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NASA NTRSDate not supplied

Hardware Systems and EDU Demonstration of the Tall Lunar Tower Project

The Tall Lunar Tower (TLT) project developed a robotic tower assembly system (RTAS) and TLT Truss engineering development units (EDUs) to perform a ground demonstration of supervised semi-autonomous robotic assembly of a truss-based tall tower. Truss structures provide exceptional strength-to-weight ratios for payload capabilities supporting large masses. On the lunar surface, tall towers are a critical structural system that will enable significant solar power generation by supporting vertical solar arrays and beyond-the-horizon communications at the lunar south pole, supporting the Artemis mission architecture, as well as a lunar economy. Tall towers, greater than 30-meters-tall, provide the elevation needed for more consistent solar power generation due to low inclination sunlight and deep shadowing from surface features on the lunar surface at the poles. The robotic structural assembly technologies developed for truss-based tall towers will also enable other large-scale functional lunar structures to be built, including launch plume deflectors, lunar safe havens for astronauts and assets, surface transportation for cargo, and other critical infrastructure. Robotic assembly of truss structures for lunar surface infrastructure is near-term enabling for future Artemis mission campaign and Moon to Mars Objectives needs for power and communication. The project team designed, fabricated, tested, and demonstrated the RTAS EDU by assembling a TLT Truss EDU in a laboratory environment. The hardware systems and the supervised semi-autonomous assembly process for a TLT assembled EDU design, along with descriptions of a hardware demonstration are presented.

In-space Assembly↗

NASA NTRSDate not supplied

Hardware Systems and EDU Demonstration of the Tall Lunar Tower Project

Lunar Infrastructure↗

NASA NTRS1990

Satellite Servicer System flight demonstration program

The major hardware elements, demonstration objectives, and technical approaches, as well as existing and developing technologies for applicability to the Satellite Servicer System (SSSFD) program are presented. In a project to develop the capability of servicing satellites in remote locations, NASA and SDI have planned a series of flights to demonstrate autonomous rendezvous and docking, supervised autonomous fluid transfer, and supervised autonomous orbital replacement unit exchange. Program objectives, design reference mission, and flight demonstrations are described. The expanded capability demonstrated by the SSSFD program will provide alternatives to excessive dependence on ground operations personnel and training, increase the reach into unique space environments, and decrease the costs of managing and operating space assets.

Moore, James S.↗

NASA NTRS2003

First Results from a Hardware-in-the-Loop Demonstration of Closed-Loop Autonomous Formation Flying

A closed-loop system for the demonstration of autonomous satellite formation flying technologies using hardware-in-the-loop has been developed. Making use of a GPS signal simulator with a dual radio frequency outlet, the system includes two GPS space receivers as well as a powerful onboard navigation processor dedicated to the GPS-based guidance, navigation, and control of a satellite formation in real-time. The closed-loop system allows realistic simulations of autonomous formation flying scenarios, enabling research in the fields of tracking and orbit control strategies for a wide range of applications. The autonomous closed-loop formation acquisition and keeping strategy is based on Lyapunov's direct control method as applied to the standard set of Keplerian elements. This approach not only assures global and asymptotic stability of the control but also maintains valuable physical insight into the applied control vectors. Furthermore, the approach can account for system uncertainties and effectively avoids a computationally expensive solution of the two point boundary problem, which renders the concept particularly attractive for implementation in onboard processors. A guidance law has been developed which strictly separates the relative from the absolute motion, thus avoiding the numerical integration of a target trajectory in the onboard processor. Moreover, upon using precise kinematic relative GPS solutions, a dynamical modeling or filtering is avoided which provides for an efficient implementation of the process on an onboard processor. A sample formation flying scenario has been created aiming at the autonomous transition of a Low Earth Orbit satellite formation from an initial along-track separation of 800 m to a target distance of 100 m. Assuming a low-thrust actuator which may be accommodated on a small satellite, a typical control accuracy of less than 5 m has been achieved which proves the applicability of autonomous formation flying techniques to formations of satellites as close as 50 m.

Gill, E.↗

NASA NTRS1998

Study Methods to Characterize and Implement Thermography Nondestructive Evaluation (NDE)

The limits and conditions under which an infrared thermographic nondestructive evaluation can be utilized to assess the quality of aerospace hardware is demonstrated in this research effort. The primary focus of this work is on applying thermography to the inspection of advanced composite structures such as would be found in the International Space Station Instrumentation Racks, Space Shuttle Cargo Bay Doors, Bantam RP-1 tank or RSRM Nose Cone. Here, the detection of delamination, disbond, inclusion and porosity type defects are of primary interest. In addition to composites, an extensive research effort has been initiated to determine how well a thermographic evaluation can detect leaks and disbonds in pressurized metallic systems "i.e. the Space Shuttle Main Engine Nozzles". In either case, research into developing practical inspection procedures was conducted and thermographic inspections were performed on a myriad of test samples, subscale demonstration articles and "simulated" flight hardware. All test samples were fabricated as close to their respective structural counterparts as possible except with intentional defects for NDE qualification. As an added benefit of this effort to create simulated defects, methods were devised for defect fabrication that may be useful in future NDE qualification ventures.

Walker, James L.↗

NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗

NASA NTRS1992

Environmental qualification testing of the prototype pool boiling experiment

The prototype Pool Boiling Experiment (PBE) flew on the STS-47 mission in September 1992. This report describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the prototype hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave the project team a wider latitude in determining which shuttle thermal altitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the project's laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗

NASA NTRS1992

VME rollback hardware for time warp multiprocessor systems

The purpose of the research effort is to develop and demonstrate innovative hardware to implement specific rollback and timing functions required for efficient queue management and precision timekeeping in multiprocessor discrete event simulations. The previously completed phase 1 effort demonstrated the technical feasibility of building hardware modules which eliminate the state saving overhead of the Time Warp paradigm used in distributed simulations on multiprocessor systems. The current phase 2 effort will build multiple pre-production rollback hardware modules integrated with a network of Sun workstations, and the integrated system will be tested by executing a Time Warp simulation. The rollback hardware will be designed to interface with the greatest number of multiprocessor systems possible. The authors believe that the rollback hardware will provide for significant speedup of large scale discrete event simulation problems and allow multiprocessors using Time Warp to dramatically increase performance.

Robb, Michael J.↗

NASA NTRS2003

First Results from a Hardware-in-the-Loop Demonstration of Closed-Loop Autonomous Formation Flying

A closed-loop system for the demonstration of formation flying technologies has been developed at NASA s Goddard Space Flight Center. Making use of a GPS signal simulator with a dual radio frequency outlet, the system includes two GPS space receivers as well as a powerful onboard navigation processor dedicated to the GPS-based guidance, navigation, and control of a satellite formation in real-time. The closed-loop system allows realistic simulations of autonomous formation flying scenarios, enabling research in the fields of tracking and orbit control strategies for a wide range of applications. A sample scenario has been set up where the autonomous transition of a satellite formation from an initial along-track separation of 800 m to a final distance of 100 m has been demonstrated. As a result, a typical control accuracy of about 5 m has been achieved which proves the applicability of autonomous formation flying techniques to formations of satellites as close as 50 m.

Gill, E.↗

NASA NTRS2004

Advanced Manufacturing Techniques Demonstrated for Fabricating Developmental Hardware

NASA Glenn Research Center's Engineering Development Division has been working in support of innovative gas turbine engine systems under development by Glenn's Combustion Branch. These one-of-a-kind components require operation under extreme conditions. High-temperature ceramics were chosen for fabrication was because of the hostile operating environment. During the designing process, it became apparent that traditional machining techniques would not be adequate to produce the small, intricate features for the conceptual design, which was to be produced by stacking over a dozen thin layers with many small features that would then be aligned and bonded together into a one-piece unit. Instead of using traditional machining, we produced computer models in Pro/ENGINEER (Parametric Technology Corporation (PTC), Needham, MA) to the specifications of the research engineer. The computer models were exported in stereolithography standard (STL) format and used to produce full-size rapid prototype polymer models. These semi-opaque plastic models were used for visualization and design verification. The computer models also were exported in International Graphics Exchange Specification (IGES) format and sent to Glenn's Thermal/Fluids Design & Analysis Branch and Applied Structural Mechanics Branch for profiling heat transfer and mechanical strength analysis.

Redding, Chip↗

NASA NTRS1975

Space vehicle onboard command encoder

A flexible onboard encoder system was designed for the space shuttle. The following areas were covered: (1) implementation of the encoder design into hardware to demonstrate the various encoding algorithms/code formats, (2) modulation techniques in a single hardware package to maintain comparable reliability and link integrity of the existing link systems and to integrate the various techniques into a single design using current technology. The primary function of the command encoder is to accept input commands, generated either locally onboard the space shuttle or remotely from the ground, format and encode the commands in accordance with the payload input requirements and appropriately modulate a subcarrier for transmission by the baseband RF modulator. The following information was provided: command encoder system design, brassboard hardware design, test set hardware and system packaging, and software.

Source record↗

NASA NTRS2001

Cryogenic Tank Technology Program (CTTP)

The objectives of the Cryogenic Tank Technology Program were to: (1) determine the feasibility and cost effectiveness of near net shape hardware; (2) demonstrate near net shape processes by fabricating large scale-flight quality hardware; and (3) advance state of current weld processing technologies for aluminum lithium alloys.

Vaughn, T. P.↗

NASA NTRS2008

NASA Activities: SpaceWire Working Group Meeting

This brief presentation highlights the efforts of the SpaceWire working group. The European Space Agency (ESA) contracted with the University of Dundee (UoD) to develop a prototype SpaceFibre Codec, which UoD has been demonstrated in hardware. UoD released a SpaceFibre Outline Specification which NASA plans to evaluate using a SpaceFibre sub-orbital demonstration (in development). Comments, questions and recommendations for ESA and UoD are provided here to generate discussion and expand participation. General findings are that the system level behavior of SpaceFibre is missing from the SpaceFibre Outline Specification, there is a need to understand how SpaceWire maps to SpaceFibre (and vice versa), and there is a need to clarify user interface to resolve inconsistencies. Architecture, virtual channel and programmatic recommendations are presented.

Rakow, Glenn↗

NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗

NASA NTRSDate not supplied

20 Watt 20 Kelvin Reverse Turbo-Brayton Cycle Cryocooler Testing and Applications

Long-term storage of cryogens is an essential capability required to enable NASA’s anticipated missions to both the Lunar and Martian surfaces. A key component to furthering these capabilities is the development of a high capacity, low temperature cryocooler to allow for zero-boil-off storage of liquid hydrogen propellant. The technology being developed by NASA to meet this objective is a reverse turbo-Brayton cycle cryocooler capable of removing 20 Watts (W) of heat at 20 Kelvin (K). This hardware was recently tested at Creare LLC in a vacuum chamber to simulate a relevant mission environment. This testing demonstrated the hardware’s functionality and established a baseline for the cryocooler’s capabilities. Additional NASA led characterization testing is underway and will provide a broader picture of the operational capability of the cryocooler. This paper will discuss the results of this recent testing, along with highlighting the applications for high capacity cryocoolers on future NASA missions, such as Nuclear Thermal Propulsion (NTP) and a sustainable lunar architecture.

Cryocooler↗

NASA NTRS1993

Advanced launch system. Advanced development oxidizer turbopump program

On May 19, 1989, Pratt & Whitney was awarded contract NAS8-37595 by the National Aeronautics and Space Administration, Marshall Space Flight Center, Huntsville Alabama for an Advanced Development Program (ADP) to design, develop and demonstrate a highly reliable low cost, liquid oxygen turbopump for the Advanced Launch System (ALS). The ALS had an overall goal of reducing the cost of placing payloads in orbit by an order of magnitude. This goal would require a substantial reduction in life cycle costs, with emphasis on recurring costs, compared to current launch vehicles. Engine studies supporting these efforts were made for the Space Transportation Main Engine (STME). The emphasis on low cost required design simplification of components and subsystems such that the ground maintenance and test operations was minimized. The results of the Oxygen Turbopump ADP technology effort would provide data to be used in the STME. Initially the STME baseline was a gas generator cycle engine with a vacuum thrust level of 580,000 lbf. This was later increased to 650,000 lbf and the oxygen turbopump design approach was changed to reflect the new thrust level. It was intended that this ADP program be conducted in two phases. Phase 1, a basic phase, would encompass the preliminary design effort, and Phase II, an optional contract phase to cover design, fabrication and test evaluation of an oxygen turbopump at a component test facility at the NASA John C. Stennis Space Center in Mississippi. The basic phase included preliminary design and analysis, evaluation of low cost concepts, and evaluation of fabrication techniques. The option phase included design of the pump and support hardware, analysis of the final configuration to ensure design integrity, fabrication of hardware to demonstrate low cost, DVS Testing of hardware to verify the design, assembly of the turbopump and full scale turbopump testing. In December 1990, the intent of this ADP to support the design and development was changed. The design effort for the oxygen turbopump became part of the STME Phase B contract. The status of the pump design funded through this ADP was presented at the Preliminary Design Review (PDR) at the MSFC on October 24, 1990. Advancements in the design of the pump were subsequently continued under the Phase B Contract. The emphasis of this ADP became the demonstration of individual technologies that would have the greatest potential for reducing the recurring cost and increasing reliability. In October of 1992, overall program funding was reduced and work on this ADP was terminated.

Source record↗

NASA NTRS1971

Information management system study results. Volume 1: IMS study results

The information management system (IMS) special emphasis task was performed as an adjunct to the modular space station study, with the objective of providing extended depth of analysis and design in selected key areas of the information management system. Specific objectives included: (1) in-depth studies of IMS requirements and design approaches; (2) design and fabricate breadboard hardware for demonstration and verification of design concepts; (3) provide a technological base to identify potential design problems and influence long range planning (4) develop hardware and techniques to permit long duration, low cost, manned space operations; (5) support SR&T areas where techniques or equipment are considered inadequate; and (6) permit an overall understanding of the IMS as an integrated component of the space station.

Source record↗

NASA NTRS2004

Solar Sail GN and C Model Comparisons

The Solar Sail Propulsion project is engaged in an ambitious program to raise the Technology Readiness Level of solar sails and prepare for a validation flight via a series of hardware ground demonstrations and development of a number of high fidelity simulations and models. Guidance, navigation, and control of solar sails is a key part of this effort. The large flexible structure and optical nature of solar sails create a considerable challenge for attitude control, thrust modeling, and navigation. In this paper, we present an overview and comparison of two recently delivered prototype solar sail guidance, navigation, and control software tools currently funded by the Solar Sail Propulsion project. The results of some key test cases are presented. Where possible, we also make comparisons to other software tools. We discuss the implications of the results of these comparative studies to the future direction and scope of development efforts for guidance, navigation and control software for solar sails, including the relationship to hardware test efforts such as the Thrust Vector Control Authority Demonstration.

Heaton, Andrew F.↗