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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2014

RS-34 Phoenix In-Space Propulsion System Applied to Active Debris Removal Mission

In-space propulsion is a high percentage of the cost when considering Active Debris Removal mission. For this reason it is desired to research if existing designs with slight modification would meet mission requirements to aid in reducing cost of the overall mission. Such a system capable of rendezvous, close proximity operations, and de-orbit of Envisat class resident space objects has been identified in the existing RS-34 Phoenix. RS-34 propulsion system is a remaining asset from the de-commissioned United States Air Force Peacekeeper program; specifically the pressure-fed storable bi-propellant Stage IV Post Boost Propulsion System. The National Aeronautics and Space Administration (NASA) Marshall Space Flight Center (MSFC) gained experience with the RS-34 propulsion system on the successful Ares I-X flight test program flown in the Ares I-X Roll control system (RoCS). The heritage hardware proved extremely robust and reliable and sparked interest for further utilization on other potential in-space applications. Subsequently, MSFC has obtained permission from the USAF to obtain all the remaining RS-34 stages for re-use opportunities. The MSFC Advanced Concepts Office (ACO) was commissioned to lead a study for evaluation of the Rocketdyne produced RS-34 propulsion system as it applies to an active debris removal design reference mission for resident space object targets including Envisat. Originally designed, the RS-34 Phoenix provided in-space six-degrees-of freedom operational maneuvering to deploy payloads at multiple orbital locations. The RS-34 Concept Study lead by sought to further understand application for a similar orbital debris design reference mission to provide propulsive capability for rendezvous, close proximity operations to support the capture phase of the mission, and deorbit of single or multiple large class resident space objects. Multiple configurations varying the degree of modification were identified to trade for dry mass optimization and propellant load. The results of the RS-34 Phoenix Concept Study show that the system is technically sufficient to successfully support all of the missions to rendezvous, capture, and de-orbit targets including Envisat and Hubble Space Telescope. The results and benefits of the RS-34 Orbital Debris Application Concept Study are presented in this paper.

Esther, Elizabeth A.↗
NASA NTRS2015

CO2 Data Distribution and Support from the Goddard Earth Science Data and Information Services Center (GES-DISC)

This talk will describe the support and distribution of CO2 data products from OCO-2, AIRS, and ACOS, that are archived and distributed from the Goddard Earth Sciences Data and Information Services Center. We will provide a brief summary of the current online archive and distribution metrics for the OCO-2 Level 1 products and plans for the Level 2 products. We will also describe collaborative data sets and services (e.g., matchups with other sensors) and solicit feedback for potential future services.

AIRS↗
NASA NTRS2015

Technology Alignment and Portfolio Prioritization (TAPP)

Technology Alignment and Portfolio Prioritization (TAPP) is a method being developed by the Advanced Concepts Office, at NASA Marshall Space Flight Center. The TAPP method expands on current technology assessment methods by incorporating the technological structure underlying technology development, e.g., organizational structures and resources, institutional policy and strategy, and the factors that motivate technological change. This paper discusses the methods ACO is currently developing to better perform technology assessments while taking into consideration Strategic Alignment, Technology Forecasting, and Long Term Planning.

Funaro, Gregory V.↗
NASA NTRS2015

Exercise Equipment Usability Assessment for a Deep Space Concept Vehicle

With international aspirations to send astronauts to deep space, the world is now faced with the complex problem of keeping astronauts healthy in unexplored hostile environments for durations of time never before attempted by humans. The great physical demands imparted by space exploration compound the problem of astronaut health, as the astronauts must not only be healthy, but physically fit upon destination arrival in order to perform the scientific tasks required of them. Additionally, future deep space exploration necessitates the development of environments conducive to long-duration habitation that would supplement propulsive vehicles. Space Launch System (SLS) core stage barrel sections present large volumes of robust structure that can be recycled and used for long duration habitation. This assessment will focus on one such conceptual craft, referred to as the SLS Derived Habitat (SLS-DH). Marshall Space Flight Center's (MSFC) Advanced Concepts Office (ACO) has formulated a high-level layout of this SLS-DH with parameters such as floor number and orientation, floor designations, grid dimensions, wall placement, etc. Yet to be determined, however, is the layout of the exercise area. Currently the SLS-DH features three floors laid out longitudinally, leaving 2m of height between the floor and ceilings. This short distance between levels introduces challenges for proper placement of exercise equipment such as treadmills and stationary bicycles, as the dynamic envelope for the 95th percentile male astronauts is greater than 2m. This study aims to assess the optimal equipment layout and sizing for the exercise area of this habitat. Figure 1 illustrates the layout of the DSH concept demonstrator located at MSFC. The exercise area is located on the lower level, seen here as the front half of the level occupied by a crew member. This small volume does not allow for numerous or bulky exercise machines, so the conceptual equipment has been limited to a treadmill and stationary bicycle. With the most current treadmill aboard the International Space Station (ISS), the Combined Operational Load-Bearing External Resistance Treadmill (COLBERT), being located in an International Standard Payload Rack (ISPR), the bottom of the conceptual treadmill features a height of 38in. Making the treadmill flush with the floor would be impossible in this rack configuration, as the distance from the outer wall of the spacecraft to the bottom floor would be too shallow. From preliminary sizing, the 38in required for the bottom of the treadmill combined with a 78in operational envelope for a 95th percentile may not be accommodated in the exercise area in a vertical orientation. Figure 2 demonstrates the volume required (in maroon) for an ISPR-bound treadmill in the concept demonstrator. Early indications as seen in this figure indicate that the crew members would contact the ceiling in such an arrangement. An assessment will be conducted to evaluate various orientations of exercise equipment in the concept demonstrator. Orientations to be tested include putting the bottom of the treadmill on the wall, having the treadmill at an angle in the floor both horizontally and vertically, and having a shorter (non-rack bound) treadmill in a vertical orientation on the floor. This assessment will yield findings regarding sizing of the area and how well participants feel they could exercise in such an environment. Due to the restrictions of assessing a microgravity vehicle in a normal-gravity environment, simulations in MSFC's Virtual Environments Lab (VEL) may be necessary. Final deliverables will include recommendations regarding the location and size of possible exercise equipment aboard the SLS-Derived DSH.

Rhodes, Brooke M.↗
NASA NTRS2015

Electric Sail Propulsion for Exploring Nearby Interstellar Space

An Electric Sail is a revolutionary propellant-less propulsion system that is ideal for deep space missions to the outer planets, the Heliopause, and beyond. It is revolutionary in that it uses momentum exchange with the hypersonic solar wind to propel a spacecraft within the heliosphere. The momentum exchange is affected by the deflection of charged solar wind particles by an array of electrically biased wires that extend outward up to 30 km from a slowly rotating spacecraft. A high-voltage, positive bias on the wires, which are oriented normal to the solar wind flow, deflects the streaming protons, resulting in a reaction force on the wires that is also directed radially away from the sun. Over a period of months, this small force can accelerate the spacecraft to enormous speeds-on the order of 100-150 km/s (approximately 20 to 30 AU/yr). Unlike solar sails, Electric Sails do not rely on a fixed area to produce thrust. In fact, as they move away from the Sun and solar wind pressure decreases, the area for solar proton momentum transfer becomes larger, increasing system efficiency. As a result, thrust decreases at ≈1/r**(7/6) instead of the ≈1/r**2 rate typical for solar sails. The net effect is that an increased radial range of operation, together with increased thrust, both contribute to higher velocities and shorter total trip times to distant destinations. The MSFC Advanced Concepts Office (ACO) was awarded a Phase II NASA Innovative Advanced Concepts (NIAC) study to mature the technology for possible future demonstration and implementation. Preliminary results indicate that the physics of the system is viable and that a spacecraft propelled by an Electric Sail could reach the Heliopause in less than 15 years - and could be developed within a decade.

Johnson, Les↗
NASA NTRS2015

An Inversion Analysis of Recent Variability in Natural CO2 Fluxes Using GOSAT and In Situ Observations

About one-half of the global CO2 emissions from fossil fuel combustion and deforestation accumulates in the atmosphere, where it contributes to global warming. The rest is taken up by vegetation and the ocean. The precise contribution of the two sinks, and their location and year-to-year variability are, however, not well understood. We use two different approaches, batch Bayesian synthesis inversion and variational data assimilation, to deduce the global spatiotemporal distributions of CO2 fluxes during 2009-2010. One of our objectives is to assess different sources of uncertainties in inferred fluxes, including uncertainties in prior flux estimates and observations, and differences in inversion techniques. For prior constraints, we utilize fluxes and uncertainties from the CASA-GFED model of the terrestrial biosphere and biomass burning driven by satellite observations and interannually varying meteorology. We also use measurement-based ocean flux estimates and two sets of fixed fossil CO2 emissions. Here, our inversions incorporate column CO2 measurements from the GOSAT satellite (ACOS retrieval, filtered and bias-corrected) and in situ observations (individual flask and afternoon-average continuous observations) to estimate fluxes in 108 regions over 8-day intervals for the batch inversion and at 3 x 3.75 weekly for the variational system. Relationships between fluxes and atmospheric concentrations are derived consistently for the two inversion systems using the PCTM atmospheric transport model driven by meteorology from the MERRA reanalysis. We compare the posterior fluxes and uncertainties derived using different data sets and the two inversion approaches, and evaluate the posterior atmospheric concentrations against independent data including aircraft measurements. The optimized fluxes generally resemble those from other studies. For example, the results indicate that the terrestrial biosphere is a net CO2 sink, and a GOSAT-only inversion suggests a shift in the global sink from the tropics south to the north relative to the prior and to an in-situ-only inversion. We also find a smaller terrestrial sink in higher-latitude northern regions in boreal summer of 2010 relative to 2009.

Carbon dioxide↗
NASA NTRS2016

Green Monopropellant Status at Marshall Space Flight Center

NASA Marshall Space Flight Center is continuing investigations into the use of green monopropellants as a replacement for hydrazine in spacecraft propulsion systems. Work to date has been to push technology development through multiple activities designed to understand the capabilities of these technologies. Future work will begin to transition to mission pull as these technologies are mature while still keeping a solid goal of pushing technology development as opportunities become available. The AF-M315E activities began with hot-fire demonstration testing of a 1N monopropellant thruster in FY 14 and FY15. Following successful completion of the preliminary campaign, changes to the test stand to accommodate propellant conditioning capability and better control of propellant operations was incorporated to make testing more streamlined. The goal is to conduct hot-fire testing with warm and cold propellants using the existing feed system and original thruster design. Following the 1N testing, a NASA owned 100 mN thruster will be hot-fire tested in the same facility to show feasibility of scaling to smaller thrusters for cubesat applications. The end goal is to conduct a hot-fire test of an integrated cubesat propulsion system using an SLM printed propellant tank, an MSFC designed propulsion system electronic controller and the 100 mN thruster. In addition to the AF-M315E testing, MSFC is pursuing hot-fire testing with LMP-103S. Following our successful hot-fire testing of the 22N thruster in April 2015, a test campaign was proposed for a 440N LMP-103S thruster with Orbital ATK and Plasma Processes. This activity was funded through the Space Technology Mission Directorate (STMD) ACO funding call in the last quarter of CY15. Under the same funding source a test activity with Busek and Glenn Research Center for testing of 5N AF-M315E thrusters was proposed and awarded. Both activities are in-work with expected completion of hot-fire testing by the end of FY17. MSFC is continuing to coordinate with the AF and academia on understanding the chemical reactions that occur in AF-M315E. An on-going investigation of the catalyst bed species using Raman Spectroscopy through the NASA Technology Research Fellowship Program (NSTRF) is looking for ways to minimize the amount of computation required by understanding the intermediate species created in the catalyst bed. The MSFC team is also working with commercial partners through Cooperative Agreement Notices (CAN's). Partnerships with commercial and academia include work in non-catalytic ignition of AF-M315, spark ignition of hybrid cubesat systems, printed SLM tanks, and dual-mode (electric and chemical) propulsion systems is continuing.

Burnside, Christopher G.↗
NASA NTRS2016

Application of Design of Experiments and Surrogate Modeling within the NASA Advanced Concepts Office, Earth-to-Orbit Design Process

Decisions made during early conceptual design can have a profound impact on life-cycle cost (LCC). Widely accepted that nearly 80% of LCC is committed. Decisions made during early design must be well informed. Advanced Concepts Office (ACO) at Marshall Space Flight Center aids in decision making for launch vehicles. Provides rapid turnaround pre-phase A and phase A studies. Provides customer with preliminary vehicle sizing information, vehicle feasibility, and expected performance.

Zwack, Matthew R.↗
NASA NTRS2016

Augmenting Parametric Optimal Ascent Trajectory Modeling with Graph Theory

It has been well documented that decisions made in the early stages of Conceptual and Pre-Conceptual design commit up to 80% of total Life-Cycle Cost (LCC) while engineers know the least about the product they are designing [1]. Once within Preliminary and Detailed design however, making changes to the design becomes far more difficult to enact in both cost and schedule. Primarily this has been due to a lack of detailed data usually uncovered later during the Preliminary and Detailed design phases. In our current budget-constrained environment, making decisions within Conceptual and Pre-Conceptual design which minimize LCC while meeting requirements is paramount to a program's success. Within the arena of launch vehicle design, optimizing the ascent trajectory is critical for minimizing the costs present within such concerns as propellant, aerodynamic, aeroheating, and acceleration loads while meeting requirements such as payload delivered to a desired orbit. In order to optimize the vehicle design its constraints and requirements must be known, however as the design cycle proceeds it is all but inevitable that the conditions will change. Upon that change, the previously optimized trajectory may no longer be optimal, or meet design requirements. The current paradigm for adjusting to these updates is generating point solutions for every change in the design's requirements [2]. This can be a tedious, time-consuming task as changes in virtually any piece of a launch vehicle's design can have a disproportionately large effect on the ascent trajectory, as the solution space of the trajectory optimization problem is both non-linear and multimodal [3]. In addition, an industry standard tool, Program to Optimize Simulated Trajectories (POST), requires an expert analyst to produce simulated trajectories that are feasible and optimal [4]. In a previous publication the authors presented a method for combatting these challenges [5]. In order to bring more detailed information into Conceptual and Pre-Conceptual design, knowledge of the effects originating from changes to the vehicle must be calculated. In order to do this, a model capable of quantitatively describing any vehicle within the entire design space under consideration must be constructed. This model must be based upon analysis of acceptable fidelity, which in this work comes from POST. Design space interrogation can be achieved with surrogate modeling, a parametric, polynomial equation representing a tool. A surrogate model must be informed by data from the tool with enough points to represent the solution space for the chosen number of variables with an acceptable level of error. Therefore, Design Of Experiments (DOE) is used to select points within the design space to maximize information gained on the design space while minimizing number of data points required. To represent a design space with a non-trivial number of variable parameters the number of points required still represent an amount of work which would take an inordinate amount of time via the current paradigm of manual analysis, and so an automated method was developed. The best practices of expert trajectory analysts working within NASA Marshall's Advanced Concepts Office (ACO) were implemented within a tool called multiPOST. These practices include how to use the output data from a previous run of POST to inform the next, determining whether a trajectory solution is feasible from a real-world perspective, and how to handle program execution errors. The tool was then augmented with multiprocessing capability to enable analysis on multiple trajectories simultaneously, allowing throughput to scale with available computational resources. In this update to the previous work the authors discuss issues with the method and solutions.

Patrick D Dees↗
NASA NTRS2017

GES DISC Greenhouse Gas Data Sets and Associated Services

NASA Goddard Earth Sciences (GES) Data and Information Services Center (DISC) archives and distributes rich collections of data on atmospheric greenhouse gases from multiple missions. Hosted data include those from the Atmospheric Infrared Sounder (AIRS) mission (which has observed CO2, CH4, ozone, and water vapor since 2002); legacy water vapor and ozone retrievals from TIROS Operational Vertical Sounder (TOVS); and Upper Atmosphere Research Satellite (UARS) going back to the early 1980s. GES DISC also archives and supports data from seven projects of the Making Earth System Data Records for Use in Research Environments (MEaSUREs) program that have ozone and water vapor records. Greenhouse gases data from the A-Train satellite constellation is also available: (1) Aura-Ozone Monitoring Instrument (OMI) and Microwave Limb Sounder (MLS) ozone, nitrous oxide, and water vapor since 2004; (2) Greenhouse Gases Observing Satellite (GOSAT) CO2 observations since 2009 from the Atmospheric CO2 Observations from Space (ACOS) task; and (3) Orbiting Carbon Observatory-2 (OCO-2) CO2 data since 2014. The most recent related data set that the GES DISC archives is methane flux for North America, as part of NASAs Carbon Monitoring System (CMS) project. This dataset contains estimates of methane emission in North America based on an inversion of the GEOS-Chem chemical transport model constrained by GOSAT observations (Turner et al., 2015). Along with data stewardship, an important focus area of the GES DISC is to enhance the usability of its data and broaden its user base. Users have unrestricted access to a new user-friendly search interface, which includes many services such as variable subsetting, format conversion, quality screening, and quick browse. The majority of the GES DISC data sets are also accessible through Open-source Project for a Network Data Access Protocol (OPeNDAP) and Web Coverage Service (WCS). The latter two services provide more options for specialized subsetting, format conversion, and image viewing. Additional data exploration, data preview, and preliminary analysis capabilities are available via NASA Giovanni, which obviates the need forusers to download the data (Acker and Leptoukh, 2007). Giovanni provides a bridge between the data and science and has been very successful in extending GES DISC data to educational users and to users with limited resources.

data ordering↗
NASA NTRS2019

Development Concepts for Mars Ascent Vehicle (MAV) Solid and Hybrid Vehicle Systems

The Advanced Concepts Office (ACO) at Marshall Space Flight Center (MSFC) has conducted ongoing studies and trades into options for both hybrid and solid vehicle systems for potential Mars Ascent Vehicle (MAV) concepts for the Jet Propulsion Laboratory (JPL). Two MAV propulsion options are being studied for use in a potential Mars Sample Retrieval (MSR) campaign. The following paper describes the current concepts for hybrid and solid propulsion vehicles for MAV as part of a potential MSR campaign, and provides an overview of the ongoing studies and trades for both hybrid and solid vehicle system concepts. Concepts and options under consideration for vehicle subsystems include reaction control system (RCS), separation, and structures will be described in terms of technology readiness level (TRL), benefit to the vehicle design, and associated risk. A hybrid propulsion system, which uses a solid fuel core and liquid oxidizer, is currently being developed by JPL with support from MSFC. This type of hybrid propulsion vehicle would allow the MAV to be more flexible at the cost of higher complexity, in contrast to the solid propulsion vehicle that is simpler, but allows less flexibility. The solid propulsion vehicle study performed by MSFC in 2018 further refined the solid propulsion system sizing as well as added definition to vehicle subsystem concepts, including the RCS, structures and configuration, interstage and separation, aerodynamics, and power/avionics. The studies were performed using an iterative concept design methodology, engaging subject matter experts from across MSFC’s propulsion and vehicle systems disciplines as well as seeking trajectory feedback from analysts at JPL.

McCollum, Lisa Tunstill↗
NASA NTRS2019

Development Concepts for Mars Ascent Vehicle (MAV) Solid and Hybrid Vehicle Systems

Mars Ascent Vehicle (MAV) Study Introduction: Previous Studies -Solid, liquid and hybrid rocket propulsion feasibility studies since 2011 -Focus on hybrid rocket propulsion since 2016; Reassessing Propulsion Systems for Risk Reduction - Liquid propulsion vehicle found to not be feasible; Challenges -An autonomous return mission has never been done -Mars surface environments -Platform packaging limitations -Performance and trajectory requirements; Study Team -MSFC’s Advanced Concepts Office (ACO) -MSFC propulsion and vehicle design engineering expertise -JPL MAV team.

McCollum, Lisa Tunstill↗
NASA NTRS2015

Validation of GOSAT Data Products; Interim Report on the GOSAT/TANSO Project

The Orbiting Carbon Observatory-2 (OCO-2) Team has continued working closely with the Greenhouse Gases Observing Satellite (GOSAT) team to (i) conduct vicarious calibration experiments in Railroad Valley, NV, U.S.A., (ii) retrieve estimates of X CO2 from OCO-2 and GOSAT TANSO-FTS data, and (iii) validate these products using internationally recognized standards. The OCO-/GOSAT relationship was reinforced in March 2015 with the signing a new Memorandum of Understanding between NASA and the GOSAT and GOSAT-2 partners. Over the past year, while the GOSAT team has been finalizing the V201 product, the OCO-2 team has focused primarily on the delivery of the OCO-2 product, providing new opportunities for cross calibration of the OCO-2 and GOSAT instruments and cross validation of their products. These efforts are just now producing results. Members of the OCO-2 team have also continued the analysis of the GOSAT V161.161 data and the ACOS B3.5 products. Those efforts have produced 2 new refereed publications and several others in review. The OCO-2 now preparing to reprocess the entire GOSAT TANSO-FTS data record using the GOSAT V201 product and OCO-2 B7 algorithm to produce a 7-year, multi-satellite climate data record for X(sub CO2).

Wennberg, Paul↗
NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗
NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗
NASA NTRS2019

Thermal, Avionics, and Power Considerations for Designing a Nuclear Thermal Propulsion Flight Demonstrator

As part of the Appropriations Bill passed by the US Congress in February 2019, NASA was instructed to develop a nuclear thermal propulsion (NTP) flight demonstrator by 2024. [4] In response to this directive, the Advanced Concepts Office (ACO) at Marshall Space Flight Center (MSFC) was tasked with beginning concept studies for the flight demonstration (FD) mission. During the NTP study formulation, two philoso- phies emerged with regards to FD concept design. The first, Flight Demo 1 (FD1), strictly observes the 2024 schedule requirement at the expense of lower engine performance than expected of theoretical NTP engines. The second concept, Flight Demo 2 (FD2), relaxes the schedule requirement to allow for higher engine performance and more traceability to future operational systems. Both the FD1 and FD2 concepts present considerable challenges for subsystem design, specifically in the areas of thermal control, avionics, and power. To guard against undesired graveyard orbits, a requirement to keep the NTP engine and the reaction control system (RCS) separate was put in place. As a result of this requirement, the avionics subsystem must provide separate command and data handling (CDH) and instrumentation for each propulsion system. In-space instrumentation and monitoring of a NTP system has never been done before, necessitating the development of novel strategies and unique hardware. The heating rates produced by the NTP engine are extremely high, leading to difficulties with thermal control. The FD1 concept utilizes high-pressure gaseous hydrogen (GH2), which is largely insensitive to temperature fluctuations. The FD2 concept, however, utilizes cryogenic liquid hydrogen (LH2) which must be kept stable near 20 Kelvin. A high-performance thermal control system (TCS) will be required to ensure all components and subsystems are maintained within their operational temperature ranges. This paper will highlight the thermal, avionics, and power solutions required for the full scope of challenges for a NTP flight demonstrator.

Johnson, W. E.↗
NASA NTRSDate not supplied

Digital Prototyping Methods to Enable Product Development Analysis Cycle Compression in Aerospace Systems

Historically, the product development life cycle (spanning from origination of a systems concept to initial delivery or fielding) for large-scale aerospace systems is 10-25 years. Examples of recent programs exhibiting this timeline are the Space Shuttle (13 years), , International Space Station (18 years), NASA Hubble telescope (16 years), USAF F-35 Strike Fighter (22 years), Missile Defense Agency THAAD (21 years), USAF V-22 Osprey (26 years), USAF B-2 Spirt (19 years), US Army RAH-66 Comanche (22 years, cancelled prior to fielding), James Webb Space Telescope (25 years), Space Launch System (10 years). This list illustrates the challenges of developing and fielding a modern integrated multi-disciplinary aerospace system. These development timelines are often preceded by significant research and development programs and followed by multiple increments, blocks, or spirals to reach planned operational capability. In the modern era of aerospace system acquisition, there is significant pressure to reduce system development timelines to meet system objectives and enable competitiveness in the current industry and landscape. Across the aerospace industry, a range of rapid acquisition and prototyping programs are seeking to achieve system development within timelines considerably less than 10 years. Notably, in September of 2019, NASA issued a solicitation for the development and demonstration of a Human Landing System (HLS) to deliver humans to the lunar surface by 2024 (5 years) and for the development and demonstration of a more sustainable HLS by 2026 (7 years). Lengthy product development cycle timelines are a product of multiple factors ranging from programmatic, sociological, technical, and systems engineering issues. New approaches in systems engineering provide new ways to enable these compressed development timelines. These approaches employ expanded application of advanced systems engineering methods and cross-cutting digital tools to accelerate system development, utilizing digital prototyping to connect maturing sub-system or component technologies into system or system-of-systems hardware prototypes. Approaches such as the use of system integrating physics relationships to reduce the number of design analysis cycle iterations and state analysis modeling to reduce necessary software testing (and improving coverage of system execution scenarios) represent steps forward in reducing the engineering time needed to field new systems. In addition to cost, schedule and performance benefits, expanded digital exploration and demonstration reduce risk in live system test and demonstration. This incremental demonstration approach, where digital prototyping and demonstration leads and informs full system test and demonstration, could be more important for space applications because of the increased difficulty of test and demonstration of space systems and architectures. The Advanced Concepts Office (ACO) at Marshall Space Flight Center merges traditional multi-disciplinary concept definition methods with modern, cross-cutting systems engineering concepts to enable iterative design and analysis of space architectures and systems through coordinated, strategic management of human capital, technical processes, and technology. This paper provides an overview of that approach, including recent examples and a strategic path forward to enabling continued reduction of aerospace system product development life cycles.

Michael D Watson↗
NASA NTRSDate not supplied

Cryogenic Fluid Management Technologies Enabling for the Artemis Program and Beyond

NASA is endeavoring on an ambitious return to the Moon and eventually on to Mars through the Artemis Program leveraging innovative technologies to establish sustainable exploration architectures collaborating with US commercial and international partners[1]. Future NASA architectures have baselined cryogenic propulsion systems to support lunar missions and ultimately future missions to Mars. NASA has been investing in maturing CFM active and passive storage, transfer, and gauging technologies over the last decade plus primarily focused on ground development with a few small-scale microgravity fluid experiments. Recently, NASA created a Cryogenic Fluid Management (CFM)Technology Roadmap identifying the critical gaps requiring further development to reach a technology readiness level (TRL) of 6 prior to infusion to flight applications. To address the technology gaps the Space Technology Mission Directorate(STMD)strategically plans to invest in a diversified CFM portfolio approach through ground and flight demonstrations ,collaborating with international partners, and leveraging Public Private Partnerships (PPPs) opportunities with US industry through the Tipping Point and Announcement of Collaborative Opportunities (ACO) solicitations. Once proven, these system capabilities will enable the high performing cryogenic propellant systems needed for the Artemis Program and beyond.

Cryogenic Fluid Management↗