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At least 109 records · Page 6

Plasma Processing of Lunar Regolith Simulant for Diverse Applications

Versatile manufacturing technologies for extracting resources from the moon are needed to support future space missions. Of particular interest is the production of gases and metals from lunar resources for life support, propulsion, and in-space fabrication. Deposits made from lunar regolith could yield highly emissive coatings and near-net shaped parts for replacement or repair of critical components. Equally important is development of high fidelity lunar simulants for ground based validation of potential lunar surface operations. Described herein is an innovative plasma processing technique for insitu production of gases, metals, coatings, and deposits from lunar regolith, and synthesis of high fidelity lunar simulant from NASA issued lunar simulant JSC-1. Initial plasma reduction trials of JSC-1 lunar simulant have indicated production of metallic iron and magnesium. Evolution of carbon monoxide has been detected subsequent to reduction of the simulant using the plasma process. Plasma processing of the simulant has also resulted in glassy phases resembling the volcanic glass and agglutinates found in lunar regolith. Complete and partial glassy phase deposits have been obtained by varying the plasma process variables. Experimental techniques, product characterization, and process gas analysis will be discussed.

Schofield, Elizabeth C.↗

In Space Manufacturing and Extraterrestrial Construction: How Did We Get Here?Where Are We? Where Should We Be Going? THE CHALLENGE: Will We Be Ready?

NASA has held multiple workshops and sought inputs from a broad spectrum of sources, including international partners, other space agencies, industry, large and small businesses, academia, and private citizens to develop its Moon to Mars Strategy and Objectives. The goals and objectives set forth in the resulting documents are “designed to achieve the vision to create a blueprint for sustained human presence and exploration throughout the solar system.” The objectives were categorized into four distinct tracks: Operations, Infrastructure, Transportation and Habitation, and Science. In addition, common themes across the objectives were captured under Recurring Tenets. Within the Infrastructure category, several objectives directly address the need for manufacturing and construction on the lunar surface to support continuous human lunar presence and a robust lunar economy. In exploring the vision for creation of on-demand infrastructure on the lunar surface and beyond, this presentation will examine the development of these capabilities, starting in the late 1990’s and early 2000’s, up to the current state, and offer a perspective on the challenges facing operational implementation of these technologies. In the early 2000’s, the destination was the Moon. The International Space Station (ISS) was to be the test bed for demonstration of in space manufacturing technologies. Additive construction was in its infancy. These pioneering initiatives, having begun primarily under NASA’s Office of Biological and Physical Research In Situ Fabrication and Repair (ISFAR) Project, were short-lived. It was not until the early 2010’s that in space manufacturing and later extraterrestrial construction experienced renewed interest and support. At this time, the destination was Mars. This period saw the initial in space additive manufacturing experiments on the ISS, creation of a roadmap for development of in space manufacturing technologies, and development of additive construction systems for terrestrial use at scale. The period also included NASA’s 3D Printed Mars Habitat Centennial Challenge, which catalyzed interest in extraterrestrial construction. With NASA’s announcement of the intention to return to the Moon, and the subsequent release of the Artemis Accords in 2020, and the commensurate Moon to Mars Strategy, NASA’s Space Technology Mission Directorate initiated the Lunar Surface Innovation Initiative (LSII). The LSII has spurred technology development and maturation efforts across a spectrum of capabilities that would be needed to live on the lunar surface. The presentation will provide an overview of current technology developments in the areas of in space manufacturing and extraterrestrial construction. Looking forward from the current state, a perspective will be offered on capabilities that are still needed to “institutionalize” in space manufacturing and extraterrestrial construction to achieve the vision of NASA’s Moon to Mars Strategy. Finally, a challenge will be posed to the community to accelerate the development of these capabilities. When the explorers of the future need these enabling capabilities, will they be ready?

Raymond G Clinton Jr.↗

Summary of the Manufacture, Testing and Model Validation of a Full-Scale Radiator for Fission Surface Power Applications

A full-scale radiator for a lunar fission surface power application was manufactured by Material innovations, Inc., for the NASA Glenn Research Center. The radiator was designed to reject 6 kWt with an inlet water temperature of 400 K and a water mass flow rate of 0.5 kg/s. While not flight hardware, the radiator incorporated many potential design features and manufacturing techniques for future flight hardware. The radiator was tested at NASA Glenn Research Center for heat rejection performance. The results showed that the radiator design was capable of rejecting over 6 kWt when operating at the design conditions. The actual performance of the radiator as a function of operational manifolds, inlet water temperature and facility sink temperature was compared to the predictive model developed by NASA Glenn Research Center. The results showed excellent agreement with the model with the actual average face sheet temperature being within 1% of the predicted value. The results will be used in the design and production of NASA s next generation fission power heat rejection systems. The NASA Glenn Research Center s Technology Demonstration Unit will be the first project to take advantage of the newly developed manufacturing techniques and analytical models.

Ellis, David L.↗

The initial lunar supply base

The first lunar supply base should have a mass less than 1000 tons, be deployed by 24 persons in 4 months, and be maintained by 10 persons. Output could be expanded 20 times in 5 years to 600,000 tons/yr by a factor of 10 expansion of the area of the solar array on the lunar surface, using low power soil beneficiation, increasing the fleet of mining vehicles, and illuminating the base continuously at night with lunar orbiting mirrors. The space manufacturing facility (SMF) will supply most of the mass (solar cells and orbiting mirrors) necessary for expansion. Several devices and procedures are suggested for development which could further reduce the total mass necessary to transport to the Moon to establish the initial lunar supply base.

Criswell, D.↗

Apollo experience report: Lunar module structural subsystem

In the Apollo Program, the lunar-orbit rendezvous mode was used for the lunar-landing mission. To accomplish the lunar landing, a lunar module spacecraft was built. A description of the design requirements for the structural subsystem and of the structural configuration and the method of design verification are given. A discussion is presented of several problems encountered and the corrective actions taken during the designing, manufacturing, and testing of the lunar module.

Weiss, S. P.↗

Geopolymer Lunar Concrete under Reduced-Pressure Curing and Vacuum Exposure

Geopolymer concrete has emerged as a promising material for constructing habitats, roads, landing pads, and other necessary infrastructure on the lunar surface. Proper in-situ resource utilization (ISRU) is an important aspect of any candidate lunar construction material. Geopolymer concrete is effective at ISRU, as the lunar regolith can be used in the “as found” condition and mixed with an alkaline solution, such as sodium silicate and sodium hydroxide, which could also be mostly produced in-situ. It is envisioned that any concrete material on the lunar surface would be deposited with additive manufacturing techniques and would require a temporary environmental enclosure to mitigate the harsh lunar environment during construction and curing, such as pressure and temperature. Data are needed to set a benchmark for the conditions to be achieved within the deployable environmental enclosure during printing, as well as the resultant material properties after the enclosure is removed. This novel study investigated the influence of reduced atmospheric pressures during the initial curing period on the compressive strength of geopolymer lunar concrete created with two types of lunar regolith simulant. The simulants used in the study represent the regolith for the lunar mare (OPRL2N) and lunar highlands (OPRH2N) regions. Results show a noticeable decline in strength with a reduction in pressure and visible degradation. After the deployable environmental enclosure is removed from the printed segment of infrastructure on the lunar surface, it would then be exposed to the harsh vacuum environment. To understand the importance of curing time required within the deployable enclosure before it is removed, samples were cast and cured for different lengths of time and then exposed to a vacuum chamber capable of achieving 100 mTorr. Control samples were also cast at the same time but left in a standard laboratory environment after curing. The weight change and compressive strength as a function of time in the vacuum chamber were monitored for up to 56 days. The results showed that exposure to the vacuum limits further reaction and strength gain in comparison to control samples left in the laboratory environment. This research is in strong alignment with the 2020 NASA Technology Taxonomy materials area (12.1) and the in-situ resource utilization area (7.1), as it provides necessary data on the geopolymer lunar concrete material to support safe and sustainable options for maintaining a human presence on the Moon.

Moon to Mars Planetary Autonomous Construction Tec↗

Outfitting the In-Space Manufacturing Advancement Center (ISMAC)

Marshall Space Flight Center has begun investment into a new collaborative workspace where ISM technologies can be advanced utilizing multidisciplinary teams. Equipment has been commissioned to explore ISM technologies related to electronics, welding, additive manufacturing, recycling, and metal extraction from Lunar or Martian regolith. This is an overview of the latest capabilities outfit to the new In-Space Manufacturing Advancement Center.

In-Space Manufacturing↗

Small optical telescopes on the moon.

Problems associated with the design and operation of efficient lunar-based telescopes are discussed. The various types of reflecting telescopes and catadioptric optical systems developed so far are characterized and compared. Requirements concerning mounting of a telescope on the lunar surface are examined. Properties of materials to be used in manufacturing telescopes for a safe operation in the lunar environment are considered. Finally, the telescope size is dealt with.

Wells, E. H.↗

NASA LSII Lunar Simulant Project

Introduction: America has entered a new era of exploration. NASA’s Artemis program will lead humanity forward to the Moon and prepare us for the next giant leap, the exploration of Mars [1]. To champion technologies needed to live on and explore the Moon, NASA’s Space Technology Mission Directorate (STMD) established the Lunar Surface Innovation Initiative (LSII)[2].LSII's technology development portfolio includes: Utilizing the Moon’s resources; Establishing sustainable surface power; Building machinery and electronics that work in extreme environments, like super-chilly permanently shadowed craters; Mitigating lunar dust; Carrying out surface excavation, manufacturing and construction duties; and Extreme access which includes navigating and exploring the surface/subsurface. To support the development and testing of these technologies, LSII created the lunar simulant project, to create and/or acquire low-, medium-and high-fidelity lunar simulants to match the needs of STMD projects at all levels of technology readiness levels (TRL), as well as other NASA programs. There is not one bulk lunar simulant that will satisfy the needs of all projects. NASA's Approach to Simulants: Just as LSII's activities are being implemented through a combination of unique NASA work and public-private partnerships, NASA will work with commercial simulant providers to acquire simulants that meet NASA's needs. If warranted, NASA will develop simulants using government agencies, as was done with the NASA/USGS Lunar Highlands Type (NU-LHT)series of lunar simulants [3].NASA is also collaborating with the Johns Hopkins University Applied Physics Laboratory(JHUAPL) Lunar Surface Innovation Consortium (LSIC) in the development and characterization of lunar simulants [4]. Within NASA, a small team (< 10 people) is coordinating simulant activities across the agency, with team members located at several NASA centers. The overall objective of the project is to procure lunar simulants in sufficient amounts for earth-based testing of subsystems and systems in a variety of environments (i.e., laboratory, high-bay, thermal-vacuum chambers), required for Artemis missions to the Moon, as well as other missions carrying NASA lunar payloads, such as the Commercial Lunar Payload Services (CLPS)program [5]. Lunar Highlands Simulant: NASA's Artemis Program is targeting the lunar south pole region for initial human missions and the Artemis Base Camp. Hence, the LSII lunar simulant project is currently focusing on the mineralogy and properties of lunar highlands regolith [6 and 7]. Plagioclase-rich rocks (e.g., anorthosite, norite) are the dominant constituent in highlands simulants, with Shawmere, Stillwater, and White Mountain anorthosites being used in commercially available simulants. However, because these feedstocks are terrestrial in nature, they include hydrated minerals, carbon-bearing minerals, and other chemical signatures that are not present on the Moon, and these minor mineral assemblages need to be taken into account when trying to understand test procedures and results. Glass Component: While much attention has been placed on the rock/mineral component of lunar simulants, glass is just as important when creating simulants. The glass component in lunar regoliths is often greater than 50% by volume [8]. This component includes impact melt glass, dark matrix breccias, and agglutinates. However, this component is difficult, time-consuming and expensive to make. Most lunar simulants, past and current, have relied on basaltic cinder as a feedstock for glass. Getting better glass components at a lower cost, particularly agglutinates and glass with an anorthositic composition is a near-term objective that the NASA simulant project is trying to address . Characterization: It is extremely important for lunar simulants to be characterized by several analytical methods. Gruener et al. [9] and JHUAPL LSIC [10] conducted initial assessments of some of the commercially available simulants in 2019 and early 2020, before the global pandemic. Further analyses are needed to better quantify important parameters such as, modal mineralogy and glass content, particle shape, and particle size distribution. These quantified results can then be used in determining figures of merit (FOM) that show how well simulants compare to lunar regolith [11 and 12].

J E Gruener↗

Moon-to-Mars Planetary Construction Technology (MMPACT) Scoop, Tamp, Filter (STF) Sub-System

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. This paper summarizes recent efforts to develop and test a scoop, tamp and filter (STF) sub-system to prepare and deposit lunar regolith for a laser-based vitreous material transformation system being developed under a NASA contract by ICON, inc., which is hoped to eventually be used for automated additive construction with indigenous regolith on the Moon.

Moon↗

Electron Beam Freeform Fabrication in the Space Environment

The influence of reduced gravitational forces (in space and on the lunar or Martian surfaces) on manufacturing processes must be understood for effective fabrication and repair of structures and replacement parts during long duration space missions. The electron beam freeform fabrication (EBF3) process uses an electron beam and wire to fabricate metallic structures. The process efficiencies of the electron beam and the solid wire feedstock make the EBF3 process attractive for use in-space. This paper will describe the suitability of the EBF3 process in the space environment and will highlight preliminary testing of the EBF3 process in a zero-gravity environment.

Hafley, Robert A.↗

Guidance and trajectory considerations in lunar mass transportation

Flight-mechanics problems associated with large-scale transport of lunar mass to a space colony or manufacturing facility are discussed. The proposed transport method involves launch of payloads from a mass-driver on the lunar surface, onto ballistic trajectories to a passive mass-catcher located near the L2 libration point, with the caught mass subsequently being transported to the colony. Arrival velocities at L2, sensitivities in arrival dispersion due to launch errors, and effects of launch site location are treated, via numerically integrated orbits in the restricted three-body problem. From any launch site it is possible to define a target point reached with zero dispersion due to errors in a selected component of launch velocity. Effects of lunar geometrical librations and of obliquity, as well as the conditions for biasing a trajectory away from L2 so as to reduce stationkeeping costs, are dealt with along with transfer orbits from L2 to the colony. The theory of capture and the theory of resonance lead to a colony orbit, with period approximately two weeks, reached from L2 with velocity increment as low as 9.02 m/sec.

Heppenheimer, T. A.↗

Extraterrestrial processing and manufacturing of large space systems. Volume 3: Executive summary

Facilities and equipment are defined for refining processes to commercial grade of lunar material that is delivered to a 'space manufacturing facility' in beneficiated, primary processed quality. The manufacturing facilities and the equipment for producing elements of large space systems from these materials and providing programmatic assessments of the concepts are also defined. In-space production processes of solar cells (by vapor deposition) and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, converters, and others are described.

Miller, R. H.↗

Structural Efficiency of Composite Struts for Aerospace Applications

The structural efficiency of carbon-epoxy tapered struts is considered through trade studies, detailed analysis, manufacturing and experimentation. Since some of the lunar lander struts are more highly loaded than struts used in applications such as satellites and telescopes, the primary focus of the effort is on these highly loaded struts. Lunar lander requirements include that the strut has to be tapered on both ends, complicating the design and limiting the manufacturing process. Optimal stacking sequences, geometries, and materials are determined and the sensitivity of the strut weight to each parameter is evaluated. The trade study results indicate that the most efficient carbon-epoxy struts are 30 percent lighter than the most efficient aluminum-lithium struts. Structurally efficient, highly loaded struts were fabricated and loaded in tension and compression to determine if they met the design requirements and to verify the accuracy of the analyses. Experimental evaluation of some of these struts demonstrated that they could meet the greatest Altair loading requirements in both tension and compression. These results could be applied to other vehicles requiring struts with high loading and light weight.

Jegley, Dawn C.↗

Development and Manufacture of A Proof-of-Concept Magnetically-Geared Actuator for Use in Extremely Cold Lunar Environments

A magnetically-geared actuator is being developed for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. This paper describes the lessons learned while designing, manufacturing, and assembling a proof-of-concept prototype similar to the preliminary design of the actuator.

lunar surface↗

Development and Manufacture of A Proof-of-Concept Magnetically-Geared Actuator for Use in Extremely Cold Lunar Environments

A magnetically-geared actuator is being developed for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. This paper describes the lessons learned while designing, manufacturing, and assembling a proof-of-concept prototype similar to the preliminary design of the actuator.

lunar surface↗