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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 NTRS2017

Supportability Challenges, Metrics, and Key Decisions for Future Human Spaceflight

Future crewed missions beyond Low Earth Orbit (LEO) represent a logistical challenge that is unprecedented in human space flight. Astronauts will travel farther and stay in space for longer than any previous mission, far from timely abort or resupply from Earth. Under these conditions, supportability { defined as the set of system characteristics that influence the logistics and support required to enable safe and effective operations of systems { will be a much more significant driver of space system lifecycle properties than it has been in the past. This paper presents an overview of supportability for future human space flight. The particular challenges of future missions are discussed, with the differences between past, present, and future missions highlighted. The relationship between supportability metrics and mission cost, performance, schedule, and risk is also discussed. A set of pro- posed strategies for managing supportability is presented (including reliability growth, uncertainty reduction, level of repair, commonality, redundancy, In-Space Manufacturing (ISM) (including the use of material recycling and In-Situ Resource Utilization (ISRU) for spares and maintenance items), reduced complexity, and spares inventory decisions such as the use of predeployed or cached spares - along with a discussion of the potential impacts of each of those strategies. References are provided to various sources that describe these supportability metrics and strategies, as well as associated modeling and optimization techniques, in greater detail. Overall, supportability is an emergent system characteristic and a holistic challenge for future system development. System designers and mission planners must carefully consider and balance the supportability metrics and decisions described in this paper in order to enable safe and effective beyond-LEO human space flight.

Owens, Andrew C.↗
NASA NTRS2017

Oxygen Storage Tanks Are Feasible for Mars Transit

The Mars transit tanks will probably be titanium lined, composite over wrapped pressure vessels (COPVs) similar to those used in the space shuttle and International Space Station(ISS). Since the mass of a storage tank is proportional to the mass of the gas it contains, the required oxygen will use about the same mass of tanks regardless of the number and size ofthe tanks. Using existing relatively small COPVs is possible. Pressure vessels can fail due torupture and leakage but no failures have occurred in space and the expected failure rates are very low. Since one or two spare tanks are required for reliability, using smaller tanks can reduce the total mass. For a Mars round trip, the mass of oxygen and tanks including spares is roughly equal to the mass of the ISS Oxygen Generation Assembly (OGA) and its spares. Since the OGA must orbit Mars and be returned to Earth, while half the storage tanks are emptied on the way to Mars and can be abandoned, storage tanks have a significant launch mass advantage over the OGA. Storage tanks are simpler, more reliable,and have fewer failure modes than an OGA. They would have smaller design and development costs and need less crew time and maintenance. Oxygen storage tanks are feasible for Mars transit and are attractive compared to the ISS OGA.

Jones, Harry W.↗
NASA NTRSDate not supplied

ECLSS Does Not Exist in a Vacuum: Integrated Analysis is Necessary to Inform System Architecture Decisions

Environmental Control and Life Support System (ECLSS) architecture selection has profound implications for mission cost and mass extending far beyond the ECLSS itself. Similarly, other mission architecture decisions – particularly involving transportation systems – can influence optimal ECLSS architectures. Loop closure influences requirements for water, oxygen, and other consumables. System maintainability and reliability influences spares mass and risk. System, consumables, and spares mass interact with transportation system architectures and propellant demands and propulsion element sizing. All these interactions with other systems must be considered when evaluating ECLSS options. Analyses that focus only on maximizing ECLSS loop closure – or minimizing ECLSS mass, or minimizing ECLSS life cycle cost – may lead to sub-optimal or even counterproductive system architecture and investment decisions at the mission level. For example, an ECLSS architecture that minimizes ECLSS lifecycle cost but results in excessively high logistics mass could lead to significantly increased transportation system costs or make interplanetary transportation infeasible. Increased loop closure could result in higher development costs and higher mass if system/spares mass increases outweigh consumables reduction. In addition, systems mass and consumables mass are not directly comparable and have different impacts on propellant requirements, as consumables mass changes over the course of the mission. This paper presents an integrated analysis examining the overall impact of different ECLSS and transportation architectures on mass for a crewed Mars mission, including the habitat and transportation systems as well as consumables, spares, and propellant. Key observations are discussed, along with opportunities for further sensitivity analysis and model development. Overall, ECLSS development activities must consider their impacts at the mission level, as part of an integrated system, rather than in isolation.

Systems Analysis↗
NASA NTRSDate not supplied

Integrated Trajectory, Habitat, and Logistics Analysis and Trade Study for Human Mars Missions

Environmental Control and Life Support System (ECLSS) architecture selection has profound implications for mission cost and mass extending far beyond the ECLSS itself. Similarly, other mission architecture decisions – particularly involving transportation systems – can influence optimal ECLSS architectures. Loop closure influences requirements for water, oxygen, and other consumables. System maintainability and reliability influences spares mass and risk. System, consumables, and spares mass interact with transportation system architectures and propellant demands and propulsion element sizing. All these interactions with other systems must be considered when evaluating ECLSS options. Analyses that focus only on maximizing ECLSS loop closure – or minimizing ECLSS mass, or minimizing ECLSS life cycle cost – may lead to sub-optimal or even counterproductive system architecture and investment decisions at the mission level. For example, an ECLSS architecture that minimizes ECLSS life cycle cost but results in excessively high logistics mass could lead to significantly increased transportation system costs or make interplanetary transportation infeasible. Increased loop closure could result in higher development costs and higher mass if system/spares mass increases outweigh consumables reduction. In addition, systems mass and consumables mass are not directly comparable and have different impacts on propellant requirements, as consumables mass changes over the course of the mission. This paper presents an integrated analysis examining the overall impact of different ECLSS and transportation architectures on mass for a crewed Mars mission, including the habitat and transportation systems as well as consumables, spares, and propellant. Key observations are discussed, along with opportunities for further sensitivity analysis and model development. Overall, ECLSS development activities must consider their impacts at the mission level, as part of an integrated system, rather than in isolation.

Mars↗
NASA NTRSDate not supplied

Integrated Trajectory, Habitat, and Logistics Analysis and Trade Study for Human Mars Missions

Environmental Control and Life Support System (ECLSS) architecture selection has profound implications for mission cost and mass extending far beyond the ECLSS itself. Similarly, other mission architecture decisions – particularly involving transportation systems – can influence optimal ECLSS architectures. Loop closure influences requirements for water, oxygen, and other consumables. System maintainability and reliability influences spares mass and risk. System, consumables, and spares mass interact with transportation system architectures, including propellant demands and propulsion element sizing. All these interactions with other systems must be considered when evaluating ECLSS options. Analyses that focus only on maximizing ECLSS loop closure – or minimizing ECLSS mass, or minimizing ECLSS life cycle cost – may lead to sub-optimal or even counterproductive system architecture and investment decisions at the mission level. For example, an ECLSS architecture that minimizes ECLSS life cycle cost but results in excessively high logistics mass could lead to significantly increased transportation system costs or make interplanetary transportation infeasible. Increased loop closure could result in higher development costs and higher mass if system/spares mass increases outweigh consumables reduction. In addition, systems mass and consumables mass are not directly comparable and have different impacts on propellant requirements, as consumables mass changes over the course of the mission. This paper presents an integrated analysis examining the overall impact of different ECLSS and transportation architectures on Earth departure mass for a crewed Mars mission, including the habitat and transportation systems as well as consumables, spares, and propellant. Key observations are discussed, along with opportunities for further sensitivity analysis and model development. Overall, ECLSS development activities must consider their impacts at the mission level, as part of an integrated system, rather than in isolation.

Mars↗
NASA NTRSDate not supplied

Analysis and Optimization of Test Plans for Advanced Exploration Systems Reliability and Supportability

Future crewed exploration missions beyond Low Earth Orbit (LEO) will operate farther from Earth and be logistically isolated for longer than any previous human spaceflight mission. Under these conditions, supportability and reliability willbestronger drivers of mission mass and risk than they have been in the past. Items with high failure rates, or uncertain failure rates, can result in high spares mass requirements and/or high risk on deep space missions. Testing is a critical element of system development which provides the opportunity to identify and resolve design issues, defects, or other failure modes before they cause problems during a mission. Reliability growth programs can reduce failure rates by identifying and remove failure modes via design changes, and long-duration life testing can provide valuable data to reduce failure rate estimate uncertainty and verify (to some level of confidence) that components are as reliable as expected. Testing activities take time and resources, however, and must be incorporated into program plans in order to be fully effective. This paper presents an integrated reliability test plan analysis and optimization methodology, which has been used to inform Advanced Exploration Systems (AES) Life Support Systems (LSS) ground test planning for future missions. The methodology determines the optimal number of test units to purchase and allocation of test time –split between reliability growth and uncertainty reduction testing –across a given set of items in order to minimize spares mass for a given mission under constraints on total test cost and schedule. Model outputs also include expected spares mass after testing and the expected number of modifications or refurbishments during testing, both of which can inform program planning. Discussion of the model, conclusions, and future work are also presented.

Testing↗
NASA NTRSDate not supplied

Analysis and Optimization of Test Plans for Advanced Exploration Systems Reliability and Supportability

Future crewed exploration missions beyond Low Earth Orbit (LEO) will operate farther from Earth and be logistically isolated for longer than any previous human spaceflight mission. Under these conditions, supportability and reliability willbestronger drivers of mission mass and risk than they have been in the past. Items with high failure rates, or uncertain failure rates, can result in high spares mass requirements and/or high risk on deep space missions. Testing is a critical element of system development which provides the opportunity to identify and resolve design issues, defects, or other failure modes before they cause problems during a mission. Reliability growth programs can reduce failure rates by identifying and remove failure modes via design changes, and long-duration life testing can provide valuable data to reduce failure rate estimate uncertainty and verify (to some level of confidence) that components are as reliable as expected. Testing activities take time and resources, however, and must be incorporated into program plans in order to be fully effective. This paper presents an integrated reliability test plan analysis and optimization methodology, which has been used to inform Advanced Exploration Systems (AES) Life Support Systems (LSS) ground test planning for future missions. The methodology determines the optimal number of test units to purchase and allocation of test time –split between reliability growth and uncertainty reduction testing –across a given set of items in order to minimize spares mass for a given mission under constraints on total test cost and schedule. Model outputs also include expected spares mass after testing and the expected number of modifications or refurbishments during testing, both of which can inform program planning. Discussion of the model, conclusions, and future work are also presented.

Testing↗
NASA NTRSDate not supplied

Surface Hardness Testing of Mobile Launcher 1 (ML-1) Vehicle Support Posts (VSP) Following Artemis I Launch Exposure

Following the successful launch of Artemis I on November 16th, 2022 (Fig 1), a surface hardness assessment was performed on the eight primary VSPs (Figs. 2, 3) located on the Zero Deck of the ML. This assessment was performed as part of an instrument investigation for strain gauges installed on VSP interior surfaces that had a “strange reaction”. This report does not address the VSP strain gauge investigation, but rather VSP structural integrity for future service (Artemis II, III, …). Surface hardness measurements were taken to assess the strength of the ASTM A148 steel castings to confirm thermal exposure from launch had not reannealed the VSPs. However unlikely, it is possible high temperature may have heated and tempered (reannealed) the VSPs, resulting in a change of built-in stresses. This loss in built-in stress may explain the change in off-set measured by the strain gauges. Initial hardness measurements were made at two interior surfaces of VSPs near the strain gauges and the corresponding exterior surfaces (engine hole-facing). Field hardness measurements on the exterior, engine hole surface-facing surfaces for all eight VSPs ranged from 175 to 226 HB/P, well below the minimum hardness of 302 Brinell (HB). Opposing interior surface hardness measurements near strain gauges ranged from 264 to 358 HB/P. In all cases for flight VSPs, a drop in interior-to-exterior hardness ranging from 70 to 132 HB/P was measured. Surface hardness measurements were then made on the two spare VSPs not exposed to launch temperatures for baseline comparison. These two spare VSPs had a drop in Brinell hardness from interior to exterior surfaces ranging from 3 to 17 HB/P. The large interior-to-exterior delta hardness for eight flight VSPs but not for the two spare VSPs suggests launch exposure temperatures softened the exterior surfaces, raising two questions: 1) Are the VSPs compromised for future use, and 2) How deep is the exterior surface softening effect? To address concerns of low surface hardness values at non-critical exterior surfaces, additional field surface hardness measurements were taken at high-stress locations on VSP3: Both door jams, back radius, and internal left and right radius near the base. These values came in well above the required minimum hardness (317 to 365 HB/P). For a more representative pre-launch versus post-launch surface hardness comparison, VSP Acceptance Data Packages (ADPs) were reviewed, and hardness measurements were made at the same eight original locations on VSP3 where hardness measurements were made at the foundry. To determine the degree of softening, 1/8” of material was machined away at three exterior surfaces of engine hole-facing side (Fig. 4). A significant increase in surface hardness was measured ranging from 50 to 86 HB/P. Values at these three locations were still slightly below the required minimum hardness, so an additional 1/8” material was machined away, and hardness values were retaken. At the ¼” depth, hardness values increased to 321 to 324 HB/P. These values fall above the required minimum, concluding surface hardness testing. Rationale for VSP continued use was reached with no restrictions during a Chief Engineering Review based on hardness values exceeding minimum at critical locations and subsurface locations for VSP #3.

Artemis I↗
NASA NTRSDate not supplied

More Data Needed for Failure Rate Estimation, Validation, and Uncertainty Reduction

Current Environmental Control and Life Support System (ECLSS) development and test activities are not generating data fast enough to provide statistically-supportable precise Orbital Replacement Unit (ORU) failure rate estimates for future missions. Accurate and precise failure rate estimates are critical for missions beyond Low Earth Orbit (LEO) because current risk mitigation approaches – namely regular resupply and rapid abort capabilities – will not be available. Safe operations will depend on mission planners’ ability to accurately forecast spares demand and efficiently provide the necessary resources. However, even after more than a decade of operations on board the International Space Station (ISS), a significant amount of uncertainty remains in failure rate estimates. Uncertain or inaccurate failure rates result in increased risk and spares mass for future missions. A Bayesian failure rate estimation approach, such as the one currently implemented by the ISS Program, can help reduce uncertainty by incorporating engineering judgement into failure rate estimates. However, experience on the ISS and with other complex systems shows that these prior failure rate estimates are often inaccurate. In addition, prior failure rate estimates are typically point values; some level of uncertainty must be added to convert these into probability distributions for Bayesian updating, and there are several potential methods for doing so. Due to the low rate of data collection, these subjective (and often inaccurate) prior estimates currently have a strong influence on the end result. This paper examines the challenges associated with failure rate estimation, validation, and uncertainty reduction in the context of ECLSS development for beyond-LEO missions. A variety of techniques for generating and updating Bayesian priors are discussed and evaluated using both real-world and simulated data. Potential solutions for improving failure rate estimation, including testing additional units, are analyzed and discussed, and a set of recommendations are provided for next-generation system development activities.

Supportability↗
NASA NTRS1971

Hybrid redundancy system for improving reliability - A concept

System combines two concepts - triple modular redundancy (TMR) and spares (replacement system) redundancy. System has triplicated active unit core with associated bank of specifically arranged standby spare units. Curves plotted from characteristic equation show hybrid system is more reliable than conventional TMR systems.

Mathur, F. P.↗
NASA NTRS1973

A reliability and comparative analysis of two standby system configurations.

Equations are derived which enable one to calculate the system reliability for parallel or triple modular redundant systems with standby spares. Software error detection is introduced into the TMR/Spares system configuration in order to utilize fully all of the units. An indication of the sensitivity of the system reliability to an increase in the number of spares, partitioning, switching, variations in the powered and unpowered failures rates, and time is presented. A comparison of the parallel and the TMR/Spares system configurations, under similar conditions, is given.

Taylor, D. S.↗
NASA NTRS1974

Skylab program. Earth resources experiment package. Sensor performance report. Volume 7 (S190B): SL2, SL3 and SL4 evaluations

The S190B Earth Terrain Camera (ETC) operated acceptably for all of its scheduled EREP passes throughout the SL2 mission. The crew reported no problems in unstowing the camera, changing filters, installing the ETC window in the SAL, or installing the camera onto the window. The ETC was operated for a total of seven times with no failures. The clock on the ETC was checked on DOY 170 (June 19, 1973) and was found to be 30 min. and 58 sec. slower than GMT. The change in time was expected since a similar circumstance was experienced during ETC qualification testing for launch vibration. A leak existed in the seal of the spare magazine to the camera vacuum interface. For EREP passes 08 and 10, black-and-white film EK 3414 (roll no. 82) was installed in this spare magazine. Since there was an audible hiss, the vacuum hose was not connected to the camera. This caused the vacuum platen to be inoperable, resulting in some degradation in resolution for this roll of film. The vegetation of the South American jungle areas proved to be much darker than vegetation found in the United States, and was consequently about 1/2 stop underexposed in all cases.

Kenney, G. P.↗
NASA NTRS1975

Early Mariner comet flyby

An inexpensive first mission to a faint short period comet utilizing the spare Mariner Venus/Mercury spacecraft is studied with regard to science rationale and instrumentation and engineering feasibility and design. The spare Mariner spacecraft, suitably modified, is shown to be compatible with science requirements of a first comet flyby. Important aspects of this early mission would be penetration of the comet's gaseous coma and the approach of the nucleus to within hundreds of km in order to obtain in situ measurements and imaging that will help to establish comet science models and determine the hazards of a comet environment to future comet missions.

Nock, K. T.↗
NASA NTRS1976

Reliability and coverage analysis of non-repairable fault-tolerant memory systems

A method was developed for the construction of probabilistic state-space models for nonrepairable systems. Models were developed for several systems which achieved reliability improvement by means of error-coding, modularized sparing, massive replication and other fault-tolerant techniques. From the models developed, sets of reliability and coverage equations for the systems were developed. Comparative analyses of the systems were performed using these equation sets. In addition, the effects of varying subunit reliabilities on system reliability and coverage were described. The results of these analyses indicated that a significant gain in system reliability may be achieved by use of combinations of modularized sparing, error coding, and software error control. For sufficiently reliable system subunits, this gain may far exceed the reliability gain achieved by use of massive replication techniques, yet result in a considerable saving in system cost.

Cox, G. W.↗
NASA NTRS1984

Optimal inventories for overhaul of repairable redundant systems - A Markov decision model

A Markovian decision model was developed to calculate the optimal inventory of repairable spare parts for an avionics control system for commercial aircraft. Total expected shortage costs, repair costs, and holding costs are minimized for a machine containing a single system of redundant parts. Transition probabilities are calculated for each repair state and repair rate, and optimal spare parts inventory and repair strategies are determined through linear programming. The linear programming solutions are given in a table.

Schaefer, M. K.↗
NASA NTRS1988

Automated generation of reliability models

The abstract semi-Markov specification interface to the SURE (Semi-Markov Range Evaluator) tool (ASSIST) program allows the user to describe the Markov model in a high-level language. Instead of listing the individual states of the model, the user specifies the rules governing the behavior of the system, and these are used to automatically generate the model. A small number of statements in the abstract language can describe a large, complex model. Becuase no assumptions are made about the system being modeled, ASSIST can be used to generate models describing the behavior of any type of system. The abstract model definition and the automatic model generation strategy are described. Analysis of an example fault-tolerant architecture, a triad of processor with cold spare processors, shows how the behavior of a system can be captured by a few general rules. The syntax of the ASSIST input language is then described and demonstrated by creating a model to describe the fault behavior of the example architecture. The flexibility of the abstract language is demonstrated by expanding the example to model multiple triads of processors sharing a pool of cold spare processors.

Johnson, Sally C.↗
NASA NTRS1988

Space station electrical power system availability study

ARINC Research Corporation performed a preliminary reliability, and maintainability (RAM) anlaysis of the NASA space station Electric Power Station (EPS). The analysis was performed using the ARINC Research developed UNIRAM RAM assessment methodology and software program. The analysis was performed in two phases: EPS modeling and EPS RAM assessment. The EPS was modeled in four parts: the insolar power generation system, the eclipse power generation system, the power management and distribution system (both ring and radial power distribution control unit (PDCU) architectures), and the power distribution to the inner keel PDCUs. The EPS RAM assessment was conducted in five steps: the use of UNIRAM to perform baseline EPS model analyses and to determine the orbital replacement unit (ORU) criticalities; the determination of EPS sensitivity to on-orbit spared of ORUs and the provision of an indication of which ORUs may need to be spared on-orbit; the determination of EPS sensitivity to changes in ORU reliability; the determination of the expected annual number of ORU failures; and the integration of the power generator system model results with the distribution system model results to assess the full EPS. Conclusions were drawn and recommendations were made.

Turnquist, Scott R.↗
NASA NTRS1989

Hubble Space Telescope maintenance and refurbishment planning analysis

This paper presents an updated analytical approach toward the identification of Hubble Space Telescope system failures and downstates, maintenance requirements, and overall support to maintenance mission planning. Different sparing options of Orbital Replacement Units are evaluated, and the optimum spares complement that satisfies the expected servicing requirements is identified. Specific Space Telescope Reliability and maintenance Simulation Computer Program (SPATEL) updates and refinements are reported, and input data updates relevant to failure rates, downstate ground rules, and maintenance policy are addressed. A summary of the latest SPATEL outputs is provided along with maintenance analysis results.

Pizzano, F.↗