NASA NDE Fracture Critical Detectable Flaw Sizes History and Methodology
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Validation of Fitness for Duty Standards Using Pre- and Post-Flight Capsule Egress and Suited Functional Performance Tasks in Simulated Reduced Gravity (Pilot Egress Fitness)
As NASA prepares for exploration missions, it will be critical to understand and build upon known crew capabilities. Specifically, we need to know the functional capacities of crew at different stages of a mission and characterize these profiles so that the appropriate vehicle requirements and mission concepts of operations (ConOps) can be developed. One of the most complex phases of any missions is when there is a transition between gravity environments. For instance, both physiological adaptation to microgravity and subsequent re-entry into a gravity environment result in reduced functional capacity, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk tasks may have to be performed soon after gravity transitions: •Unassisted capsule egress task after return to Earth •Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study has been broken down into two phases. A pilot phase to assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing and the full Egress Fitness study, which will be part of the CIPHER complement. This study uses a functional task approach to characterize performance of these high-risk tasks in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and mobility to be able to complete the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth based emergency egress out of a functional capsule mockup, and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing can occur almost anytime pre-flight, but post-flight scheduling is much more critical with the capsule egress test occurring 1-4 hours after landing and the planetary EVA approximately 18-36 hours after landing. Data collected for both tasks includes task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed baseline pre-flight testing on 3 astronaut subjects. Post-flight testing of the first two subjects will be completed in November 2021 and the final subject around March 2022. Results and lessons learned from this pilot study will inform the full Egress Fitness study, which will incorporate additional pre-flight sessions, longer EVA tasks, and post-flight testing on R+1, 4, and 7 to characterize the timeframe of recovery
J R Norcross↗
NASA's In-Space Manufacturing Project: Development of a Multimaterial, Multiprocess Fabrication Laboratory for the International Space Station
NASA's long term goal is to send humans to Mars. Over the next two decades, NASA will work with private industry to develop and demonstrate the technologies and capabilities needed to support exploration of the red planet by humans and ensure their safe return to earth. To accomplish this goal, NASA is employing a capability driven approach to its human spaceflight strategy. This approach will develop a suite of evolving capabilities which provide specific functions to solve exploration challenges. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing project, its past and current activities, and how technologies under development will ultimately culminate in a multimaterial, multiprocess fabrication laboratory ('FabLab') to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit may result in a loss of mission in transit to Mars. In order to have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The paper will discuss the phased approach to FabLab development, desired capabilities, and requirements for the hardware. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the FabLab will be tested on ISS, the system is ultimately intended for use in a deep space habitat or transit vehicle.
Prater, T.↗
Overview of NASA's MODIS and Visible Infrared Imaging Radiometer Suite (VIIRS) snow-cover Earth System Data Records
Knowledge of the distribution, extent, duration and timing of snowmelt is critical for characterizing the Earth's climate system and its changes. As a result, snow cover is one of the Global Climate Observing System (GCOS) essential climate variables (ECVs). Consistent, long-term datasets of snow cover are needed to study interannual variability and snow climatology. The NASA snow-cover datasets generated from the Moderate Resolution Imaging Spectroradiometer (MODIS) on the Terra and Aqua spacecraft and the Suomi National Polar-orbiting Partnership (S-NPP) Visible Infrared Imaging Radiometer Suite (VIIRS) are NASA Earth System Data Records (ESDR). The objective of the snow-cover detection algorithms is to optimize the accuracy of mapping snow-cover extent (SCE) and to minimize snow-cover detection errors of omission and commission using automated, globally applied algorithms to produce SCE data products. Advancements in snow-cover mapping have been made with each of the four major reprocessings of the MODIS data record, which extends from 2000 to the present. MODIS Collection 6 (C6) and VIIRS Collection 1 (C1) represent the state-of-the-art global snow cover mapping algorithms and products for NASA Earth science. There were many revisions made in the C6 algorithms which improved snow-cover detection accuracy and information content of the data products. These improvements have also been incorporated into the NASA VIIRS snow cover algorithms for C1. Both information content and usability were improved by including the Normalized Snow Difference Index (NDSI) and a quality assurance (QA) data array of algorithm processing flags in the data product, along with the SCE map.The increased data content allows flexibility in using the datasets for specific regions and end-user applications.Though there are important differences between the MODIS and VIIRS instruments (e.g., the VIIRS 375m native resolution compared to MODIS 500 m), the snow detection algorithms and data products are designed to be as similar as possible so that the 16C year MODIS ESDR of global SCE can be extended into the future with the S-NPP VIIRS snow products and with products from future Joint Polar Satellite System (JPSS) platforms.These NASA datasets are archived and accessible through the NASA Distributed Active Archive Center at the National Snow and Ice Data Center in Boulder, Colorado.
Earth System Data Record↗
Radiation: microbial evolution, ecology, and relevance to mars missions
Ultraviolet (UV) radiation has been an important environmental parameter during the evolution of life on Earth, both in its role as a mutagen and as a selective agent. This was probably especially true during the time from 3.8 to 2.5 billion years ago, when atmospheric ozone levels were less than 1% of present levels. Early Mars may not have had an "ozone shield" either, and it never developed a significant one. Even though Mars is farther away from the Sun than the Earth, a substantial surficial UV flux is present on Mars today. But organisms respond to dose rate, and on Mars, like on Earth, organisms would be exposed to diurnal variations in UV flux. Here we present data on the effect of diurnal patterns of UV flux on microbial ecosystems in nature, with an emphasis on photosynthesis and DNA synthesis effects. These results indicate that diurnal patterns of metabolism occur in nature with a dip in photosynthesis and DNA synthesis in the afternoon, in part regulated by UV flux. Thus, diurnal patterns must be studied in order to understand the effect of UV radiation in nature. The results of this work are significant to the success of human missions to Mars for several reasons. For example, human missions must include photosynthetic organisms for food production and likely oxygen production. An evolutionary approach suggests which organisms might be best suited for high UV fluxes. The diurnal aspect of these studies is critical. Terraforming is a potential goal of Mars exploration, and it will require studies of the effect of Martian UV fluxes, including their diurnal changes, on terrestrial organisms. Such studies may suggest that diurnal changes in UV only require mitigation at some times of day or year.
Review, Tutorial↗
On the Application of the Energy Method to Stability Problems
Since stability problems have come into the field of vision of engineers, energy methods have proved to be one of the most powerful aids in mastering them. For finding the especially interesting critical loads special procedures have evolved that depart somewhat from those customary in the usual elasticity theory. A clarification of the connections seemed desirable,especially with regard to the post-critical region, for the treatment of which these special methods are not suited as they are. The present investigation discusses this question-complex (made important by shell construction in aircraft) especially in the classical example of the Euler strut, because in this case - since the basic features are not hidden by difficulties of a mathematical nature - the problem is especially clear. The present treatment differs from that appearing in the Z.f.a.M.M. (1938) under the title "Uber die Behandlung von Stabilittatsproblemen mit Hilfe der energetischen Methode" in that, in order to work out the basic ideas still more clearly,it dispenses with the investigation of behavior at large deflections and of the elastic foundation;in its place the present version gives an elaboration of the 6th section and (in its 7 th and 8th secs.)a new example that shows the applicability of the general criterion to a stability problem that differs from that of Euler in many respects.
Marguerre, Karl↗
A New Method for Incremental Testing of Finite State Machines
The automatic generation of test cases is an important issue for conformance testing of several critical systems. We present a new method for the derivation of test suites when the specification is modeled as a combined Finite State Machine (FSM). A combined FSM is obtained conjoining previously tested submachines with newly added states. This new concept is used to describe a fault model suitable for incremental testing of new systems, or for retesting modified implementations. For this fault model, only the newly added or modified states need to be tested, thereby considerably reducing the size of the test suites. The new method is a generalization of the well-known W-method and the G-method, but is scalable, and so it can be used to test FSMs with an arbitrarily large number of states.
Pedrosa, Lehilton Lelis Chaves↗
Advanced Supported Liquid Membranes for CO2 Control in Extravehicular Activity Applications
Developing a new, robust, portable life support system (PLSS) is currently a high priority for NASA in order to support longer and safer extravehicular activity (EVA) missions. One of the critical PLSS functions is maintaining the carbon dioxide (CO2) concentration in the suit at acceptable levels. Although the Metal Oxide (MetOx) canister has worked well, it has a finite CO2 adsorption capacity. Consequently, the unit would have to be larger and heavier to extend EVA times. Therefore, new CO2 control technologies must be developed to meet mission objectives without increasing the size of the PLSS. Although recent work has centered on sorbents that can be regenerated during the EVA, this strategy increases the system complexity and power consumption. A simpler approach is to use a membrane that selectively vents CO2 to space. A membrane has many advantages over current technology: it is a continuous system with no theoretical capacity limit, it requires no consumables, and it requires no hardware for switching beds between absorption and regeneration. Unfortunately, conventional gas separation membranes do not have adequate selectivity for use in the PLSS. However, the required performance could be obtained with a supported liquid membrane (SLM), which consists of a micro porous material filled with a liquid that selectively reacts with CO2 over oxygen (O2). In a current Phase II SBIR project, Reaction Systems has developed a new reactive liquid, which has effectively zero vapor pressure making it an ideal candidate for use in an SLM. The SLM function has been demonstrated with representative pressures of CO2, O2, and water (H2O). In addition to being effective for CO2 control, the SLM also vents moisture to space. Therefore, this project has demonstrated the feasibility of using an SLM to control CO2 in an EVA application. 1 President
Wickham, David T.↗
Advanced Supported Liquid Membranes for CO2 Control in Extravehicular Activity Applications
Developing a new, robust, portable life support system (PLSS) is currently a high priority for NASA in order to support longer and safer extravehicular activity (EVA) missions. One of the critical PLSS functions is maintaining the carbon dioxide (CO2) concentration in the suit at acceptable levels. Although the Metal Oxide (MetOx) canister has worked well, it has a finite CO2 adsorption capacity. Consequently, the unit would have to be larger and heavier to extend EVA times. Therefore, new CO2 control technologies must be developed to meet mission objectives without increasing the size of the PLSS. Although recent work has centered on sorbents that can be regenerated during the EVA, this strategy increases the system complexity and power consumption. A simpler approach is to use a membrane that selectively vents CO2 to space. A membrane has many advantages over current technology: it is a continuous system with no theoretical capacity limit, it requires no consumables, and it requires no hardware for switching beds between absorption and regeneration. Unfortunately, conventional gas separation membranes do not have adequate selectivity for use in the PLSS. However, the required performance could be obtained with a supported liquid membrane (SLM), which consists of a micro porous material filled with a liquid that selectively reacts with CO2 over oxygen (O2). In a current Phase II SBIR project, Reaction Systems has developed a new reactive liquid, which has effectively zero vapor pressure making it an ideal candidate for use in an SLM. The SLM function has been demonstrated with representative pressures of CO2, O2, and water (H2O). In addition to being effective for CO2 control, the SLM also vents moisture to space. Therefore, this project has demonstrated the feasibility of using an SLM to control CO2 in an EVA application.
Wickham, David T.↗
Continued Advancement of Supported Liquid Membranes for Carbon Dioxide Control in Extravehicular Activity Applications
The development of a new, robust, portable life support system (PLSS) is a high priority for NASA in order to support longer and safer extravehicular activity (EVA) missions. One of the critical PLSS functions is maintaining the carbon dioxide (CO2) concentration in the suit at acceptable levels. Although the Metal Oxide (MetOx) canister has historically performed very well, it has a finite CO2 adsorption capacity. Therefore, the size and weight of the unit would have to be increased to extend EVA times. Consequently, new CO2 control technologies must be developed in order to meet mission objectives without increasing the size of the PLSS. Recent work has centered on sorbents that can be regenerated during the EVA; however, this strategy increases the system complexity and power consumption. A much simpler approach is to employ a membrane that vents CO2 to space and retains oxygen (O2). A membrane has many advantages over current technology: it is a continuous system with no limit on capacity, it requires no consumables, and it does not need any hardware to switch beds between absorption and regeneration. Unfortunately, conventional gas separation membranes do not have the needed selectivity for use in the PLSS. However, the required performance could be obtained with a supported liquid membrane (SLM), which consists of a microporous material filled with a liquid that selectively reacts with CO2 over O2. In a recently completed Phase II SBIR project, Reaction Systems, Inc. achieved the required CO2 permeance and selectivity with an SLM in a flat sheet configuration. This paper describes work to convert the SLM into a more compact form and to scale it up to handle more representative process flow rates.
Wickham, David T.↗
Continued Advancement of Supported Liquid Membranes for Carbon Dioxide Control in Extravehicular Activity Applications
The Development of a new, robust, portable life support system (PLSS) is currently a high NASA priority in order to support longer and safer extravehicular activity (EVA) missions that will be necessary as space travel extends to near-Earth asteroids and eventually Mars. One of the critical PLSS functions is maintaining the carbon dioxide (CO2) concentration in the suit at acceptable levels. The Metal Oxide (MetOx) canister has a finite CO2 adsorption capacity and therefore in order to extend mission times, the unit would have to be larger and heavier, which is undesirable; therefore new CO2 control technologies must be developed. While recent work has centered on the use of alternating sorbent beds that can be regenerated during the EVA, this strategy increases the system complexity and power consumption. A simpler approach is to use a membrane that vents CO2 to space but retains oxygen(O2). A membrane has many advantages over current technology: it is a continuous system with no theoretical capacity limit, it requires no consumables, and it requires no hardware for switching beds between absorption and regeneration. Conventional gas separation membranes do not have adequate selectivity for use in the PLSS, but the required performance could be obtained with a supported liquid membrane (SLM), which consists of a microporous film filled with a liquid that selectively reacts with CO2 over oxygen (O2). In a recently completed Phase II Small Business Innovative Research project, Reaction Systems developed a new reactive liquid that has effectively zero vapor pressure, making it an ideal candidate for use in an SLM. Results obtained with the SLM in a flat sheet configuration with representative pressures of CO2, O2, and water (H2O) have shown that the CO2 permeation rate and CO2/O2 selectivity requirements have been met. In addition, the SLM vents moisture to space very effectively. The SLM has also been prepared and tested in a hollow fiber form, which will be necessary to meet size requirements in the PLSS. In initial tests, the required CO2 permeance values have been obtained, while the current CO2/O2 selectivity values are somewhat lower than needed. However, the performance of the SLM is a strong function of the method used to impregnate the sorbent in the hollow fiber walls and rapid progress is being made in that area.
Wickham, David T.↗
SiAl Alloy Feedhorn Arrays: Material Properties, Feedhorn Design, and Astrophysical Applications
We present here a study of the use of the SiAl alloy CE7 for the packaging of silicon devices at cryogenic temperatures. We report on the development of baseplates and feedhorn arrays for millimeter wave bolometric detectors for astrophysics. Existing interfaces to such detectors are typically made either of metals, which are easy to machine but mismatched to the thermal contraction profile of Si devices, or of silicon, which avoids the mismatch but is difficult to directly machine. CE7 exhibits properties of both Si and Al, which makes it uniquely well suited for this application. We measure CE7 to a) superconduct below a critical transition temperature, T (sub c), 1.2 K, b) have a thermal contraction profile much closer to Si than metals, which enables simple mating, and c) have a low thermal conductivity which can be improved by Au-plating. Our investigations also demonstrate that CE7 can be machined well enough to fabricate small structures, such as #0-80 threaded holes, to tight tolerances (approximately 25 microns) in contrast with pure silicon and similar substrates. We have fabricated CE7 baseplates being deployed in the 93 gigahertz polarimetric focal planes used in the Cosmology Large Angular Scale Surveyor (CLASS). We also report on the development of smooth-walled feedhorn arrays made of CE7 that will be used in a focal plane of dichroic 150/220 gigahertz detectors for the CLASS High-Frequency camera.
Ali, Aamir M.↗
Regenerative Blower for EVA Suit Ventilation Fan
Portable life support systems in future space suits will include a ventilation subsystem driven by a dedicated fan. This ventilation fan must meet challenging requirements for pressure rise, flow rate, efficiency, size, safety, and reliability. This paper describes research and development that showed the feasibility of a regenerative blower that is uniquely suited to meet these requirements. We proved feasibility through component tests, blower tests, and design analysis. Based on the requirements for the Constellation Space Suit Element (CSSE) Portable Life Support System (PLSS) ventilation fan, we designed the critical elements of the blower. We measured the effects of key design parameters on blower performance using separate effects tests, and used the results of these tests to design a regenerative blower that will meet the ventilation fan requirements. We assembled a proof-of-concept blower and measured its performance at sub-atmospheric pressures that simulate a PLSS ventilation loop environment. Head/flow performance and maximum efficiency point data were used to specify the design and operating conditions for the ventilation fan. We identified materials for the blower that will enhance safety for operation in a lunar environment, and produced a solid model that illustrates the final design. The proof-of-concept blower produced the flow rate and pressure rise needed for the CSSE ventilation subsystem while running at 5400 rpm, consuming only 9 W of electric power using a non-optimized, commercial motor and controller and inefficient bearings. Scaling the test results to a complete design shows that a lightweight, compact, reliable, and low power regenerative blower can meet the performance requirements for future space suit life support systems.
Izenson, Michael G.↗
EVA safety: Space suit system interoperability
The results and the recommendations of the International Academy of Astronautics extravehicular activities (IAA EVA) Committee work are presented. The IAA EVA protocols and operation were analyzed for harmonization procedures and for the standardization of safety critical and operationally important interfaces. The key role of EVA and how to improve the situation based on the identified EVA space suit system interoperability deficiencies were considered.
Skoog, A. I.↗
Human Thermal Assessment of Traverse and Geology Task Iterations During Simulated Lunar Extravehicular Activity
Spacewalks or extravehicular activities (EVA) in microgravity are mentally and physically demanding. Current microgravity EVAs are predominantly focused on upper body tasks on engineered surfaces; however, the introduction of gravity means that crew members during future lunar EVAs will be required to perform tasks that generate full body workloads such as navigating natural lunar terrain while conducting geological sampling. To date, only 12 people have walked on the surface of the Moon resulting in limited knowledge of suited thermal regulation under lunar-relevant physical workloads. To address this gap, a study is underway to focus on spacesuit operations with simulated lunar EVA workloads. This study presents methodology for collecting standard thermal measures during suit testing. In this pilot study, two suited subjects underwent simulated lunar EVAs using the NASA Active Response Gravity Offload System (ARGOS) to simulate the effects of partial gravity. Each lunar EVA, lasting three to five hours, included various metabolically demanding EVA tasks. Subjects donned the NASA Mark III (MK III) space suit and were offloaded to 1/6th G (lunar gravity). A subset task circuit from one of these simulations replicated an EVA traverse to a lunar crater, taking a geological sample, and returning to base. The suited subject walked one 1500 m (0% grade) and three 500 m traverses at three different grades (10, 20, 30%). Between each traverse, subjects performed geology sampling tasks (0 and 10% grade). Thermal measurements included core and skin temperature, liquid cooling garment (LCG) inlet and outlet temperature, and spacesuit gas inlet and outlet temperature and humidity. Compared to baseline core temperature (S1 = 37.07±0.32 °C, S2 = 37.27±0.01 °C) and mean skin temperature (S1 = 32.38±0.34 °C, S2 = 33.62±0.03 °C), after a 1500 m traverse, each suited subject showed an increased core temperature (S1 = 37.23±0.12 °C, S2 = 37.41±0.11°C) and decreased mean skin temperature (S1 = 32.16±0.17 °C, S2 = 31.53±1.15 °C) at a delta LCG temperature (S1 = 1.86±0.24 °C, S2 = 2.20±0.76 °C) and delta suit humidity (S1 = 9.66±1.49 %, S2 = 11.50±1.58 %). Core temperature continued to increase from compounding traverse and geology tasks (S1 = 38.04±0.03 °C, S2 = 38.1±0.02 °C) accompanied by an increase in delta LCG temperature (S1 = 2.24±0.13 °C, S2 = 2.67±0.12 °C) and delta suit humidity (S1 = 28±2.42 %, S2 = 31±2.13 %). Conversely, as the circuit progressed, mean skin temperature continued to decrease due to sustained LCG heat rejection (S1 = 30.08±0.15 °C, S2 = 30.28±0.07 °C). During the simulated EVA circuit core temperature increased to elevated values and remained elevated as heat was retained while mean skin temperature decreased due to peripheral heat offloaded to the LCG. The thermal measures collected during this study provided critical heat loading dynamics during lunar EVA tasks. Including core and skin temperatures along with suited thermal measures provides a standard data collection scheme for human thermal metrics during EVA task management. Data collected in this configuration can be used to build future lunar EVA task circuits and human thermal predictions.
Bradley Hoffmann↗
Spacesuit Fit and Mobility Assessments by Digital Human Modeling
Spacesuit Fit and Mobility Assessments by Digital Human Modeling K. Han Kim (Leidos, Inc.) Elizabeth A. Benson (KBR, Inc.) Sudhakar L. Rajulu (NASA Johnson Space Center) Spacesuits are required to accommodate safe operations for astronauts across gender and a wide variety of body shapes and sizes. This goal has been of particular importance given the increasing diversity of NASA crewmembers for upcoming Missions. While testing with design prototypes is a critical step for spacesuit development, iterative mockup design, fabrication, and human subject tests can be extremely costly and time consuming. Moreover, testing with a limited subject pool has often raised questions for validity, as test subjects need to represent the entire astronaut population, not only of the past or current, but also the future. This study is aimed at demonstrating how digital human modeling (DHM) tools have been built and directly supported NASA spacesuit developments. With DHM, the computer aided design (CAD) model of a spacesuit was integrated with human body models. Two use scenarios are presented in this paper, namely fit and mobility. For fit assessments, the suit-to-body contact and compression patterns were estimated using 3D human body scan models virtually wearing a spacesuit model. A statistical fit classifier was made from the contact patterns and applied against a large database of body scans (N=2,500). With this technique, the NASA reference design spacesuit Exploration EVA Mobility Unit (xEMU)was verified to accommodate 90% of the astronaut-like population, with the critical dimensions covering 1stto 99thpercentiles of the target body measurements. A similar technique assessed XEMU mobility. The maximum reach envelopes were considered, within which the work objects and critical hardware interfaces should be located for safe and ergonomic operations. While the reach envelope geometry varies significantly with the suit wearer’s body size and strength, the existing test data did not include the subjects critically required to define suit mobility requirements, such as very small females or large males. Using the xEMU virtual model kinematically simulated and permuted for a hypothetical wearer, however, the existing data were statistically transformed and scaled. This method enabled for a parametric estimation of the reach envelopes from the 1stpercentile female or 99thpercentile male. The outcome was successfully incorporated for requirement developments. With the new DHM tools, human integration of the spacesuit was structurally simulated and predictively assessed, which would have been otherwise impossible. Also, the needs for iterative mockup and subject tests were significantly reduced, which resulted in time and cost saving. Additional work is in progress to integrate additional vehicles, tools, and hardware with DHM framework.
K Han Kim↗
Exploration Extra-Vehicular Mobility Unit (xEMU) Composite Hard Upper Torso (CHUT) Development
The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.
spacesuit↗
Composite Hard Upper Torso (CHUT) for xEMU Space Suit
The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.
spacesuit↗