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Marshall Space Flight Center Research and Technology Report 2020

Many of NASA’s missions would not be possible if it were not for the investments made in research advancements and technology development efforts. The technologies developed at Marshall Space Flight Center contribute to NASA’s strategic array of missions through technology development and accomplishments. This annual Research and Technology Report features brief write-ups from the scientists, researchers, and technologists of Marshall Space Flight Center who are working these enabling technology efforts, which are facilitating NASA’s ability to fulfill the ambitious goals of innovation, exploration, and discovery.

MSFC Research and Technology Report 2020↗

Marshall Space Flight Center Research and Technology Report 2021

Many of NASA’s missions would not be possible if it were not for the investments made in research advancements and technology development efforts. The technologies developed at Marshall Space Flight Center contribute to NASA’s strategic array of missions through technology development and accomplishments. This annual Research and Technology Report features brief write-ups from the scientists, researchers, and technologists of Marshall Space Flight Center who are working these enabling technology efforts, which are facilitating NASA’s ability to fulfill the ambitious goals of innovation, exploration, and discovery.

MSFC Research and Technology Report 2020↗

Digital flight control for the NASA 737 airplane

A brief description of the hardware and software for the digital flight control computers for the NASA 737 airplane is given. Software modules include the basic executive, scheduler, redundancy management, software signal selection, system test, mode logic, pitch axis flight control program and the lateral axis flight control program. A more detailed description of the software development effort is given for the digital flight control software. The software development tasks discussed are: software requirements, development, documentation, control, lab evaluation and formal lab tests. The software development costs are identified and conclusions are drawn concerning the software development effort required to support digital flight control for commercial jet transport applications.

Malcom, L. G.↗

EVA Communications Avionics and Informatics

The Glenn Research Center is investigating and developing technologies for communications, avionics, and information systems that will significantly enhance extra vehicular activity capabilities to support the Vision for Space Exploration. Several of the ongoing research and development efforts are described within this presentation including system requirements formulation, technology development efforts, trade studies, and operational concept demonstrations.

Carek, David Andrew↗

A report on the USL NASA/RECON project. Part 2: PC-based R and D in support of IS and R applications

This Working Paper Series entry describes the PC R and D development effort initiated as part of the NASA/RECON Project at the University of Southwestern Louisiana. This effort involves the development of a PC-based environment for the prototyping and evaluation of various tools designed to enhance the interaction between scientists and engineers and remote information systems. The design of PC-based tools for the enhancement of the NASA/RECON university-level courses is described as well as the design of a multi-functional PC-based workstation to support access to and processing of information from local, distributed, and remote sources. Course preparation activities are described in a companion report entitled A Report on the USL NASA/RECON Project: Part 1, the Development of a Transportable, University-Level, IS and R Educational Program, by Suzy Gallagher and Martin Granier, USL/DBMS NASA/RECON Working Paper Series report number DBMS.NASA/RECON-7.

Dominick, Wayne D.↗

Navy superconductivity efforts

Both the new high temperature superconductors (HTS) and the low temperature superconductors (LTS) are important components of Navy's total plan to integrate superconductivity into field operational systems. Fundamental research is an important component of the total Navy program and focuses on the HTS materials. Power applications (ship propulsion, etc.) use LTS materials while space applications (MMW electronics, etc.) use HTS materials. The Space Experiment being conducted at NRL will involve space flight testing of HTS devices built by industry and will demonstrate the ability to engineer and space qualify these devices for systems use. Another important component of the Navy's effort is the development of Superconducting Quantum Interference Device (SQUID) magnetometers. This program will use LTS materials initially, but plans to implement HTS materials as soon as possible. Hybrid HTS/LTS systems are probable in many applications. A review of the status of the Navy's HTS materials research is given as well as an update on the Navy's development efforts in superconductivity, with particular emphasis on the related SDIO sponsored program on HTS applications.

Gubser, D. U.↗

Update of the Solar Concentrator Advanced Development Project

The Solar Concentrator Advanced Development Project, which has achieved the successful design, fabrication, and testing of a full-scale prototypical solar dynamic concentrator, is discussed. The design and fabrication process are summarized, and the test results for the reflective facet optical performance and the concentrator structural repeatability are reported. Initial testing of structural repeatability of a seven panel portion of the concentrator was followed by assembly and testing of the full nineteen-panel structure. The testing, which consisted of theodolite and optical measurements over an assembly-disassembly-reassembly cycle, demonstrated that the concentrator maintained the as-built contour and optical characteristics. The facet development effort, which entailed developing a vapor-deposited reflective facet, produced a viable design with demonstrated optical characteristics that are within the project goals.

Corrigan, Robert D.↗

US Navy superconductivity program

Both the new high temperature superconductors (HTS) and the low temperature superconductors (LTS) are important components of the Navy's total plan to integrate superconductivity into field operational systems. Fundamental research is an important component of the total Navy program and focuses on the HTS materials. Power applications (ship propulsion) use LTS materials while space applications (millimeter wave electronics) use HTS materials. The Space Experiment to be conducted at NRL will involve space flight testing of HTS devices built by industry and will demonstrate the ability to engineer and space qualify these devices for systems use. Another important component of the Navy's effort is the development of Superconducting Quantum Interference Device (SQUID) magnetometers. This program will use LTS materials initially, but plans to implement HTS materials as soon as possible. Hybrid HTS/LTS systems are probable in many applications. A review of the status of the Navy's HTS materials research is given as well as an update on the Navy's development efforts in superconductivity.

Gubser, Donald U.↗

H-P adaptive methods for finite element analysis of aerothermal loads in high-speed flows

The commitment to develop the National Aerospace Plane and Maneuvering Reentry Vehicles has generated resurgent interest in the technology required to design structures for hypersonic flight. The principal objective of this research and development effort has been to formulate and implement a new class of computational methodologies for accurately predicting fine scale phenomena associated with this class of problems. The initial focus of this effort was to develop optimal h-refinement and p-enrichment adaptive finite element methods which utilize a-posteriori estimates of the local errors to drive the adaptive methodology. Over the past year this work has specifically focused on two issues which are related to overall performance of a flow solver. These issues include the formulation and implementation (in two dimensions) of an implicit/explicit flow solver compatible with the hp-adaptive methodology, and the design and implementation of computational algorithm for automatically selecting optimal directions in which to enrich the mesh. These concepts and algorithms have been implemented in a two-dimensional finite element code and used to solve three hypersonic flow benchmark problems (Holden Mach 14.1, Edney shock on shock interaction Mach 8.03, and the viscous backstep Mach 4.08).

Chang, H. J.↗

Quartz/fused silica chip carriers

The primary objective of this research and development effort was to develop monolithic microwave integrated circuit (MMIC) packaging which will operate efficiently at millimeter-wave frequencies. The packages incorporated fused silica as the substrate material which was selected due to its favorable electrical properties and potential performance improvement over more conventional materials for Ka-band operation. The first step towards meeting this objective is to develop a package that meets standard mechanical and thermal requirements using fused silica and to be compatible with semiconductor devices operating up to at least 44 GHz. The second step is to modify the package design and add multilayer and multicavity capacity to allow for application specific integrated circuits (ASIC's) to control multiple phase shifters. The final step is to adapt the package design to a phased array module with integral radiating elements. The first task was a continuation of the SBIR Phase 1 work. Phase 1 identified fused silica as a viable substrate material by demonstrating various plating, machining, and adhesion properties. In Phase 2 Task 1, a package was designed and fabricated to validate these findings. Task 2 was to take the next step in packaging and fabricate a multilayer, multichip module (MCM). This package is the predecessor to the phased array module and demonstrates the ability to via fill, circuit print, laminate, and to form vertical interconnects. The final task was to build a phased array module. The radiating elements were to be incorporated into the package instead of connecting to it with wire or ribbon bonds.

Source record↗

Task 4 supporting technology. Part 1: Detailed test plan for leading edge tile development. Leading edge material development and testing

This task develops two alternative candidate tile materials for leading edge applications: coated alumina enhanced thermal barrier (AETB) tile and silicone impregnated reusable ceramic ablator (SIRCA) tile. Upon reentry of the X-33/RLV space vehicle, the leading edges experience the highest heating rates and temperatures. The wing leading edge and nose cap experience peak temperatures in the range 2000 to 2700 F. Replacing reinforced carbon-carbon (RCC) with tile-based thermal protection system (TPS) materials is the primary objective. Weight, complexity, coating impact damage, and repairability are among the problems that this tile technology development addresses. The following subtasks will be performed in this development effort: tile coating development; SIRCA tile development; robustness testing of tiles; tile repair development; tile operations/processing; tile leading edge configuration; and life cycle testing.

Hogenson, P. A.↗

The Integration of COTS/GOTS within NASA's HST Command and Control System

NASA's mission critical Hubble Space Telescope (HST) command and control system has been re-engineered with COTS/GOTS and minimal custom code. This paper focuses on the design of this new HST Control Center System (CCS) and the lessons learned throughout its development. CCS currently utilizes 31 COTS/GOTS products with an additional 12 million lines of custom glueware code; the new CCS exceeds the capabilities of the original system while significantly reducing the lines of custom code by more than 50%. The lifecycle of COTS/GOTS products will be examined including the pack-age selection process, evaluation process, and integration process. The advantages, disadvantages, issues, concerns, and lessons teamed for integrating COTS/GOTS into the NASA's mission critical HST CCS will be examined in detail. Command and control systems designed with traditional custom code development efforts will be compared with command and control systems designed with new development techniques relying heavily on COTS/COTS integration. This paper will reveal the many hidden costs of COTS/GOTS solutions when compared to traditional custom code development efforts; this paper will show the high cost of COTS/GOTS solutions including training expenses, consulting fees, and long-term maintenance expenses.

Pfarr, Thomas↗

2005 NASA Seal/Secondary Air System Workshop, Volume 1

The 2005 NASA Seal/Secondary Air System workshop covered the following topics: (i) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (ii) Overview of the NASA-sponsored Propulsion 21 Project; (iii) Overview of NASA Glenn s seal project aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (iv) Reviews of NASA prime contractor, vendor, and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. Turbine engine studies have shown that reducing high-pressure turbine (HPT) blade tip clearances will reduce fuel burn, lower emissions, retain exhaust gas temperature margin, and increase range. Several organizations presented development efforts aimed at developing faster clearance control systems and associated technology to meet future engine needs. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle. Seal technical challenges (including space environments, temperature variation, and seal-on-seal operation) as well as plans to develop the necessary "androgynous" seal technologies were reviewed. Researchers also reviewed tests completed for the shuttle main landing gear door seals.

Steinetz, Bruce M.↗

2006 NASA Seal/Secondary Air System Workshop; Volume 1

The 2006 NASA Seal/Secondary Air System workshop covered the following topics: (i) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (ii) Overview of NASA s new fundamental aeronautics technology project; (iii) Overview of NASA Glenn Research Center s seal project aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (iv) Reviews of NASA prime contractor, vendor, and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. Turbine engine studies have shown that reducing seal leakages as well as high-pressure turbine (HPT) blade tip clearances will reduce fuel burn, lower emissions, retain exhaust gas temperature margin, and increase range. Several organizations presented development efforts aimed at developing faster clearance control systems and associated technology to meet future engine needs. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle. Seal technical challenges (including space environments, temperature variation, and seal-on-seal operation) as well as plans to develop the necessary "androgynous" seal technologies were reviewed. Researchers also reviewed seal technologies employed by the Apollo command module that serve as an excellent basis for seals for NASA s new Crew Exploration Vehicle (CEV).

Steinetz, Bruce, M.↗

The Use of the STAGS Finite Element Code in Stitched Structures Development

In the last 30 years NASA has worked in collaboration with industry to develop enabling technologies needed to make aircraft more fuel-efficient and more affordable. The focus on the airframe has been to reduce weight, improve damage tolerance and better understand structural behavior under realistic flight and ground loading conditions. Stitched structure is a technology that can address the weight savings, cost reduction, and damage tolerance goals, but only if it is supported by accurate analytical techniques. Development of stitched technology began in the 1990's as a partnership between NASA and Boeing (McDonnell Douglas at the time) under the Advanced Composites Technology Program and has continued under various titles and programs and into the Environmentally Responsible Aviation Project today. These programs contained development efforts involving manufacturing development, design, detailed analysis, and testing. Each phase of development, from coupons to large aircraft components was supported by detailed analysis to prove that the behavior of these structures was well-understood and predictable. The Structural Analysis of General Shells (STAGS) computer code was a critical tool used in the development of many stitched structures. As a key developer of STAGS, Charles Rankin's contribution to the programs was quite significant. Key features of STAGS used in these analyses and discussed in this paper include its accurate nonlinear and post-buckling capabilities, its ability to predict damage growth, and the use of Lagrange constraints and follower forces.

Jegley, Dawn C.↗

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview

The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future.

Hughes, Stephen J.↗

Technology base for microgravity horticulture

Advanced microgravity plant biology research and life support system development for the spacecraft environment are critically hampered by the lack of a technology base. This inadequacy stems primarily from the fact that microgravity results in a lack of convective currents and phase separation as compared to the one gravity environment. A program plan is being initiated to develop this technology base. This program will provide an iterative flight development effort that will be closely integrated with both basic science investigations and advanced life support system development efforts incorporating biological processes. The critical considerations include optimum illumination methods, root aeration, root and shoot support, and heat rejection and gas exchange in the plant canopy.

Sauer, R. L.↗

Friction Pull Plug Welding in Aluminum Alloys

NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗