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NASA NTRS2009

Exploration Life Support Technology Development for Lunar Missions

Exploration Life Support (ELS) is one of NASA's Exploration Technology Development Projects. ELS plans, coordinates and implements the development of new life support technologies for human exploration missions as outlined in NASA's Vision for Space Exploration. ELS technology development currently supports three major projects of the Constellation Program - the Orion Crew Exploration Vehicle (CEV), the Altair Lunar Lander and Lunar Surface Systems. ELS content includes Air Revitalization Systems (ARS), Water Recovery Systems (WRS), Waste Management Systems (WMS), Habitation Engineering, Systems Integration, Modeling and Analysis (SIMA), and Validation and Testing. The primary goal of the ELS project is to provide different technology options to Constellation which fill gaps or provide substantial improvements over the state-of-the-art in life support systems. Since the Constellation missions are so challenging, mass, power, and volume must be reduced from Space Shuttle and Space Station technologies. Systems engineering analysis also optimizes the overall architecture by considering all interfaces with the life support system and potential for reduction or reuse of resources. For long duration missions, technologies which aid in closure of air and water loops with increased reliability are essential as well as techniques to minimize or deal with waste. The ELS project utilizes in-house efforts at five NASA centers, aerospace industry contracts, Small Business Innovative Research contracts and other means to develop advanced life support technologies. Testing, analysis and reduced gravity flight experiments are also conducted at the NASA field centers. This paper gives a current status of technologies under development by ELS and relates them to the Constellation customers who will eventually use them.

Ewert, Michael K.↗

NASA NTRS2009

Achieving a Prioritized Research and Technology Development Portfolio for the Dust Management Project

Mission architectures for human exploration of the lunar surface continue to advance as well as the definitions of capability needs, best practices and engineering design to mitigate the impact of lunar dust on exposed systems. The NASA DMP has been established as the agency focal point for dust characterization, technology, and simulant development. As described in this paper, the DMP has defined a process for selecting and justifying its R&T portfolio. The technology prioritization process, which is based on a ranking system according to weighted criteria, has been successfully applied to the current DMP dust mitigation technology portfolio. Several key findings emerged from this assessment. Within the dust removal and cleaning technologies group, there are critical technical challenges that must be overcome for these technologies to be implemented for lunar applications. For example, an in-situ source of CO2 on the moon is essential to the CO2 shower technology. Also, significant development effort is required to achieve technology readiness level TRL 6 for the electrostatic cleaning system for removal of particles smaller than 50 pm. The baseline materials related technologies require considerable development just to achieve TRL 6. It is also a nontrivial effort to integrate the materials in hardware for lunar application. At present, there are no terrestrial applications that are readily adaptable to lunar surface applications nor are there any obvious leading candidates. The unique requirements of dust sealing systems for lunar applications suggest an extensive development effort will be necessary to mature dust sealing systems to TRL 6 and beyond. As discussed here, several alternate materials and technologies have achieved high levels of maturity for terrestrial applications and warrant due diligence in ongoing assessment of the technology portfolio. The present assessment is the initial step in an ongoing effort to continually evaluate the DMP technology portfolio and external non-NASA relevant technology developments efforts to maintain an optimal investment profile. At the same time, there is an ongoing review of agency-wide dust-related R&T activities. The results of these ongoing assessments will be reported in future publications.

Hyatt, Mark J.↗

NASA NTRS2009

The Establishment of a New Friction Stir Welding Process Development Facility at NASA/MSFC

Full-scale weld process development is being performed at MSFC to develop the tools, fixtures, and facilities necessary for Ares I production. Full scale development in-house at MSFC fosters technical acuity within the NASA engineering community, and allows engineers to identify and correct tooling and equipment shortcomings before they become problems on the production floor. Finally, while the new weld process development facility is currently being outfitted in support of Ares I development, it has been established to support all future Constellation Program needs. In particular, both the RWT and VWT were sized with the larger Ares V hardware in mind.

Carter, Robert W.↗

NASA NTRS2010

Quiet, Efficient Fans for Spaceflight: An Overview of NASA's Technology Development Plan

A Technology Development Plan to improve the aerodynamic and acoustic performance of spaceflight fans has been submitted to NASA s Exploration Technology Development Program. The plan describes a research program intended to make broader use of the technology developed at NASA Glenn to increase the efficiency and reduce the noise of aircraft engine fans. The goal is to develop a set of well-characterized government-owned fans nominally suited for spacecraft ventilation and cooling systems. NASA s Exploration Life Support community will identify design point conditions for the fans in this study. Computational Fluid Dynamics codes will be used in the design and analysis process. The fans will be built and used in a series of tests. Data from aerodynamic and acoustic performance tests will be used to validate performance predictions. These performance maps will also be entered into a database to help spaceflight fan system developers make informed design choices. Velocity measurements downstream of fan rotor blades and stator vanes will also be collected and used for code validation. Details of the fan design, analysis, and testing will be publicly reported. With access to fan geometry and test data, the small fan industry can independently evaluate design and analysis methods and work towards improvement.

Koch, L. Danielle↗

NASA NTRS2010

NASA's Planned Fuel Cell Development Activities for 2009 and Beyond in Support of the Exploration Vision

NASA s Energy Storage Project is one of many technology development efforts being implemented as part of the Exploration Technology Development Program (ETDP), under the auspices of the Exploration Systems Mission Directorate (ESMD). The Energy Storage Project is a focused technology development effort to advance lithium-ion battery and proton-exchange-membrane fuel cell (PEMFC) technologies to meet the specific power and energy storage needs of NASA Exploration missions. The fuel cell portion of the project has as its focus the development of both primary fuel cell power systems and regenerative fuel cell (RFC) energy storage systems, and is led by the NASA Glenn Research Center (GRC) in partnership with the Johnson Space Center (JSC), the Jet Propulsion Laboratory (JPL), the Kennedy Space Center (KSC), academia, and industrial partners. The development goals are to improve stack electrical performance, reduce system mass and parasitic power requirements, and increase system life and reliability.

Hoberecht, Mark A.↗

NASA NTRS2009

Explicit Finite Element Modeling of Multilayer Composite Fabric for Gas Turbine Engine Containment Systems, Phase II: Material Model Development and Simulation of Experiments - Part 3

A team consisting of Arizona State University, Honeywell Engines, Systems & Services, the National Aeronautics and Space Administration Glenn Research Center, and SRI International collaborated to develop computational models and verification testing for designing and evaluating turbine engine fan blade fabric containment structures. This research was conducted under the Federal Aviation Administration Airworthiness Assurance Center of Excellence and was sponsored by the Aircraft Catastrophic Failure Prevention Program. The research was directed toward improving the modeling of a turbine engine fabric containment structure for an engine blade-out containment demonstration test required for certification of aircraft engines. The research conducted in Phase II began a new level of capability to design and develop fan blade containment systems for turbine engines. Significant progress was made in three areas: (1) further development of the ballistic fabric model to increase confidence and robustness in the material models for the Kevlar(TradeName) and Zylon(TradeName) material models developed in Phase I, (2) the capability was improved for finite element modeling of multiple layers of fabric using multiple layers of shell elements, and (3) large-scale simulations were performed. This report concentrates on the material model development and simulations of the impact tests.

Zylon↗

NASA NTRS2008

The Development of Small-Payload Rideshare Capabilities: A 2000-2008 Summary

This paper summarizes the development from 200 to the present of rideshare capabilities by various Government agencies and Organizations. This development will allow acceptable, low cost access to space for small satellites and payloads. The paper reviews the needs for such capabilities and provides an overview of the development and status of the enabling technologies, hardware, etc. required to achieve the desired capability. It reviews the development and status of each principal element necessary in developing an acceptable, low cost, access to space capability for small satellites and payloads.

secondary payloads↗

NASA NTRS2010

TRL Assessment of Solar Sail Technology Development Following the 20-Meter System Ground Demonstrator Hardware Testing

The NASA In-Space Propulsion Technology (ISPT) Projects Office sponsored two separate, independent solar sail system design and development demonstration activities during 2002-2005. ATK Space Systems of Goleta, CA was the prime contractor for one development team and L' Garde, Inc. of Tustin, CA was the prime contractor for the other development team. The goal of these activities was to advance the technology readiness level (TRL) of solar sail propulsion from 3 towards 6 by the year 2006. Component and subsystem fabrication and testing were completed successfully, including the ground deployment of 10-meter and 20-meter demonstration hardware systems under vacuum conditions. The deployment and structural testing of the 20-meter solar sail systems was conducted in the 30 meter diameter Space Power Facility thermal-vacuum chamber at NASA Glenn Plum Brook in April though August, 2005. This paper will present the results of the TRL assessment following the solar sail technology development activities associated with the design, development, analysis and testing of the 20-meter system ground demonstrators.

Young, Roy M.↗

NASA NTRS2010

Ares I-X Flight Evaluation Tasks in Support of Ares I Development

NASA s Constellation Program successfully launched the Ares I-X Flight Test Vehicle on October 28, 2009. The Ares I-X flight was a development flight test that offered a unique opportunity for early engineering data to impact the design and development of the Ares I crew launch vehicle. As the primary customer for flight data from the Ares I-X mission, the Ares Projects Office established a set of 33 flight evaluation tasks to correlate fight results with prospective design assumptions and models. Included within these tasks were direct comparisons of flight data with pre-flight predictions and post-flight assessments utilizing models and modeling techniques being applied to design and develop Ares I. A discussion of the similarities and differences in those comparisons and the need for discipline-level model updates based upon those comparisons form the substance of this paper. The benefits of development flight testing were made evident by implementing these tasks that used Ares I-X data to partially validate tools and methodologies in technical disciplines that will ultimately influence the design and development of Ares I and future launch vehicles. The areas in which partial validation from the flight test was most significant included flight control system algorithms to predict liftoff clearance, ascent, and stage separation; structural models from rollout to separation; thermal models that have been updated based on these data; pyroshock attenuation; and the ability to predict complex flow fields during time-varying conditions including plume interactions.

Huebner, Lawrence D.↗

NASA NTRS2010

NASA Ares I Launch Vehicle First Stage Roll Control System Cold Flow Development Test Program Overview

The Ares I launch vehicle is the selected design, chosen to return humans to the moon, Mars, and beyond. It is configured in two inline stages: the First Stage is a Space Shuttle derived five-segment Solid Rocket Booster and the Upper Stage is powered by a Saturn V derived J-2X engine. During launch, roll control for the First Stage (FS) is handled by a dedicated Roll Control System (RoCS) located on the connecting Interstage. That system will provide the Ares I with the ability to counteract induced roll torque while any induced yaw or pitch moments are handled by vectoring of the booster nozzle. This paper provides an overview of NASA s Ares I FS RoCS cold flow development test program including detailed test objectives, types of tests run to meet those objectives, an overview of the results, and applicable lessons learned. The test article was built and tested at the NASA Marshall Space Flight Center in Huntsville, AL. The FS RoCS System Development Test Article (SDTA) is a full scale, flight representative water flow test article whose primary objective was to obtain fluid system performance data to evaluate integrated system level performance characteristics and verify analytical models. Development testing and model correlation was deemed necessary as there is little historical precedent for similar large flow, pulsing systems such as the FS RoCS. The cold flow development test program consisted of flight-similar tanks, pressure regulators, and thruster valves, as well as plumbing simulating flight geometries, combined with other facility grade components and structure. Orifices downstream of the thruster valves were used to simulate the pressure drop through the thrusters. Additional primary objectives of this test program were to: evaluate system surge pressure (waterhammer) characteristics due to thruster valve operation over a range of mission duty cycles at various feed system pressures, evaluate temperature transients and heat transfer in the pressurization system, including regulator blowdown and propellant ullage performance, measure system pressure drops for comparison to analysis of tubing and components, and validate system activation and re-activation procedures for the helium pressurant system. Secondary objectives included: validating system processes for loading, unloading, and purging, validating procedures and system response for multiple failure scenarios, including relief valve operation, and evaluating system performance for contingency scenarios. The test results of the cold flow development test program are essential in validating the performance and interaction of the Roll Control System and anchoring analysis tools and results to a Critical Design Review level of fidelity.

Butt, Adam↗

NASA NTRS2011

Crew Exploration Vehicle Environmental Control and Life Support Development Status

The Orion Crew Exploration Vehicle (CEV) is the first crew transport vehicle to be developed by the National Aeronautics and Space Administration (NASA) in the last thirty years. The CEV is currently being developed to transport the crew safely from the Earth to the Moon and back again. This year, the vehicle focused on building the Orion Flight Test 1 (OFT1) vehicle to be launched in 2013. The development of the Orion Environmental Control and Life Support (ECLS) System, focused on the components which are on OFT1 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. This paper covers the Orion ECLS development from April 2010 to April 2011.

Lewis, John F.↗

NASA NTRS2010

Constraints and Opportunities in GCM Model Development

Over the past 30 years climate models have evolved from relatively simple representations of a few atmospheric processes to complex multi-disciplinary system models which incorporate physics from bottom of the ocean to the mesopause and are used for seasonal to multi-million year timescales. Computer infrastructure over that period has gone from punchcard mainframes to modern parallel clusters. Constraints of working within an ever evolving research code mean that most software changes must be incremental so as not to disrupt scientific throughput. Unfortunately, programming methodologies have generally not kept pace with these challenges, and existing implementations now present a heavy and growing burden on further model development as well as limiting flexibility and reliability. Opportunely, advances in software engineering from other disciplines (e.g. the commercial software industry) as well as new generations of powerful development tools can be incorporated by the model developers to incrementally and systematically improve underlying implementations and reverse the long term trend of increasing development overhead. However, these methodologies cannot be applied blindly, but rather must be carefully tailored to the unique characteristics of scientific software development. We will discuss the need for close integration of software engineers and climate scientists to find the optimal processes for climate modeling.

Schmidt, Gavin↗

NASA NTRS2010

Airspace Systems Program: Next Generation Air Transportation System Concepts and Technology Development FY2010 Project Plan Version 3.0

This document describes the FY2010 plan for the management and execution of the Next Generation Air Transportation System (NextGen) Concepts and Technology Development (CTD) Project. The document was developed in response to guidance from the Airspace Systems Program (ASP), as approved by the Associate Administrator of the Aeronautics Research Mission Directorate (ARMD), and from guidelines in the Airspace Systems Program Plan. Congress established the multi-agency Joint Planning and Development Office (JPDO) in 2003 to develop a vision for the 2025 Next Generation Air Transportation System (NextGen) and to define the research required to enable it. NASA is one of seven agency partners contributing to the effort. Accordingly, NASA's ARMD realigned the Airspace Systems Program in 2007 to "directly address the fundamental research needs of the Next Generation Air Transportation System...in partnership with the member agencies of the JPDO." The Program subsequently established two new projects to meet this objective: the NextGen-Airspace Project and the NextGen-Airportal Project. Together, the projects will also focus NASA s technical expertise and world-class facilities to address the question of where, when, how and the extent to which automation can be applied to moving aircraft safely and efficiently through the NAS and technologies that address optimal allocation of ground and air technologies necessary for NextGen. Additionally, the roles and responsibilities of humans and automation influence in the NAS will be addressed by both projects. Foundational concept and technology research and development begun under the NextGen-Airspace and NextGen-Airportal projects will continue. There will be no change in NASA Research Announcement (NRA) strategy, nor will there be any change to NASA interfaces with the JPDO, Federal Aviation Administration (FAA), Research Transition Teams (RTTs), or other stakeholders

Kopardekar, Parimal H.↗

NASA NTRS2011

The Development of a CO2 Test Capability in the NASA JSC ARCJet for Mars Reentry Simulation

The Atmospheric Reentry Materials and Structures Evaluation Facility (ARMSEF) located at NASA Johnson Space Center is used for simulating the extreme environment experienced upon reentry for the development and certification of thermal protection systems (TPS). The facility supports a large variety of programs and was heavily leveraged for the certification and operational support of the TPS for the Orbiter and, more recently, the development of the heat shield for CEV. This paper will provide more detail into the heritage of the facility. Unique attributes of the facility include a modular aerodynamically stabilized arc heater and independently controlled O2 and N2 for the test gases. When combining the O2 and N2 in a 23:77 mass ratio respectively the Earth s atmosphere is accurately simulated and via modification of this ratio the investigation of the effects of atomic oxygen on a material s response is possible. In the summer of 2010 a development effort was started to add CO2 as a third independently controlled test gas such that, when combined with N2, opens up the possibility of accurately simulating a Martian reentry environment. This paper will discuss the test facility, especially the arc heater, in more detail. Initial testing involved relatively low concentrations of CO2 combined with N2 for the primary purpose of gathering data to answer two pressing safety concerns. The first being the rate of production of carbon monoxide (CO) within the ejector vacuum system. The main concern was that CO can be flammable and possibly explosive at high enough concentrations and pressures. The hazard control during the development phase involved the use of injecting N2 inside the test chamber diffuser to dilute and reduce the concentration of any and all CO present. A residual gas analyzer (RGA) was used to determine the relative amount of CO in the exhaust gas and provide a conversion rate of CO2 to CO. This paper will discuss in more detail the results of the RGA data and the calculated conversion rate. The second safety concern addressed is the possible formation of hydrogen cyanide (HCN) and cyanide (CN). HCN would primarily be present in the cooling water while the CN would most probably condense onto the interior surfaces of the test chamber. Water samples and wipes of the test chamber surfaces were analyzed by an industrial hygienist for the presence of HCN and CN. His paper will discuss these results in more detail. Throughout this development effort measurements of the CO2:N2 flowfield were made with heat flux and pressure probes and with laser induced fluorescence (LIF) of the atomic oxygen. This paper will discuss these results

DelPapa, Steven V.↗

NASA NTRS2011

An Overview of STS-132 MRM1 Cargo Element Thermal Model Development and Analyses

STS-132 was launched in May 2010 and delivered the Russian Mini Research Module 1 (MRM1) cargo element to the International Space Station as part of the ULF-4 assembly flight. The cargo element consisted of the module outfitted with externally mounted Multi-purpose Laboratory Module (MLM) Airlock, MLM radiator, Portable Work Platform (PWP), and a European Robotic Arm (ERA) spare elbow. Prior to every Shuttle flight, hardware developers are required to determine compatibility of their hardware to thermal environments experienced during the Shuttle mission and once the element is integrated with the ISS. Thermal models are provided to the Shuttle program to determine the impact of the payload on the Orbiter hardware, as well as the ISS program to determine impacts on other ISS payloads in the Orbiter. Historically the Russian International Partner (IP) develops models in formats not compatible with software used by Space Shuttle or ISS programs. This prompted NASA and Lockheed Martin to develop a unique set of thermal models for the MRM1 cargo element. Subsequent ULF-4 mission analyses performed with the models assessed the launch to activation response, identified operational criteria documented in flight rules, and ensured compliance with the mission timeline and no hazards to the crew, orbiter, or ISS. This presentation provides an overview of the work performed, depicts unique approaches in model development, discusses lessons learned, and issue resolution approaches. Though development and analysis efforts spanned over four years and presented various integration challenges it provided an example of successful collaboration with our International Partners.

Perez, Miguel Fernando↗

NASA NTRS2011

Developing Standards to Qualify a Fine Water Mist Fire Extinguisher for Human Spaceflight

NASA is developing a Fine Water Mist Portable Fire Extinguisher for use on the International Space Station. The International Space Station presently uses two different types of fire extinguishers: a water foam extinguisher in the Russian Segment, and a carbon dioxide extinguisher in the US Segment and Columbus and Kibo pressurized elements. Changes in emergency breathing equipment make Fine Water Mist operationally preferable. Supplied oxygen breathing systems allow for safe discharge of a carbon dioxide fire extinguisher, without concerns of the crew inhaling unsafe levels of carbon dioxide. But the Portable Breathing Apparatus offers no more than 15 minutes of capability, and continued use of hose based supplied oxygen systems increases the oxygen content in a fire situation. NASA has developed a filtering respirator cartridge for use in a fire environment. It is qualified to provide up to 90 minutes of capability, and because it is a filtering respirator it does not add oxygen to the environment. The fire response respirator cartridge does not filter carbon dioxide, so a crew member discharging a CO2 fire extinguisher while wearing this filtering respirator would be at risk of inhaling unsafe levels of CO2. Fine Water Mist extinguishes a fire without creating a large volume of air with reduced oxygen and elevated CO2. Compared to the carbon dioxide based Portable Fire Extinguisher, the flight qualification of Fine Water Mist systems requires special care. Qualification of the CO2 based Portable Fire Extinguisher began with the assumption that any fire on ISS would be extinguished if the air in the fire environment reached a critical concentration of CO2. Qualification of a CO2 based system requires the developers to make assertions and assumptions about vehicle geometry and the ability of the extinguisher to deliver CO2 in different geometric configurations, but the developers did not need to make assertions or assumptions about the size of the fire, the temperature, or the heat generation rate. Fine Water Mist systems extinguish a fire predominantly by removing heat -- so qualification standards must evaluate geometry, but also temperature, heat transfer, and heat generation rate. This paper outlines and describes the methods used to develop standards used to qualify Fine Water Mist systems for a human spaceflight environment.

Graf, John↗

NASA NTRS2011

Extravehicular Activity Technology Development Status and Forecast

The goal of NASA s current EVA technology effort is to further develop technologies that will be used to demonstrate a robust EVA system that has application for a variety of future missions including microgravity and surface EVA. Overall the objectives will be to reduce system mass, reduce consumables and maintenance, increase EVA hardware robustness and life, increase crew member efficiency and autonomy, and enable rapid vehicle egress and ingress. Over the past several years, NASA realized a tremendous increase in EVA system development as part of the Exploration Technology Development Program and the Constellation Program. The evident demand for efficient and reliable EVA technologies, particularly regenerable technologies was apparent under these former programs and will continue to be needed as future mission opportunities arise. The technological need for EVA in space has been realized over the last several decades by the Gemini, Apollo, Skylab, Space Shuttle, and the International Space Station (ISS) programs. EVAs were critical to the success of these programs. Now with the ISS extension to 2028 in conjunction with a current forecasted need of at least eight EVAs per year, the EVA hardware life and limited availability of the Extravehicular Mobility Units (EMUs) will eventually become a critical issue. The current EMU has successfully served EVA demands by performing critical operations to assemble the ISS and provide repairs of satellites such as the Hubble Space Telescope. However, as the life of ISS and the vision for future mission opportunities are realized, a new EVA systems capability will be needed and the current architectures and technologies under development offer significant improvements over the current flight systems. In addition to ISS, potential mission applications include EVAs for missions to Near Earth Objects (NEO), Phobos, or future surface missions. Surface missions could include either exploration of the Moon or Mars. Providing an EVA capability for these types of missions enables in-space construction of complex vehicles or satellites, hands on exploration of new parts of our solar system, and engages the public through the inspiration of knowing that humans are exploring places that they have never been before. This paper offers insight into what is currently being developed and what the potential opportunities are in the forecast.

Chullen, Cinda↗

NASA NTRS2011

Cryogenic Propellant Feed System Analytical Tool Development

The Propulsion Systems Branch at NASA s Lyndon B. Johnson Space Center (JSC) has developed a parametric analytical tool to address the need to rapidly predict heat leak into propellant distribution lines based on insulation type, installation technique, line supports, penetrations, and instrumentation. The Propellant Feed System Analytical Tool (PFSAT) will also determine the optimum orifice diameter for an optional thermodynamic vent system (TVS) to counteract heat leak into the feed line and ensure temperature constraints at the end of the feed line are met. PFSAT was developed primarily using Fortran 90 code because of its number crunching power and the capability to directly access real fluid property subroutines in the Reference Fluid Thermodynamic and Transport Properties (REFPROP) Database developed by NIST. A Microsoft Excel front end user interface was implemented to provide convenient portability of PFSAT among a wide variety of potential users and its ability to utilize a user-friendly graphical user interface (GUI) developed in Visual Basic for Applications (VBA). The focus of PFSAT is on-orbit reaction control systems and orbital maneuvering systems, but it may be used to predict heat leak into ground-based transfer lines as well. PFSAT is expected to be used for rapid initial design of cryogenic propellant distribution lines and thermodynamic vent systems. Once validated, PFSAT will support concept trades for a variety of cryogenic fluid transfer systems on spacecraft, including planetary landers, transfer vehicles, and propellant depots, as well as surface-based transfer systems. The details of the development of PFSAT, its user interface, and the program structure will be presented.

Lusby, Brian S.↗