Results for “spaceflight hardware” — Page 6

NASA NTRSDate not supplied

In-Space Inspection Needs: Opportunities for advanced NDE tools such as x-ray CT for additively manufactured parts, in-situ resource utilization, geological applications, and more

It is now 50 years since the first human presence on the surface of the Moon and as we strive to return with women and men in the next few years, we embrace new technical challenges, goals, and innovative solutions to address 21st century objectives. These new ambitions carry fresh challenges and risks, with the field of NDE playing an increasingly more relevant role towards meeting these essential goals. In recent years, more advanced NDE tools have triggered a rapid expansion of applications for the space industry. In particular, x-ray Computed Tomography (CT) has proven to be a trusted and powerful asset for spaceflight hardware inspection, as well as applied geotechnical analysis for natural materials (e.g., rocks, soils) for NASA and across industry. However, such methods have yet to be extended to “deep space” applications such as those that are now part of the US National Space Policy Directive (SPD-1) and the accelerated push to return humans to the Moon (i.e., Artemis). For this reason, advancing these powerful Earth-based laboratory methods via new technologies, integrated computational solutions, and creative engineering approaches is directly aligned with national space policies, as well as with multiple NASA Strategic Plan priorities. The use of x-ray CT at scales as fine as a few microns or smaller can identify spacecraft part failure modes relevant to quality assurance for flight hardware and AM parts such as those recently developed for ISS. This technology could also identify valuable metallic phases within geological materials (i.e., rocks or drill cores), enabling resource-relevant triage of samples for In-Situ Resource Utilization (ISRU) and high science value sample return to Earth laboratories. There is also significant application for 3D imaging tools for medical use such as inspecting protective gear as well as bone density degradation studies which are critical in establishing a sustained presence in space. Timing for development of these tools for space use is advantageous as we prepare for new opportunities in the next few years and recognize recent commercial technology advancements which make it feasible. Moreover, as NASA strives to take full advantage of developments in AM technologies, including In-Space Manufacturing (ISM), it is widely recognized that NDE tools such as CT will play an essential role in acceptance of these parts for widespread use. New in-space 3D inspection tools with complimentary technology such as AI-based automated feature recognition (accelerated by machine learning), rapid compositional analysis, and advanced sample manipulation, would be a game-changing step toward a new class of crew-based laboratory sensors once human outposts on the Moon are established.

In-Space Non-Destructive Evaluation↗

NASA NTRS2022

A Survey of NASA Standard Nondestructive Evaluation (NDE)

This document provides a comprehensive review to trace the evolution of NASA’s Standard nondestructive evaluation (NDE) flaw sizes provided in NASA-STD-5009B for fracture-critical metallic spaceflight hardware. A NASA Standard NDE flaw size is considered to be conservative such that most inspectors, trained and certified in the specific method, are expected to provide the required 90/95 probability of detection (POD) for that flaw size. As such, individual certified inspectors are not required to perform POD demonstration testing to be allowed to inspect fracture-critical hardware for that specific method.

Probability of Detection↗

NASA NTRSDate not supplied

Developing Approaches for Certification of Uninspectable Fracture Critical AM Components

Introduction - Human-rated spaceflight hardware is subject to the Fracture Control requirements in NASA-STD5019, which are intended to control the risk of component failure due to undetected cracks or defects. - All hardware in this mission class is classified for Fracture Control – Exempt, Non-fracture Critical, or Fracture Critical - Fracture Critical: A classification that identifies a part where failure due to the presence of a crack is a catastrophic hazard ➔ Pressure vessels, engine components, primary structure, etc. - Axiom 1: Material and manufacturing process produce structures and components with cracks or defects. - Axiom 2: The presence of a crack or defect of sufficient size reduces the strength and life of the structure. - Damage Tolerance: demonstration that a component can survive the service life (with a safety factor) in the presence of an undetected flaw or damage. - Components are manufactured from aerospace quality materials using controlled processes. - Components are inspected for damage (cracks, flaws, defects, etc.). - Components are shown by test or analysis to be tolerant to undetected flaws.

Will Tilson↗

NASA NTRSDate not supplied

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

NASA NTRSDate not supplied

Critical Current Stability of 2G REBCO Tape for Space-Flight HTS Leads

High reliability is an essential requirement for all spaceflight hardware. XRISM, a follow-on mission to the Hitomi x-ray observatory, also uses 2G REBCO tapes as current leads for the superconducting magnets that are a key component of the Adiabatic Demagnetization Refrigerator (ADR) that cools the detector array. While the Hitomi Soft X-ray Spectrometer (SXS) worked flawlessly in orbit, during its development there were indications that the critical current of its specialized REBCO tapes could degrade over time when exposed to normal-humidity air. To demonstrate that the updates to the XRISM HTS lead assemblies had mitigated this risk, a series of tests were carried out to measure the stability of Ic of dozens of samples over a period greater than the flight assemblies were exposed to air during integration and test. The test rig allowed not only the measurement of the sample Ic, but also the localization of the voltage rise as the current approached Ic. We will discuss the trends in the critical current of the samples, as well as localization of lower Ic regions.

Edgar R. Canavan↗

NASA NTRSDate not supplied

Enabling Intelligent Data Downlink Prioritization of In-Situ Observations through Generalizable and Computationally Inexpensive Anomaly Detection

High-fidelity measurements of magnetic fields and other observed properties, such as energetic particle fluxes, are a necessary component to our understanding of the highly dynamic near-Earth space environment. As our desire to study smaller-scale phenomena such as shocks and dipolorizations has increased, we have been driven to take and telemeter measurements at higher cadences. Unfortunately, many missions are unable to downlink all their captured data due to the well-known data transmission bottleneck at the DSN. These missions must then prioritize their high-cadence data such that the most scientifically useful intervals are transmitted. One simple prioritization technique uses the spacecraft position to telemeter data from only the region of interest. Although easy to implement, this method does not leverage the available scientific data and can omit intervals of useful scientific data when they lie outside the region of interest. The Magnetospheric Multiscale Mission (MMS) uses mission-specific parameterization of several data products to automatically prioritize scientifically useful intervals. Then, MMS verifies the automatically selected intervals by having a domain expert manually select intervals for downlink. The overall complexity required by this technique make it prohibitive for deployment on low-cost platforms (i.e., CubeSats) or on future missions featuring large constellations of satellites such as the Geospace Dynamics Constellation (GDC). We present preliminary results for a simple, generic, and data-driven method of downlink prioritization for magnetic field (and other) measurements. Specifically, Principal Components Analysis (PCA) and One-Class Support Vector Machines (OC-SVMs) are used to detect intervals containing anomalous activity, which can then be prioritized for subsequent downlink. The computational simplicity of this algorithm makes it an excellent candidate for implementation on spaceflight hardware, as well as provide generalizability to a broad range of missions and data products. Initial analysis of this technique has been performed using magnetic field measurements from the Magnetospheric Multiscale Mission and CASSIOP, where it automatically identified scientifically interesting intervals containing Alfvén waves and EMIC activity.

Matthew G. Finley↗

NASA NTRSDate not supplied

An Optimization-Based Toolchain for Parametric Mechanism Design

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

NASA NTRSDate not supplied

Parametric Optimization of Rigid Wheels for Planetary Surface Mobility Applications

Design-Build-Test approaches for spaceflight hardware are time and cost intensive, which can result in suboptimal mechanism designs. Optimization-based approaches that utilize high-fidelity models and physics simulation could overcome these limitations while simultaneously speeding up the mechanical design process and reducing cost. In this work, we present a toolchain that enables the multi-objective optimization of rigid rover wheels for planetary surface mobility applications. The toolchain uses Chrono’s Continuous Representation Model (CRM) functionality to simulate granular soil and performs multi-objective parametric optimization on candidate rover wheels to meet a desired performance criterion. The resulting wheel design is then evaluated experimentally using a single-wheel testbed. We end with a discussion of how the toolchain can be extended to simultaneously co-optimize other system parameters, such as system power consumption and feedback control gains.

Optimization↗

NASA NTRSDate not supplied

Enabling Intelligent Data Downlink Prioritization of In-Situ Observations through Generalizable and Computationally Inexpensive Anomaly Detection

High-fidelity measurements of magnetic fields and other observed properties, such as energetic particle fluxes, are a necessary component to our understanding of the highly dynamic near-Earth space environment. As our desire to study smaller-scale phenomena such as shocks and dipolorizations has increased, we have been driven to take and telemeter measurements at higher cadences. Unfortunately, many missions are unable to downlink all their captured data due to the well-known data transmission bottleneck at the DSN. These missions must then prioritize their high-cadence data such that the most scientifically useful intervals are transmitted. One simple prioritization technique uses the spacecraft position to telemeter data from only the region of interest. Although easy to implement, this method does not leverage the available scientific data and can omit intervals of useful scientific data when they lie outside the region of interest. The Magnetospheric Multiscale Mission (MMS) uses mission-specific parameterization of several data products to automatically prioritize scientifically useful intervals. Then, MMS verifies the automatically selected intervals by having a domain expert manually select intervals for downlink. The overall complexity required by this technique make it prohibitive for deployment on low-cost platforms (i.e., CubeSats) or on future missions featuring large constellations of satellites such as the Geospace Dynamics Constellation (GDC). We present preliminary results for a simple, generic, and data-driven method of downlink prioritization for magnetic field (and other) measurements. Specifically, Principal Components Analysis (PCA) and One-Class Support Vector Machines (OC-SVMs) are used to detect intervals containing anomalous activity, which can then be prioritized for subsequent downlink. The computational simplicity of this algorithm makes it an excellent candidate for implementation on spaceflight hardware, as well as provide generalizability to a broad range of missions and data products. Initial analysis of this technique has been performed using magnetic field measurements from the Magnetospheric Multiscale Mission and CASSIOP, where it automatically identified scientifically interesting intervals containing Alfvén waves and EMIC activity.

Matthew G. Finley↗

NASA NTRSDate not supplied

Optimization-Based Parametric Design via High-Fidelity Simulation: Overview + Examples

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This talk presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation and includes example applications related to rigid wheel design for autonomous rovers and computational fluid dynamics.

optimization↗

NASA NTRS1973

Life sciences payload definition and integration study, task C and D. Volume 4: Preliminary equipment item specification catalog

A specification catalog to define the equipment to be used for conducting life sciences experiments in a space laboratory is presented. The specification sheets list the purpose of the equipment item, and any specific technical requirements which can be identified. The status of similar hardware for ground use is stated with comments regarding modifications required to achieve spaceflight qualified hardware. Pertinent sketches, commercial catalog sheets, or drawings of the applicable equipment are included.

Source record↗

NASA NTRS2015

State-of-the-Art Instrumentation Package to Support Model Organism Research in Space

Hardware was developed for the Ames student Fruit-Fly Experiment (AFEx) to support fly growth and analysis during spaceflight. The hardware consists of a 1.5U vented aluminum box that houses an acrylic habitat, video camera, LED lighting, and environmental sensors. Power is provided via two USB connectors, one of which also supports data downlink. While the hardware was designed for use with fruit flies, it will house plants on an upcoming mission and could be adapted for use with other systems.

Fruit-Fly Experiment↗

NASA NTRS2015

Embedded Thermal Control for Subsystems for Next Generation Spacecraft Applications

Thermal Fluids and Analysis Workshop, Silver Spring MD NCTS 21070-15. NASA, the Defense Department and commercial interests are actively engaged in developing miniaturized spacecraft systems and scientific instruments to leverage smaller cheaper spacecraft form factors such as CubeSats. This paper outlines research and development efforts among Goddard Space Flight Center personnel and its several partners to develop innovative embedded thermal control subsystems. Embedded thermal control subsystems is a cross cutting enabling technology integrating advanced manufacturing techniques to develop multifunctional intelligent structures to reduce Size, Weight and Power (SWaP) consumption of both the thermal control subsystem and overall spacecraft. Embedded thermal control subsystems permit heat acquisition and rejection at higher temperatures than state of the art systems by employing both advanced heat transfer equipment (integrated heat exchangers) and high heat transfer phenomena. The Goddard Space Flight Center Thermal Engineering Branch has active investigations seeking to characterize advanced thermal control systems for near term spacecraft missions. The embedded thermal control subsystem development effort consists of fundamental research as well as development of breadboard and prototype hardware and spaceflight validation efforts. This paper will outline relevant fundamental investigations of micro-scale heat transfer and electrically driven liquid film boiling. The hardware development efforts focus upon silicon based high heat flux applications (electronic chips, power electronics etc.) and multifunctional structures. Flight validation efforts include variable gravity campaigns and a proposed CubeSat based flight demonstration of a breadboard embedded thermal control system. The CubeSat investigation is technology demonstration will characterize in long-term low earth orbit a breadboard embedded thermal subsystem and its individual components to develop optimized operational schema.

Spacecraft Systems↗

NASA NTRS1981

Earth Radiation Budget Experiment instrument design status

The design configuration of Earth Radiation Budget Experiment (ERBE) instruments are presented. The ERBE scanners and nonscanners are discussed in terms of hardware and optical development, operational parameters, and calibration plans for ground and flight systems. The various instrument designs are given and described in detail. It is emphasized that the design goal is to approach state-of-the-art laboratory radiometric accuracies with spaceflight qualified hardware in an earth orbit environment with a projected operational lifetime of over two years. Accurate inputs to models of weather and climate are expected which will allow a better understanding of radiation transfer and the energy balance of the earth.

Kopia, L. P.↗

NASA NTRS2000

Multiprocessor DSP for real-time data processing on Earth orbiting scatterometers

The implementation of a Multi DSP radar signal processor for a Ku-Band Earth orbiting scatterometer is discussed. A testbed has been assembled using a combination of commercial DSP hardware and spaceflight components to evaluate the proposed multiprocessing approaches. Test results of real-time radar echo processing are presented, as well as proposed designs for future investigation.

digital signal processing scatterometer radar↗

NASA NTRS2013

Benefits, Consequences, and Uncertainties of Conventional (Exercise) Countermeasure Approaches

This presentation will review the pros, cons, and uncertainties of using exercise countermeasures in hypothetical long duration exploration missions. The use of artificial gravity and exercise will be briefly discussed. One benefit to continued use of exercise is related to our extensive experience with spaceflight exercise hardware and programming. Exercise has been a part of each space mission dating back to the 1960's when simple isometric and bungee exercises were performed in the Gemini capsule. Over the next 50 years, exercise hardware improved cumulating in today's ISS suite of exercise equipment: Cycle Ergometer with Vibration Isolation and Stabilization System (CEVIS), Treadmill (T2) and Advanced Resistive Exercise Device (ARED). Today's exercise equipment is the most robust ever to be flown in space and allows the variety and intensity of exercise that might reasonably be expected to maintain muscle mass and function, bone density and cardiovascular fitness. A second benefit is related to the large body of research literature on exercise training. There is a considerable body of supporting research literature including >40,000 peer reviewed research articles on exercise training in humans. A third benefit of exercise is its effectiveness. With the addition of T2 and ARED to our ISS exercise suite, crew member outcomes on standard medical tests have improved. Additionally exercise has other positive side effects such as stress relief, possible improvement of immune function, improved sleep, etc. Exercise is not without its consequences. The major cons to performance of in‐flight exercise are the time and equipment required. Currently crew are scheduled 2.5 hrs/day for exercise and there is considerable cost to develop, fly and maintain exercise hardware. While no major injuries have been reported on ISS, there is always some risk of injury with any form of exercise There are several uncertainties going forward; these relate mostly to the development of small compact robust effective exercise devices for the next generation of space vehicles. It is becoming increasingly apparent that high intensity exercise is required for maintenance of fitness and functional capability and so future hardware will need to be developed, tested and implemented that allow for a wide variety of exercise, at high intensity while likely involving low mass, volume and power. There are many unanswered issues related to the minimum number and type of exercise devices required for exploration, optimizing exercise prescriptions for these devices, whether a treadmill is absolutely required, and even whether any single countermeasure can adequately protect muscle, bone, cardiovascular and sensorimotor function.

Ploutz-Snyder, Lori↗

NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗

NASA NTRS2018

Design Optimisation and Mass Saving of the Structure of the Orion-MPCV European Service Module

This paper presents an overview of the design optimisation measures that have been proposed and analysed in order to reduce the mass of the structure, including the MMOD (Micro-Meteoroid and Orbital Debris) protection system, of the ESM (European Service Module) for the “Orion” MPCV (Multi-Purpose Crew Vehicle). Under an agreement between NASA and ESA, the NASA Orion MPCV for human space exploration missions will be powered by a European Service Module, based on the design and experience of the ATV (Automated Transfer Vehicle). The development and qualification of the European Service Module is managed and implemented by ESA. The ESM prime contractor and system design responsible is Airbus Defence and Space. Thales Alenia Space Italia is responsible for the design and integration of the ESM Structure and MMOD protection system in addition to the Thermal Control System and the Consumable Storage System. The Orion Multi-Purpose Crew Vehicle is a pressurized, crewed spacecraft that transports up to four crew members from the Earth’s surface to a nearby destination or staging point. Orion then brings the crew members safely back to the Earth’s surface at the end of the mission. Orion provides all services necessary to support the crew members while on-board for short duration missions (up to 21 days) or until they are transferred to another orbiting habitat. The ESM supports the crew module from launch through separation prior to re-entry by providing: in-space propulsion capability for orbital transfer, attitude control, and high altitude ascent aborts; water and oxygen/nitrogen needed for a habitable environment; and electrical power generation. In addition, it maintains the temperature of the vehicle's systems and components and offers space for unpressurized cargo and scientific payloads. The ESM has been designed for the first 2 Lunar orbit missions, EM-1 (Exploration mission 1) is an un-crewed flight planned around mid-2020, and EM-2, the first crewed flight, is planned in 2022. At the time where the first ESM is about to be weighted, the predicted mass lies slightly above the initial requirement. For future builds, mass reduction of the Service Module has been considered necessary. This is being investigated, together with other design improvements, in order to consolidate the ESM design and increase possible future missions beyond the first two Orion MPCV missions. The mass saving study has introduced new optimised structural concepts, optimisation of the MMOD protection shields, and optimised redesign of parts for manufacturing through AM (Additive Manufacturing).

Micro-Meteroids and Orbital Debris Protection Syst↗