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NASA NTRSDate not supplied

Feasibility of Additive Manufacturing for Thermal Protection Systems

Thermal Protection Systems (TPS) use advanced materials to protect vehicles from aerodynamic heating during atmospheric entry. Manufacturing of these composite materials is often very time consuming and labor-intensive. Leveraging the additive manufacturing FDM (Fused Deposition Modeling) process enables NASA to design and manufacture advanced ablative TPS materials while reducing manufacturing time and cost. Since additive manufacturing is an automated process, it ensures part consistency over the entire heat shield area. The purpose for this presentation will be three-fold. 1) Introduce novel low-density ablative materials capable of utilizing additive manufacturing capabilities 2) show feasibility of additively manufacturing TPS coupons using the downselected TPS materials 3) Side by side comparison of high temperature test results for printable paste and state of the art low-density ablators

T. Boghozian↗
NASA NTRSDate not supplied

Backshell Thermal Protection Materials for Additive Manufacturing

Leveraging AM technology focused on the Fused Deposition Modeling (FDM) process could automate the heat shield manufacturing process and allow it to reduce cost and build time and improve the design to 3D print and process TPS materials directly on the structure in monolith segments. Furthermore, AM allows the production of complicated three-dimensional geometry and density gradient layers without custom molds or special tools. NASA invests in additive manufacturing (AM) to enable new mission architectures and design methods; AM is suited for backshell thermal protection materials that require many complex closeouts that lead to integration challenges. Current work will review backshell thermal protection material formulation, development, and characterization.3D printer was used to 3D print arc-jet test coupons. The coupons were tested at the NASA Ames arc jet facility, and the results show promising properties compared with the heritage materials.

Tane Boghozian↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed– A Robotic Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, a 3-axis robotic positioning system, and a regolith bin. For the REACT project, a pellet extruder and feed hopper have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

Moon↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed – A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRS2014

Badger COMET Compartmentalized Onboard Material Extrusion Technology

In response to the 2014 NASA Academic Innovation Challenge, the University of Wisconsin – Madison team presents the design of a collapsible Fused Deposition Modeling (FDM) system for in situ manufacturing in a space habitat environment, the Badger Compartmentalized Onboard Material Extrusion Technology (COMET). The proposed mechanism incorporates one year of design and testing on an array of current additive manufacturing techniques, with the goal of providing a reliable and maintainable manufacturing solution. Seven Level 1 requirements were employed to guide the design process, based on information in the challenge, communications with NASA, and the evolving systems feedback of project work groups. These requirements provided a baseline for the development of the System Requirements Document (SRD, Appendix I), which framed the design of the system. The design requirements deemed critical to the success of the systems are as follows: - The system shall compose an FDM workstation capable of producing parts within industry standard tolerances. - The system shall reduce to a minimum of 50 percent or less of its deployed volume when not in use, and must collapse without the need for disassembly. - The system shall meet all relevant NASA safety and functional standards. The final design for the Badger COMET was selected from multiple design iterations, which balanced the critical design requirements listed above with system reliability, with the final goal of providing a minimal system weight. The system collapses in the vertical direction, allowing for a maximum reduction in volume. Guide rods and precision, anti-backlash lead screws provide all linear movement in the device. Stepper motors were chosen to actuate each system axis, due to their high precision and repeatable accuracy. The system is controlled through an on-board computer system and embedded electronics package.

Frederick T. Elder↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed: A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRS2024

Additively Manufactured Plastic Plasma Spectrometer

We report results in development and testing of a low resource top hat electrostatic analyzer (ESA) for space plasma measurements. This device has been additively manufactured (3D-printed) using fused deposition modeling. The classic top hat design is composed of four plastic pieces, without any surface coatings. The three conducting electrodes are printed from carbon nanotube infused polyether ether ketone (CNT-PEEK). The fourth piece, an insulating electrode support, uses pure PEEK. This ESA is designed to detect electrons in space from 10eV up to 30 keV. We demonstrate that the printed CNT-PEEK is sufficiently electrically conductive to support the fast high voltage slewing often required for high time resolution measurements. The plastic ESA has been successfully vibrated beyond standard pre-flight levels, tested under keV electron beam illumination over a wide range of temperatures, and tested under UV illumination, simulating the solar Ly-α flux. In comparison with an identical machined aluminum ESA, our CNT-PEEK ESA provides nominal energy/angle band passes, closely matching simulation. These band passes imply minimal impact from surface charging at beam energies of 2-3 keV, although more investigation is needed. We also find that the CNT-PEEK ESA provides far superior out-of-band electron rejection and UV photon rejection compared to the machined aluminum ESA. We do not detect any problems with trapped gases or outgassing. This development offers potential for significant mass savings, implementation of otherwise unattainable geometric configurations, and dramatic simplification in manufacturing and assembly processes required for development of space plasma instruments.

Quetzal Larrick↗
NASA NTRSDate not supplied

Design, Development, and Test of the Advanced Apollo Orbital Assembly System

As spaceflight moves toward commercial solutions for Crew Vehicles and Space Stations, opportunity exists to lower costs with novel designs. Probe and cone docking systems provide a lightweight, low cost, and high-performance docking solution. This work revisits the Apollo probe and cone design and modifies it for the requirements of today’s computer-controlled spacecraft. This new system is called the Advanced Apollo Orbital Assembly (APOA) system, and is intended to support satellite, cargo, and space station assembly missions. A simulation of the APOA was programmed, components were sized, and a design was created by scaling the probe to the size of an EELV Secondary Payload Adapter (ESPA) tunnel. Prototype test hardware was 3D printed using Fused Deposition Modeling (FDM) methods with Polylactic Acid (PLA) material. Testing of the APOA-ESPA was conducted at Marshall Space Flight Center’s (MSFC) Flat Floor, and a test-correlated simulation is used to evaluate a Monte-Carlo of Initial Contact Conditions (ICC’s) to establish baseline performance. The successful development, test, and correlation of the APOA-ESPA proves the design validity and increases Technology Readiness Level (TRL) from 2 to 4. This work opens the door to construction of an APOA-ESPA from flight like materials, and to develop a larger scale prototype APOA. When the full scale APOA is incorporated with the Common Berthing Mechanism (CBM), becomes the Hybrid Berthing System (HBS), which allows for berthing without a robotic arm.

Berthing↗
NASA NTRS2004

Advanced Computational Modeling of Vapor Deposition in a High-pressure Reactor

In search of novel approaches to produce new materials for electro-optic technologies, advances have been achieved in the development of computer models for vapor deposition reactors in space. Numerical simulations are invaluable tools for costly and difficult processes, such as those experiments designed for high pressures and microgravity conditions. Indium nitride is a candidate compound for high-speed laser and photo diodes for optical communication system, as well as for semiconductor lasers operating into the blue and ultraviolet regions. But InN and other nitride compounds exhibit large thermal decomposition at its optimum growth temperature. In addition, epitaxy at lower temperatures and subatmospheric pressures incorporates indium droplets into the InN films. However, surface stabilization data indicate that InN could be grown at 900 K in high nitrogen pressures, and microgravity could provide laminar flow conditions. Numerical models for chemical vapor deposition have been developed, coupling complex chemical kinetics with fluid dynamic properties.

Cardelino, Beatriz H.↗
NASA NTRS2004

Advanced Computational Modeling of Vapor Deposition in a High-Pressure Reactor

In search of novel approaches to produce new materials for electro-optic technologies, advances have been achieved in the development of computer models for vapor deposition reactors in space. Numerical simulations are invaluable tools for costly and difficult processes, such as those experiments designed for high pressures and microgravity conditions. Indium nitride is a candidate compound for high-speed laser and photo diodes for optical communication system, as well as for semiconductor lasers operating into the blue and ultraviolet regions. But InN and other nitride compounds exhibit large thermal decomposition at its optimum growth temperature. In addition, epitaxy at lower temperatures and subatmospheric pressures incorporates indium droplets into the InN films. However, surface stabilization data indicate that InN could be grown at 900 K in high nitrogen pressures, and microgravity could provide laminar flow conditions. Numerical models for chemical vapor deposition have been developed, coupling complex chemical kinetics with fluid dynamic properties.

Cardelino, Beatriz H.↗
NASA NTRS2016

Asteroid Fragmentation Approaches for Modeling Atmospheric Energy Deposition

During asteroid entry, energy is deposited in the atmosphere through thermal ablation and momentum-loss due to aerodynamic drag. Analytic models of asteroid entry and breakup physics are used to compute the energy deposition, which can then be compared against measured light curves and used to estimate ground damage due to airburst events. This work assesses and compares energy deposition results from four existing approaches to asteroid breakup modeling, and presents a new model that combines key elements of those approaches. The existing approaches considered include a liquid drop or "pancake" model where the object is treated as a single deforming body, and a set of discrete fragment models where the object breaks progressively into individual fragments. The new model incorporates both independent fragments and aggregate debris clouds to represent a broader range of fragmentation behaviors and reproduce more detailed light curve features. All five models are used to estimate the energy deposition rate versus altitude for the Chelyabinsk meteor impact, and results are compared with an observationally derived energy deposition curve. Comparisons show that four of the five approaches are able to match the overall observed energy deposition profile, but the features of the combined model are needed to better replicate both the primary and secondary peaks of the Chelyabinsk curve.

Modeling↗
NASA NTRS2013

Multi-model Mean Nitrogen and Sulfur Deposition from the Atmospheric Chemistry and Climate Model Intercomparison Project (ACCMIP): Evaluation Historical and Projected Changes

We present multi-model global datasets of nitrogen and sulfate deposition covering time periods from 1850 to 2100, calculated within the Atmospheric Chemistry and Climate Model Intercomparison Project (ACCMIP). The computed deposition fluxes are compared to surface wet deposition and ice-core measurements. We use a new dataset of wet deposition for 2000-2002 based on critical assessment of the quality of existing regional network data. We show that for present-day (year 2000 ACCMIP time-slice), the ACCMIP results perform similarly to previously published multi-model assessments. For this time slice, we find a multi-model mean deposition of 50 Tg(N) yr1 from nitrogen oxide emissions, 60 Tg(N) yr1 from ammonia emissions, and 83 Tg(S) yr1 from sulfur emissions. The analysis of changes between 1980 and 2000 indicates significant differences between model and measurements over the United States but less so over Europe. This difference points towards misrepresentation of 1980 NH3 emissions over North America. Based on ice-core records, the 1850 deposition fluxes agree well with Greenland ice cores but the change between 1850 and 2000 seems to be overestimated in the Northern Hemisphere for both nitrogen and sulfur species. Using the Representative Concentration Pathways to define the projected climate and atmospheric chemistry related emissions and concentrations, we find large regional nitrogen deposition increases in 2100 in Latin America, Africa and parts of Asia under some of the scenarios considered. Increases in South Asia are especially large, and are seen in all scenarios, with 2100 values more than double 2000 in some scenarios and reaching 1300 mg(N) m2 yr1 averaged over regional to continental scale regions in RCP 2.6 and 8.5, 3050 larger than the values in any region currently (2000). The new ACCMIP deposition dataset provides novel, consistent and evaluated global gridded deposition fields for use in a wide range of climate and ecological studies.

Lamarque, J.-F.↗
NASA NTRS1974

Io - A surface evaporite deposit

A model is suggested for Io's surface composition involving evaporite salt deposits, rich in sodium and sulfur. According to this model, these deposits were produced as a result of the migration of salt-saturated aqueous solutions to Io's surface from a warm or hot interior followed by loss of the water to space. This model satisfies cosmochemical constraints based on Io's initial composition, current density, and thermal history. Salt-rich assemblages are easily derivable from the leaching of carbonaceous chondritic material. The chemical and optical properties of such deposits, after modification by irradiation, can be used to explain Io's overall albedo and spectral reflectance, its dark reddish poles, and the observed sodium emission as well as or better than other currently suggested materials.

Fanale, F. P.↗
NASA NTRS1990

Modeling of internal contaminant deposition on a cold instrument sensor

A model is developed to predict the deposition of contaminants on the CCD sensors of the Wide Field Planetary Camera to determine expected performance parameters. Contaminant deposition due to internal instrument sources is considered as is the mechanism of transport to the CCDs themselves. The Contamination Analysis Program (CAP) model considers deposition and reemission kinetics, nodal containment sources, and internodal shape factors related to line-of-sight transport. Indirect transport is also accounted for in the CAP model by considering the effect of diffuse reflection at internodal exchanges. The effective total transport factors for each node-to-node exchange is precalculated to reduce the effective number of nodes and reducing run time of the CAP program. The method is applied to four distinct conditions and is found to be suitable for the analysis of internal self-contamination. Cold traps, venting, and vacuumlike design are factors which are found to be important for cold-sensitive sensors.

Barengoltz, Jack B.↗
NASA NTRS2013

Multi-Model Mean Nitrogen and Sulfur Deposition from the Atmospheric Chemistry and Climate Model Intercomparison Project (ACCMIP): Evaluation of Historical and Projected Future Changes

We present multi-model global datasets of nitrogen and sulfate deposition covering time periods from 1850 to 2100, calculated within the Atmospheric Chemistry and Climate Model Intercomparison Project (ACCMIP). The computed deposition fluxes are compared to surface wet deposition and ice core measurements.We use a new dataset of wet deposition for 2000-2002 based on critical assessment of the quality of existing regional network data. We show that for present day (year 2000 ACCMIP time slice), the ACCMIP results perform similarly to previously published multi-model assessments. For this time slice, we find a multimodel mean deposition of approximately 50 Tg(N) yr−1 from nitrogen oxide emissions, 60 Tg(N) yr−1 from ammonia emissions, and 83 Tg(S) yr−1 from sulfur emissions. The analysis of changes between 1980 and 2000 indicates significant differences between model and measurements over the United States but less so over Europe. This difference points towards a potential misrepresentation of 1980 NH3 emissions over North America. Based on ice core records, the 1850 deposition fluxes agree well with Greenland ice cores, but the change between 1850 and 2000 seems to be overestimated in the Northern Hemisphere for both nitrogen and sulfur species. Using the Representative Concentration Pathways (RCPs) to define the projected climate and atmospheric chemistry related emissions and concentrations, we find large regional nitrogen deposition increases in 2100 in Latin America, Africa and parts of Asia under some of the scenarios considered. Increases in South Asia are especially large, and are seen in all scenarios, with 2100 values more than double their 2000 counterpart in some scenarios and reaching >1300 mg(N)m−2 yr−1 averaged over regional to continental-scale regions in RCP 2.6 and 8.5, 30-50% larger than the values in any region currently (circa 2000). However, sulfur deposition rates in 2100 are in all regions lower than in 2000 in all the RCPs. The new ACCMIP multimodel deposition dataset provides state-of-the-science, consistent and evaluated time slice (spanning 1850-2100) global gridded deposition fields for use in a wide range of climate and ecological studies.

Lamarque, J.-F.↗
NASA NTRS2011

Estuarine Sediment Deposition during Wetland Restoration: A GIS and Remote Sensing Modeling Approach

Restoration of the industrial salt flats in the San Francisco Bay, California is an ongoing wetland rehabilitation project. Remote sensing maps of suspended sediment concentration, and other GIS predictor variables were used to model sediment deposition within these recently restored ponds. Suspended sediment concentrations were calibrated to reflectance values from Landsat TM 5 and ASTER using three statistical techniques -- linear regression, multivariate regression, and an Artificial Neural Network (ANN), to map suspended sediment concentrations. Multivariate and ANN regressions using ASTER proved to be the most accurate methods, yielding r2 values of 0.88 and 0.87, respectively. Predictor variables such as sediment grain size and tidal frequency were used in the Marsh Sedimentation (MARSED) model for predicting deposition rates for three years. MARSED results for a fully restored pond show a root mean square deviation (RMSD) of 66.8 mm (<1) between modeled and field observations. This model was further applied to a pond breached in November 2010 and indicated that the recently breached pond will reach equilibrium levels after 60 months of tidal inundation.

Newcomer, Michelle↗
NASA NTRS1975

Dopant gas effect on silicon chemical vapor depositions: A surface potential model

A surface potential model is proposed to consistently explain the known dopant gas effects on silicon chemical vapor deposition. This model predicts that the effects of the same dopant gases on the diamond deposition rate using methane and carbon tetrachloride should be opposite and similar to those of silane, respectively. Available data are in agreement with this prediction.

Chang, C. A.↗