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All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Behavioral, Brain Imaging and Genomic Measures to Predict Functional Outcomes Post-Bed Rest and Space Flight

Astronauts experience sensorimotor disturbances during their initial exposure to microgravity and during the re-adaptation phase following a return to an Earth-gravitational environment. These alterations may disrupt crewmembers' ability to perform mission critical functional tasks requiring ambulation, manual control and gaze stability. Interestingly, astronauts who return from spaceflight show substantial differences in their abilities to readapt to a gravitational environment. The ability to predict the manner and degree to which individual astronauts are affected will improve the effectiveness of countermeasure training programs designed to enhance sensorimotor adaptability. For such an approach to succeed, we must develop predictive measures of sensorimotor adaptability that will allow us to foresee, before actual spaceflight, which crewmembers are likely to experience greater challenges to their adaptive capacities. The goals of this project are to identify and characterize this set of predictive measures. Our approach includes: 1) behavioral tests to assess sensory bias and adaptability quantified using both strategic and plastic-adaptive responses; 2) imaging to determine individual brain morphological and functional features, using structural magnetic resonance imaging (MRI), diffusion tensor imaging, resting state functional connectivity MRI, and sensorimotor adaptation task-related functional brain activation; and 3) assessment of genetic polymorphisms in the catechol-O-methyl transferase, dopamine receptor D2, and brain-derived neurotrophic factor genes and genetic polymorphisms of alpha2-adrenergic receptors that play a role in the neural pathways underlying sensorimotor adaptation. We anticipate that these predictive measures will be significantly correlated with individual differences in sensorimotor adaptability after long-duration spaceflight and exposure to an analog bed rest environment. We will be conducting a retrospective study, leveraging data already collected from relevant ongoing or completed bed rest and spaceflight studies. This data will be combined with predictor metrics that will be collected prospectively (as described for behavioral, brain imaging and genomic measures) from these returning subjects to build models for predicting post spaceflight and bed rest adaptive capability. In this presentation we will discuss the optimized set of tests for predictive metrics to be used for evaluating post mission adaptive capability as manifested in their outcome measures. Comparisons of model performance will allow us to better design and implement sensorimotor adaptability training countermeasures against decrements in post-mission adaptive capability that are customized for each crewmember's sensory biases, adaptive ability, brain structure, brain function, and genetic predispositions. The ability to customize adaptability training will allow more efficient use of crew time during training and will optimize training prescriptions for astronauts to mitigate the deleterious effects of spaceflight.

Mulavara, A. P.↗
DOE OSTI2019

Comparison of Thin Film Heat Flux Gauge Technologies Emphasizing Continuous-Duration Operation

Thin film heat flux gauges (HFGs) have been used for several decades to measure surface temperatures and heat flux in test turbines with the majority being used in facilities that are short-duration. These gauges are typically composed of two resistive temperature devices deposited on opposing sides of a dielectric. However, because these sensors have been traditionally applied for measurements in short-duration, transient-type facilities, the challenges facing adaptation of this technology for a continuous-duration steady facility warrant investigation. Those challenges are highlighted, and solutions are presented throughout the paper. This paper describes the nanofabrication process for heat flux gauges and a new calibration method to address potential deterioration of gauges over long runtimes in continuous-duration facilities. Because a primary uncertainty of these sensors arises from the ambiguity of the thermal properties, special emphasis is placed on the property determination and potential errors due to improper thermal properties. Also, this paper presents a discussion on the use of impulse response theory to process the data showing the feasibility of the method for steady-duration facilities after an initial settling time. The latter portion of the paper focuses on comparing well-established heat flux gauges developed for short-duration turbine test facilities to recently developed gauges fabricated using modern nanofabrication techniques for a continuous turbine test facility. Using a commercially available heat flux gauge, capable of measuring a steady heat flux as a reference, the gauges were compared using the test case of an impinging jet over a range of Reynolds numbers. The comparison between the PSU gauge and the reference device indicated agreement within 14%, and similar results were achieved through comparison with established sensors from partner institutions.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Accelerated Creep Test Qualification of Creep-Resistance Using the Wilshire–Cano–Stewart Constitutive Model and Stepped Isostress Method

In this paper, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire–Cano–Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing is a long-term continuous process; in fact, the ASME B&PV III requires that 10,000+ h of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The SSM has been developed, which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750 °C and predictions are compared to conventional creep testing data. The WCS model has proven to make long-term predictions for stress-rupture, MCSR, creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are postaudit validated using the National Institute of Material Science database. Similarly, the MCSR predictions are compared from previous studies. Finally, the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and industrial gas turbines.

42 ENGINEERING↗
NASA NTRS1992

High-toughness graphite/epoxy composite material experiment

This experiment was designed to measure the effect of near space exposure on three mechanical properties of specially toughened 5208/T300 graphite/epoxy composite materials. The properties measured are elastic modulus, strength, and fracture toughness. Six toughness specimens and nine tensile specimens were mounted on an external frame during the time of the Long Duration Exposure Facility (LDEF) mission. Three identical sets of specimens were manufactured at the outset: the flight set, a zero time non-flight set, and a total time non-flight set. To date, two toughness specimens and three strength and modulus specimens have been tested from each of the three groups.

Felbeck, David K.↗
NASA NTRS1992

Space Exposed Experiment Developed for Students (SEEDS) (P0004-2)

SEEDS, a cooperative endeavor of NASA Headquarters, the NASA Langley Research Center, and the George W. Park Seed Company, resulted in the distribution of approximately 132,000 SEEDS kits to 3.3 million students. Kits contained Rutger's tomato seeds that had flown on the Long Duration Exposure Facility (LDEF), as well as seeds that had been stored in a climate controlled warehouse for the same time period. Preliminary data indicates the germination rate for space exposed seeds was 73.8 percent while Earth based seeds germinated at a rate of 70.3 percent. Tests conducted within the first six months after retrieval indicated space exposed seeds germinated in an average of 8.0 days, while Earth based seeds' average germination time was 8.3 days. Some mutations (assumed to be radiation induced) include plants that added a leaf instead of the usual flower at the end of the flower frond. Also, fruit produced from a flower with a variegated calyx bore seeds producing albino plants, while fruit from a flower with a green calyx from the same plant bore seeds producing green plants.

Grigsby, Doris K.↗
NASA NTRS2005

Integrated Systems Health Management for Space Exploration

Integrated Systems Health Management (ISHM) is a system engineering discipline that addresses the design, development, operation, and lifecycle management of components, subsystems, vehicles, and other operational systems with the purpose of maintaining nominal system behavior and function and assuring mission safety and effectiveness under off-nominal conditions. NASA missions are often conducted in extreme, unfamiliar environments of space, using unique experimental spacecraft. In these environments, off-nominal conditions can develop with the potential to rapidly escalate into mission- or life-threatening situations. Further, the high visibility of NASA missions means they are always characterized by extraordinary attention to safety. ISHM is a critical element of risk mitigation, mission safety, and mission assurance for exploration. ISHM enables: In-space maintenance and repair; a) Autonomous (and automated) launch abort and crew escape capability; b) Efficient testing and checkout of ground and flight systems; c) Monitoring and trending of ground and flight system operations and performance; d) Enhanced situational awareness and control for ground personnel and crew; e) Vehicle autonomy (self-sufficiency) in responding to off-nominal conditions during long-duration and distant exploration missions; f) In-space maintenance and repair; and g) Efficient ground processing of reusable systems. ISHM concepts and technologies may be applied to any complex engineered system such as transportation systems, orbital or planetary habitats, observatories, command and control systems, life support systems, safety-critical software, and even the health of flight crews. As an overarching design and operational principle implemented at the system-of-systems level, ISHM holds substantial promise in terms of affordability, safety, reliability, and effectiveness of space exploration missions.

Uckun, Serdar↗
NASA NTRS2017

Practical Applications of Cables and Ropes in the ISS Countermeasures System

National Aeronautics and Space Administration (NASA) uses exercise countermeasures on the International Space Station (ISS) to maintain crew health and combat the negative effects of long-duration spaceflight on the human body. Most ISS exercise countermeasures system (CMS) equipment rely heavily on the use of textile and wire ropes to transmit resistive loads and provide stability in a microgravity environment. For a variety of reasons, including challenges in simulating microgravity environments for testing and limits on time available for life cycle testing, the textiles and wire ropes have contributed significantly to on-orbit planned and unplanned maintenance time. As a result, continued ground testing and on-orbit experience since the first expedition on the ISS in 2000 provide valuable data and lessons learned in materials selection, applications, and design techniques to increase service life of these ropes. This paper will present a review of the development and failure history of textile and wire ropes for four exercise countermeasure systems-the Treadmill with Vibration Isolation and Stabilization (TVIS) System, Cycle Ergometer with Vibration Isolation and Stabilization (CEVIS) System, Interim Resistive Exercise Device (IRED), and the Advanced Resistive Exercise Device (ARED)-to identify lessons learned in order to improve future systems. These lessons learned, paired with thorough testing on the ground, offer a forward path towards reduced maintenance time and up-mass for future space missions.

Svetlik, Randall G.↗
NASA NTRS1996

Integrated Pump Assembly - An Active Cooling System for Mars Pathfinder Thermal Control

The Mars Pathfinder spacecraft which will be launched in December 1996 features an active cooling system for controlling the temperature of the spacecraft. This will be the first time that such a mechanical pump cooling system is used on an interplanetary or long duration flight (over two weeks) in space. The major element of the cooling system is the Integrated Pump Assembly (IPA). It uses centrifugal pumps to circulate liquid Freon to transfer heat from spacecraft electronics to an external radiator. This paper describes the design, fabrication, assembly, and testing of the IPA.

cooling↗
NASA NTRS2007

Continuously Regenerable Freeze-Out CO2 Control Technology

Carbon dioxide (CO2) removal technology development for portable life support systems (PLSS) has traditionally concentrated in the areas of solid and liquid chemical sorbents and semi-permeable membranes. Most of these systems are too heavy in gravity environments, require prohibitive amounts of consumables for operation on long term planetary missions, or are inoperable on the surface of Mars due to the presence of a CO2 atmosphere. This paper describes the effort performed to mature an innovative CO2 removal technology that meets NASA s planetary mission needs while adhering to the important guiding principles of simplicity, reliability, and operability. A breadboard cryogenic carbon dioxide scrubber (Cryo Scrubber) for a closed loop cryogenic PLSS was developed, designed, and tested, and a conceptual design suitable for a PLSS was developed based on the results of the breadboard testing. The Cryo Scrubber freezes CO2 and other trace contaminants out of expired vent loop gas using cooling available from a liquid oxygen (LOX) based PLSS. The device is continuously regenerable, with solid CO2 being removed from the cold freeze-out surfaces, sublimated, and vented overboard. Duration is limited only by the supply of LOX stored in the PLSS. Simplicity, reliability, and operability are universally important criteria for critical hardware on long duration Lunar or Mars missions. The Cryo Scrubber has no moving parts, requires no additional consumables, and uses no electrical power, contributing to its simplicity and reliability. It is easy to use; no operator action is required to prepare, use, or shut down the Cryo Scrubber, and it does not require charging or regeneration. The versatility of the concept allows for operation on earth, the moon, and Mars, and in microgravity.

Fricker, John↗
NASA NTRS1987

Statistical aspects of solar flares

A survey of the statistical properties of 850 H alpha solar flares during 1975 is presented. Comparison of the results found here with those reported elsewhere for different epochs is accomplished. Distributions of rise time, decay time, and duration are given, as are the mean, mode, median, and 90th percentile values. Proportions by selected groupings are also determined. For flares in general, mean values for rise time, decay time, and duration are 5.2 + or - 0.4 min, and 18.1 + or 1.1 min, respectively. Subflares, accounting for nearly 90 percent of the flares, had mean values lower than those found for flares of H alpha importance greater than 1, and the differences are statistically significant. Likewise, flares of bright and normal relative brightness have mean values of decay time and duration that are significantly longer than those computed for faint flares, and mass-motion related flares are significantly longer than non-mass-motion related flares. Seventy-three percent of the mass-motion related flares are categorized as being a two-ribbon flare and/or being accompanied by a high-speed dark filament. Slow rise time flares (rise time greater than 5 min) have a mean value for duration that is significantly longer than that computed for fast rise time flares, and long-lived duration flares (duration greater than 18 min) have a mean value for rise time that is significantly longer than that computed for short-lived duration flares, suggesting a positive linear relationship between rise time and duration for flares. Monthly occurrence rates for flares in general and by group are found to be linearly related in a positive sense to monthly sunspot number. Statistical testing reveals the association between sunspot number and numbers of flares to be significant at the 95 percent level of confidence, and the t statistic for slope is significant at greater than 99 percent level of confidence. Dependent upon the specific fit, between 58 percent and 94 percent of the variation can be accounted for with the linear fits. A statistically significant Northern Hemisphere flare excess (P less than 1 percent) was found, as was a Western Hemisphere excess (P approx 3 percent). Subflares were more prolific within 45 deg of central meridian (P less than 1 percent), while flares of H alpha importance or = 1 were more prolific near the limbs greater than 45 deg from central meridian; P approx 2 percent). Two-ribbon flares were more frequent within 45 deg of central meridian (P less than 1 percent). Slow rise time flares occurred more frequently in the western hemisphere (P approx 2 percent), as did short-lived duration flares (P approx 9 percent), but fast rise time flares were not preferentially distributed (in terms of east-west or limb-disk). Long-lived duration flares occurred more often within 45 deg 0 central meridian (P approx 7 percent). Mean durations for subflares and flares of H alpha importance or + 1, found within 45 deg of central meridian, are 14 percent and 70 percent, respectively, longer than those found for flares closer to the limb. As compared to flares occurring near cycle maximum, the flares of 1975 (near solar minimum) have mean values of rise time, decay time, and duration that are significantly shorter. A flare near solar maximum, on average, is about 1.6 times longer than one occurring near solar minimum.

Wilson, Robert M.↗
NASA NTRS2005

Strategies for Radiation Hardness Testing of Power Semiconductor Devices

Plans on the drawing board for future space missions call for much larger power systems than have been flown in the past. These systems would employ much higher voltages and currents to enable more powerful electric propulsion engines and other improvements on what will also be much larger spacecraft. Long term human outposts on the moon and planets would also require high voltage, high current and long life power sources. Only hundreds of watts are produced and controlled on a typical robotic exploration spacecraft today. Megawatt systems are required for tomorrow. Semiconductor devices used to control and convert electrical energy in large space power systems will be exposed to electromagnetic and particle radiation of many types, depending on the trajectory and duration of the mission and on the power source. It is necessary to understand the often very different effects of the radiations on the control and conversion systems. Power semiconductor test strategies that we have developed and employed will be presented, along with selected results. The early results that we have obtained in testing large power semiconductor devices give a good indication of the degradation in electrical performance that can be expected in response to a given dose. We are also able to highlight differences in radiation hardness that may be device or material specific.

Soltis, James V.↗
NASA NTRS1992

Long Duration Exposure Facility (LDEF) low temperature heat pipe experiment package (HEPP) flight results

The Low Temperature Heat Pipe Flight Experiment (HEPP) is a fairly complicated thermal control experiment that was designed to evaluate the performance of two different low temperature ethan heat pipes. A total of 388 days of continuous operation with an axially grooved aluminum transporter heat pipe and an axially grooved stainless steel heat pipe diode was demonstrated before the EPDS batteries lost power. Preliminary postflight tests showed that the heat pipes are still functioning. A summary of the flight data analysis for the heat pipes and the related support systems is presented.

Mcintosh, Roy↗
DOE OSTI2021

ACCELERATED CREEP TEST (ACT) QUALIFICATION OF CREEP RESISTANCE USING THE WCS CONSTITUTIVE MODEL AND STEPPED ISOSTRESS METHOD (SSM)

In this study, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire-Cano-Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing (CCT) is a long-term continuous process, in fact, the ASME B&PV III requires that 10,000+ hours of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle (TTSSP) that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The stepped isostress method (SSM) has been developed which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750°C and predictions are compared to CCT data. The WCS model has proven to make long-term predictions for stress-rupture, minimum-creep-strain-rate (MCSR), creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are post-audit validated using the National Institute of Material Science (NIMS) database. Similarly, the MCSR predictions are compared from previous studies. Finally the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and Industrial Gas Turbines (IGT).

36 MATERIALS SCIENCE↗
NASA NTRS1987

Self-lubricating coatings for high-temperature applications

Some present-day aeropropulsion systems impose severe demands on the thermal and oxidative stability of lubricant, bearing, and seal materials. These demands will be much more severe for operational systems around the turn of the century. Solid lubricants with maximum temperature capabilities of about 1100 C are known. Unfortunately, none of the solid lubricants with the highest temperature capabilities are effective below approximately 400 C. However, research shows that silver and stable fluorides, such as calcium and barium fluoride act synergistically to provide lubrication from below room temperature to approximately 900 C. Plasma-sprayed, self-lubricating composite coatings that were developed at Lewis are described. Background information is given on coatings, designed as PS100 and PS101, that contain the solid lubricants in a Nichrome matrix. These coatings have low friction coefficients over a wide temperature range, but they have inadequate wear resistance for some long-duration applications. Wear resistance was dramatically improved in a recently developed coating PS200, by replacing the Nichrome matrix material with metal-bonded chromium carbide containing dispersed silver and calcium fluoride/barium fluoride eutectic (CaF2/BaF2). The lubricants control friction and the carbide matrix provides excellent wear resistance. Successful tests of these coatings are discussed.

Sliney, Harold E.↗
NASA NTRS1999

Circadian Entrainment, Sleep-Wake Regulation and Neurobehavioral Performance During Extended Duration Space Flight

Long-duration manned space flight requires crew members to maintain a high level of cognitive performance and vigilance while operating and monitoring sophisticated instrumentation. However, the reduction in the strength of environmental synchronizers in the space environment leads to misalignment of circadian phase among crew members, coupled with restricted time available to sleep, results in sleep deprivation and consequent deterioration of neurobehavioral function. Crew members are provided, and presently use, long-acting benzodiazepine hypnotics on board the current, relatively brief space shuttle missions to counteract such sleep disruption, a situation that is only likely to worsen during extended duration missions. Given the known carry-over effects of such compounds on daytime performance, together with the reduction in emergency readiness associated with their use at night, NASA has recognized the need to develop effective but safe countermeasures to allow crew members to obtain an adequate amount of sleep. Over the past eight years, we have successfully implemented a new technology for shuttle crew members involving bright light exposure during the pre-launch period to facilitate adaptation of the circadian timing system to the inversions of the sleep-wake schedule often required during dual shift missions. However for long duration space station missions it will be necessary to develop effective and attainable countermeasures that can be used chronically to optimize circadian entrainment. Our current research effort is to study the effects of light-dark cycles with reduced zeitgeber strength, such as are anticipated during long-duration space flight, on the entrainment of the endogenous circadian timing system and to study the effects of a countermeasure that consists of scheduled brief exposures to bright light on the human circadian timing system. The proposed studies are designed to address the following Specific Aims: (1) test the hypothesis that synchronization of the human circadian pacemaker will be disturbed in men and women by the reduction in LD cycle strength. (2) test the hypothesis that this disturbed circadian synchronization will result in the secretion of the sleep-promoting hormone melatonin during the waking day, disturbed sleep, reduced growth hormone secretion, and impaired performance and daytime alertness; (3) as a countermeasure, test the hypothesis that brief daily exposures to bright light (10,000 lux) will reestablish normal entrained circadian phase, resulting in improved sleep consolidation, normalized sleep structure and endogenous growth hormone secretion and enhanced daytime performance. To date, we have carried out twelve experiments to address Hypotheses I and 2 and data analyses are in progress. The results of the current research may have important implications for the treatment of circadian rhythm sleep disorders, such as delayed sleep phase syndrome and shift-work dyssomnia, which are anticipated to have a high incidence and prevalence during extended duration space flight such as planned for the International Space Station and manned missions to Mars.

Czeisler, Charles A.↗
NASA NTRS2010

NASA Astronaut Selection 2009: Behavioral Overview

NASA's multi-phase U.S. astronaut selection process seeks to identify the most qualified astronaut candidates from a large number of applicants. With the approaching retirement of the Space Shuttle, NASA focused on selecting those individuals who were most suited to the unique demands of long-duration spaceflight. In total, NASA received 3,535 applications for the 2009 astronaut selection cycle. Of these, 123 were invited to NASA Johnson Space Center (JSC) for Round 1 initial screening and interviews, which consisted of an Astronaut Selection Board (ASB) preliminary interview, medical review, and psychological testing. Of these, 48 individuals were invited to return for Round 2. This round consisted of medical testing, further behavioral assessments, and a second ASB interview. Following this, nine astronaut candidates (ASCANs) were ultimately chosen to go forward to basic training. The contents, benefits, and lessons learned from implementing this phased process will be discussed. The lessons learned can benefit the future selection of space flyers, whether they are NASA or commercial. Learning Objective: 1) Familiarization with the 2009 NASA behavioral screening process for astronaut applicants.

Holland, A. W.↗
NASA NTRS2016

Paving the Path for Human Space Exploration: The Challenges and Opportunities

Lauri Hansen, Director of Engineering at NASA Johnson Space Center will discuss the challenges of human space exploration. The future of human exploration begins with our current earth reliant missions in low earth orbit. These missions utilize the International Space Station to learn how to safely execute deep space missions. In addition to serving as an exploration test bed and enabling world class research, the International Space Station enables NASA to build international and commercial partnerships. NASA's next steps will be to enable the commercialization of low earth orbit while concentrating on developing the spacecraft and infrastructure necessary for deep space exploration and long duration missions. The Orion multi-purpose crew vehicle and the Space Launch System rocket are critical building blocks in this next phase of exploration. There are many challenges in designing spacecraft to perform these missions including safety, complex vehicle design, and mass challenges. Orion development is proceeding well, and includes a significant partnership with the European Space Agency (ESA) to develop and build the Service Module portion of the spacecraft. Together, NASA and ESA will provide the capability to take humans further than we have ever been before - 70,000 km past the moon. This will be the next big step in expanding the frontiers of human exploration, eventually leading to human footprints on Mars.

Hansen, Lauri↗
NASA NTRS2014

Service Life Extension of the Propulsion System of Long-Term Manned Orbital Stations

One of the critical non-replaceable systems of a long-term manned orbital station is the propulsion system. Since the propulsion system operates beginning with the launch of station elements into orbit, its service life determines the service life of the station overall. Weighing almost a million pounds, the International Space Station (ISS) is about four times as large as the Russian space station Mir and about five times as large as the U.S. Skylab. Constructed over a span of more than a decade with the help of over 100 space flights, elements and modules of the ISS provide more research space than any spacecraft ever built. Originally envisaged for a service life of fifteen years, this Earth orbiting laboratory has been in orbit since 1998. Some elements that have been launched later in the assembly sequence were not yet built when the first elements were placed in orbit. Hence, some of the early modules that were launched at the inception of the program were already nearing the end of their design life when the ISS was finally ready and operational. To maximize the return on global investments on ISS, it is essential for the valuable research on ISS to continue as long as the station can be sustained safely in orbit. This paper describes the work performed to extend the service life of the ISS propulsion system. A system comprises of many components with varying failure rates. Reliability of a system is the probability that it will perform its intended function under encountered operating conditions, for a specified period of time. As we are interested in finding out how reliable a system would be in the future, reliability expressed as a function of time provides valuable insight. In a hypothetical bathtub shaped failure rate curve, the failure rate, defined as the number of failures per unit time that a currently healthy component will suffer in a given future time interval, decreases during infant-mortality period, stays nearly constant during the service life and increases at the end when the design service life ends and wear-out phase begins. However, the component failure rates do not remain constant over the entire cycle life. The failure rate depends on various factors such as design complexity, current age of the component, operating conditions, severity of environmental stress factors, etc. Development, qualification and acceptance test processes provide rigorous screening of components to weed out imperfections that might otherwise cause infant mortality failures. If sufficient samples are tested to failure, the failure time versus failure quantity can be analyzed statistically to develop a failure probability distribution function (PDF), a statistical model of the probability of failure versus time. Driven by cost and schedule constraints however, spacecraft components are generally not tested in large numbers. Uncertainties in failure rate and remaining life estimates increase when fewer units are tested. To account for this, spacecraft operators prefer to limit useful operations to a period shorter than the maximum demonstrated service life of the weakest component. Running each component to its failure to determine the maximum possible service life of a system can become overly expensive and impractical. Spacecraft operators therefore, specify the required service life and an acceptable factor of safety (FOS). The designers use these requirements to limit the life test duration. Midway through the design life, when benefits justify additional investments, supplementary life test may be performed to demonstrate the capability to safely extend the service life of the system. An innovative approach is required to evaluate the entire system, without having to go through an elaborate test program of propulsion system elements. Evaluating every component through a brute force test program would be a cost prohibitive and time consuming endeavor. ISS propulsion system components were designed and built decades ago. There are no representative ground test articles for some of the components. A 'test everything' approach would require manufacturing new test articles. The paper outlines some of the techniques used for selective testing, by way of cherry picking candidate components based on failure mode effects analysis, system level impacts, hazard analysis, etc. The type of testing required for extending the service life depends on the design and criticality of the component, failure modes and failure mechanisms, life cycle margin provided by the original certification, operational and environmental stresses encountered, etc. When specific failure mechanism being considered and the underlying relationship of that mode to the stresses provided in the test can be correlated by supporting analysis, time and effort required for conducting life extension testing can be significantly reduced. Exposure to corrosive propellants over long periods of time, for instance, lead to specific failure mechanisms in several components used in the propulsion system. Using Arrhenius model, which is tied to chemically dependent failure mechanisms such as corrosion or chemical reactions, it is possible to subject carefully selected test articles to accelerated life test. Arrhenius model reflects the proportional relationship between time to failure of a component and the exponential of the inverse of absolute temperature acting on the component. The acceleration factor is used to perform tests at higher stresses that allow direct correlation between the times to failure at a high test temperature to the temperatures to be expected in actual use. As long as the temperatures are such that new failure mechanisms are not introduced, this becomes a very useful method for testing to failure a relatively small sample of items for a much shorter amount of time. In this article, based on the example of the propulsion system of the first ISS module Zarya, theoretical approaches and practical activities of extending the service life of the propulsion system are reviewed with the goal of determining the maximum duration of its safe operation.

Kamath, Ulhas↗