator Facility (DSGF). Solar illumination angles of the target vehicle and candidate docking target ranging from eclipse to full sun will be explored. The sensor will be transportable for testing at the MSFC Flight Robotics Laboratory (EB24) using the Dynamic Overhead Telerobotic Simulator (DOTS).

Grimm, Gary E.↗