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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 NTRS2014

TBS (Trabecular Bone Score) Expands Understanding of Spaceflight Effects on the Lumbar Spine of Long Duration Astronauts

Background: Bone loss due to long-duration spaceflight has been characterized by both DXA and QCT serial scans. It is unclear if these spaceflight-induced changes in bone mineral density and structure result in increased fracture incidence. NASA astronauts currently fly on 5-6-month missions on the International Space Station (ISS) and at least one 12-month mission is planned. While NASA has measured areal BMD (by DXA) and volumetric BMD (by QCT), and has estimated hip strength (by finite element models of QCT data, no method has yet been used to examine bone microarchitecture from lumbar spine (LS). DXA scans are routinely performed pre- and post-flight on all ISS astronauts to follow BMD changes associated with space flight. Trabecular Bone Score (TBS) is a relatively new method that measures grey-scale-level texture information extracted from lumbar spine DXA images and correlates with 3D parameters of bone micro-architecture. We evaluated the ability of LS TBS to discriminate changes in astronauts who have flown on ISS missions and to determine if TBS can provide additional information compared to DXA. Methods: LS (L1-4) DXA scans from 51 astronauts (mean age, 47 +/- 4) were divided into 3 groups based on the exercise regimes performed while onboard the ISS. Pre-ARED (exercise using a load-limited resistive exercise device, <300lb), ARED (exercise with a high-load resistive exercise device, up to 600lb) and a Bisphos group (ARED exercise and a 70-mg alendronate tablet once a week before and during flight, starting 17 days before launch). DXA scans were performed and analyzed on a Hologic Discovery W using the same technician for the pre- and postflight scans. LSC for the LS in our laboratory is 0.025 g/cm2. TBS was performed at the Mercy Hospital, Cincinnati, Ohio on a similar Hologic computer. TBS precision was calculated from 16 comparable test subjects (0.0XX g/cm2). Data were preliminary analyzed using a paired, 2-tailed t-test for the difference between pre- and postflight means.

Sibonga, Jean D.↗
NASA NTRS2021

TLSLEAF: Automatic Leaf Angle Estimates From Single-Scan Terrestrial Laser Scanning

Leaf angle distribution (LAD) in forest canopies affects estimates of leaf area, light interception, and global-scale photosynthesis, but is often simplified to a single theoretical value. Here, we present TLSLeAF (Terrestrial Laser Scanning Leaf Angle Function), an automated open-source method of deriving LADs from terrestrial laser scanning. TLSLeAF produces canopy-scale leaf angle and LADs by relying on gridded laser scanning data. The approach increases processing speed, improves angle estimates, and requires minimal user input. Key features are automation, leaf–wood classification, beta parameter output, and implementation in R to increase accessibility for the ecology community. TLSLeAF precisely estimates leaf angle with minimal distance effects on angular estimates while rapidly producing LADs on a consumer-grade machine. We challenge the popular spherical LAD assumption, showing sensitivity to ecosystem type in plant area index and foliage profile estimates that translate to c. 25% and c. 11% increases in canopy net photosynthesis (c. 25%) and solar-induced chlorophyll fluorescence (c. 11%). TLSLeAF can now be applied to the vast catalog of laser scanning data already available from ecosystems around the globe. The ease of use will enable widespread adoption of the method outside of remote-sensing experts, allowing greater accessibility for addressing ecological hypotheses and large-scale ecosystem modeling efforts.

3D↗
NASA NTRS1991

Relaxation processes in a low-order three-dimensional magnetohydrodynamics model

The time asymptotic behavior of a Galerkin model of 3D magnetohydrodynamics (MHD) has been interpreted using the selective decay and dynamic alignment relaxation theories. A large number of simulations has been performed that scan a parameter space defined by the rugged ideal invariants, including energy, cross helicity, and magnetic helicity. It is concluded that time asymptotic state can be interpreted as a relaxation to minimum energy. A simple decay model, based on absolute equilibrium theory, is found to predict a mapping of initial onto time asymptotic states, and to accurately describe the long time behavior of the runs when magnetic helicity is present. Attention is also given to two processes, operating on time scales shorter than selective decay and dynamic alignment, in which the ratio of kinetic to magnetic energy relaxes to values 0(1). The faster of the two processes takes states initially dominant in magnetic energy to a state of near-equipartition between kinetic and magnetic energy through power law growth of kinetic energy. The other process takes states initially dominant in kinetic energy to the near-equipartitioned state through exponential growth of magnetic energy.

Stribling, Troy↗
NASA NTRS2019

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗
NASA NTRS2015

International Space Station (ISS) 3D Printer Performance and Material Characterization Methodology

In order for human exploration of the Solar System to be sustainable, manufacturing of necessary items on-demand in space or on planetary surfaces will be a requirement. As a first step towards this goal, the 3D Printing In Zero-G (3D Print) technology demonstration made the first items fabricated in space on the International Space Station. From those items, and comparable prints made on the ground, information about the microgravity effects on the printing process can be determined. Lessons learned from this technology demonstration will be applicable to other in-space manufacturing technologies, and may affect the terrestrial manufacturing industry as well. The flight samples were received at the George C. Marshall Space Flight Center on 6 April 2015. These samples will undergo a series of tests designed to not only thoroughly characterize the samples, but to identify microgravity effects manifested during printing by comparing their results to those of samples printed on the ground. Samples will be visually inspected, photographed, scanned with structured light, and analyzed with scanning electron microscopy. Selected samples will be analyzed with computed tomography; some will be assessed using ASTM standard tests. These tests will provide the information required to determine the effects of microgravity on 3D printing in microgravity.

Bean, Q. A.↗
NASA NTRS2011

HIWRAP Radar Development for High-Altitude Operation on the NASA Global Hawk and ER-2

The NASA High-Altitude Imaging Wind and Rain Airborne Profiler (HIWRAP) is a solid-state transmitter-based, dual-frequency (Ka- and Ku-band), dual-beam (30 degree and 40 degree incidence angle), conical scan Doppler radar system, designed for operation on the NASA high-altitude (20 km) aircrafts, such as the Global Hawk Unmanned Aerial System (UAS). Supported by the NASA Instrument Incubator Program (IIP), HIWRAP was developed to provide high spatial and temporal resolution 3D wind and reflectivity data for the research of tropical cyclone and severe storms. With the simultaneous measurements at both Ku- and Ka-band two different incidence angles, HIWRAP is capable of imaging Doppler winds and volume backscattering from clouds and precipitation associated with tropical storms. In addition, HIWRAP is able to obtain ocean surface backscatter measurements for surface wind retrieval using an approach similar to QuikScat. There are three key technology advances for HIWRAP. Firstly, a compact dual-frequency, dual-beam conical scan antenna system was designed to fit the tight size and weight constraints of the aircraft platform. Secondly, The use of solid state transmitters along with a novel transmit waveform and pulse compression scheme has resulted in a system with improved performance to size, weight, and power ratios compared to typical tube based Doppler radars currently in use for clouds and precipitation measurements. Tube based radars require high voltage power supply and pressurization of the transmitter and radar front end that complicates system design and implementation. Solid state technology also significantly improves system reliability. Finally, HIWRAP technology advances also include the development of a high-speed digital receiver and processor to handle the complex receiving pulse sequences and high data rates resulting from multi receiver channels and conical scanning. This paper describes HIWRAP technology development for dual-frequency operation at high-altitudes using low peak power transmitters and pulse compression. The hardware will be described along with the methods and concepts for the system design. Finally, we will present recent preliminary results from flights on the NASA Global Hawk in support of the NASA Genesis and Rapid Intensification Processes (GRIP) field campaign, and on the NASA ER-2 as fixed nadir pointing mode for the NASA Global Precipitation Measurement (GPM) ground validation (GV) mission - Midlatitude Continental Convective Cloud Experiment (MC3E)

Li, Lihua↗
NASA NTRSDate not supplied

New Features of the NEQAIR Radiation Code

The longest-lived code for predicting shock layer radiation, NEQAIR, is now in its 5th decade of service. Substantial changes to the code have been made over the previous decade, the most recent report of which was at the 5th Workshop on Radiation in High Temperature Gases in 2014, for the version referred to as NEQAIR14. This paper will review some of the improvements made to the NEQAIR code since then, which is now at v15.2. Some of these features are discussed briefly below. NEQAIR15 and subsequent versions have enabled parallel evaluation of multiple lines of sight. This is accomplished by utilizing the HDF5 file format and placing multiple lines into a single file, LOS.h5, which is used for both input and output. This approach enables straightforward parallel execution both over the number of lines of sight and the number of points per line. For large problems, runtime reduces linearly with the number of nodes deployed since each line is processed independently by a subset of MPI ranks. Three applications of the multi-line solver are discussed. The first has to do with performing loosely coupled radiation-flowfield solutions. In this case the computed absorption and emission coefficients are used to evaluate the total energy absorbed or emitted at each point, allowing evaluation of the volumetric source term in the flowfield. The second computation is for obtaining heat flux from nonuniform flows, which require integration over spherical co-ordinates. These are of particular interest for evaluating radiation on the vehicle backshell. This 3D option improves the angular integration scheme and allows adaptive line selection that together reduce the number of lines required by about an order of magnitude. The final application is for remote observation, which is essentially the 3D integration problem over a small solid angle. For all three of these computations, data can be stored in the HDF5 file which allows a NEQAIR run to be restarted when it times out, or to add atmospheric absorption or instrument scan functions. An additional level of parallelism is enabled in NEQAIR15.2 using GPU routines. The GPU parallelism has realized up to 8x speed-up when running on a single core but diminishes as CPU parallelism is increased. For running multi-line simulations, it may be easier to reserve a large number of CPU nodes than to obtain the number of GPU nodes required for similar performance. A GUI, known as NEQTPY, allows for reading and creating input files, running NEQAIR, and displaying results. A significant feature of NEQTPY is the ability to perform spectral fits to data. The fits can operate on a single line spectrum (radiance vs. wavelength) or a 3D input file with multiple columns of data. Other new features include improved constants, additional species, more detailed non-Boltzmann modelling, advanced user controls, the ability to read and calculate spectra from HITRAN datafiles, photodissociation and photoionization cross-sections. A “fast” automatic grid option may reduce the size and time of spectral calculations while still maintaining good accuracy for total heat flux.

Brett A Cruden↗
NASA NTRS1999

NASA/NOAA: Earth Science Electronic Theater 1999

The Electronic Theater (E-theater) presents visualizations which span the period from the original Suomi/Hasler animations of the first ATS-1 GEO weather satellite images in 1966 to the latest 1999 NASA Earth Science Vision for the next 25 years. Hot off the SGI-Onyx Graphics-Supercomputer are NASA's visualizations of Hurricanes Mitch, Georges, Fran and Linda. These storms have been recently featured on the covers of National Geographic, Time, Newsweek and Popular Science. Highlights will be shown from the NASA hurricane visualization resource video tape that has been used repeatedly this season on National and International network TV. Results will be presented from a new paper on automatic wind measurements in Hurricane Luis from 1-min GOES images that appeared in the November BAMS. The visualizations are produced by the NASA Goddard Visualization and Analysis Laboratory (VAL/912), and Scientific Visualization Studio (SVS/930), as well as other Goddard and NASA groups using NASA, NOAA, ESA, and NASDA Earth science datasets. Visualizations will be shown from the Earth Science E-Theater 1999 recently presented in Tokyo, Paris, Munich, Sydney, Melbourne, Honolulu, Washington, New York, and Dallas. The presentation Jan 11-14 at the AMS meeting in Dallas used a 4-CPU SGI/CRAY Onyx Infinite Reality Super Graphics Workstation with 8 GB RAM and a Terabyte Disk at 3840 X 1024 resolution with triple synchronized BarcoReality 9200 projectors on a 60ft wide screen. Visualizations will also be featured from the new Earth Today Exhibit which was opened by Vice President Gore on July 2, 1998 at the Smithsonian Air & Space museum in Washington, as well as those presented for possible use at the American Museum of Natural History (NYC), Disney EPCOT, and other venues. New methods are demonstrated for visualizing, interpreting, comparing, organizing and analyzing immense HyperImage remote sensing datasets and three dimensional numerical model results. We call the data from many new Earth sensing satellites, HyperImage datasets, because they have such high resolution in the spectral, temporal, spatial, and dynamic range domains. The traditional numerical spreadsheet paradigm has been extended to develop a scientific visualization approach for processing HyperImage datasets and 3D model results interactively. The advantages of extending the powerful spreadsheet style of computation to multiple sets of images and organizing image processing were demonstrated using the Distributed image SpreadSheet (DISS). The DISS is being used as a high performance testbed Next Generation Internet (NGI) VisAnalysis of: 1) El Nino SSTs and NDVI response 2) Latest GOES 10 5-min rapid Scans of 26 day 5000 frame movie of March & April '98 weather and tornadic storms 3) TRMM rainfall and lightning 4)GOES 9 satellite images/winds and NOAA aircraft radar of hurricane Luis, 5) lightning detector data merged with GOES image sequences, 6) Japanese GMS, TRMM, & ADEOS data 7) Chinese FY2 data 8) Meteosat & ERS/ATSR data 9) synchronized manipulation of multiple 3D numerical model views; and others will be illustrated. The Image SpreadSheet has been highly successful in producing Earth science visualizations for public outreach. Many of these visualizations have been widely disseminated through the world wide web pages of the HPCC/LTP/RSD program which can be found at http://rsd.gsfc.nasa.gov/rsd The one min interval animations of Hurricane Luis on ABC Nightline and the color perspective rendering of Hurricane Fran published by TIME, LIFE, Newsweek, Popular Science, National Geographic, Scientific American, and the "Weekly Reader" are some of the examples which will be shown.

Hasler, A. Fritz↗
NASA NTRS1999

NASA/NOAA: Earth Science Electronic Theater 1999. Earth Science Observations, Analysis and Visualization: Roots in the 60s - Vision for the Next Millennium

The Etheater presents visualizations which span the period from the original Suomi/Hasler animations of the first ATS-1 GEO weather satellite images in 1966, to the latest 1999 NASA Earth Science Vision for the next 25 years. Hot off the SGI-Onyx Graphics-Supercomputer are NASA''s visualizations of Hurricanes Mitch, Georges, Fran and Linda. These storms have been recently featured on the covers of National Geographic, Time, Newsweek and Popular Science. Highlights will be shown from the NASA hurricane visualization resource video tape that has been used repeatedly this season on National and International network TV. Results will be presented from a new paper on automatic wind measurements in Hurricane Luis from 1-min GOES images that appeared in the November BAMS. The visualizations are produced by the NASA Goddard Visualization & Analysis Laboratory, and Scientific Visualization Studio, as well as other Goddard and NASA groups using NASA, NOAA, ESA, and NASDA Earth science datasets. Visualizations will be shown from the Earth Science ETheater 1999 recently presented in Tokyo, Paris, Munich, Sydney, Melbourne, Honolulu, Washington, New York, and Dallas. The presentation Jan 11-14 at the AMS meeting in Dallas used a 4-CPU SGI/CRAY Onyx Infinite Reality Super Graphics Workstation with 8 GB RAM and a Terabyte Disk at 3840 X 1024 resolution with triple synchronized BarcoReality 9200 projectors on a 60ft wide screen. Visualizations will also be featured from the new Earth Today Exhibit which was opened by Vice President Gore on July 2, 1998 at the Smithsonian Air & Space Museum in Washington, as well as those presented for possible use at the American Museum of Natural History (NYC), Disney EPCOT, and other venues. New methods are demonstrated for visualizing, interpreting, comparing, organizing and analyzing immense HyperImage remote sensing datasets and three dimensional numerical model results. We call the data from many new Earth sensing satellites, HyperImage datasets, because they have such high resolution in the spectral, temporal, spatial, and dynamic range domains. The traditional numerical spreadsheet paradigm has been extended to develop a scientific visualization approach for processing HyperImage datasets and 3D model results interactively. The advantages of extending the powerful spreadsheet style of computation to multiple sets of images and organizing image processing were demonstrated using the Distributed Image SpreadSheet (DISS). The DISS is being used as a high performance testbed Next Generation Internet (NGI) VisAnalysis of: 1) El Nino SSTs and NDVI response 2) Latest GOES 10 5-min rapid Scans of 26 day 5000 frame movie of March & April 198 weather and tornadic storms 3) TRMM rainfall and lightning 4)GOES 9 satellite images/winds and NOAA aircraft radar of hurricane Luis, 5) lightning detector data merged with GOES image sequences, 6) Japanese GMS, TRMM, & ADEOS data 7) Chinese FY2 data 8) Meteosat & ERS/ATSR data 9) synchronized manipulation of multiple 3D numerical model views; etc. will be illustrated. The Image SpreadSheet has been highly successful in producing Earth science visualizations for public outreach.

Hasler, A. Fritz↗
NASA NTRS2012

NASA Tech Briefs, June 2012

Topics covered include: iGlobe Interactive Visualization and Analysis of Spatial Data; Broad-Bandwidth FPGA-Based Digital Polyphase Spectrometer; Small Aircraft Data Distribution System; Earth Science Datacasting v2.0; Algorithm for Compressing Time-Series Data; Onboard Science and Applications Algorithm for Hyperspectral Data Reduction; Sampling Technique for Robust Odorant Detection Based on MIT RealNose Data; Security Data Warehouse Application; Integrated Laser Characterization, Data Acquisition, and Command and Control Test System; Radiation-Hard SpaceWire/Gigabit Ethernet-Compatible Transponder; Hardware Implementation of Lossless Adaptive Compression of Data From a Hyperspectral Imager; High-Voltage, Low-Power BNC Feedthrough Terminator; SpaceCube Mini; Dichroic Filter for Separating W-Band and Ka-Band; Active Mirror Predictive and Requirement Verification Software (AMP-ReVS); Navigation/Prop Software Suite; Personal Computer Transport Analysis Program; Pressure Ratio to Thermal Environments; Probabilistic Fatigue Damage Program (FATIG); ASCENT Program; JPL Genesis and Rapid Intensification Processes (GRIP) Portal; Data::Downloader; Fault Tolerance Middleware for a Multi-Core System; DspaceOgreTerrain 3D Terrain Visualization Tool; Trick Simulation Environment 07; Geometric Reasoning for Automated Planning; Water Detection Based on Color Variation; Single-Layer, All-Metal Patch Antenna Element with Wide Bandwidth; Scanning Laser Infrared Molecular Spectrometer (SLIMS); Next-Generation Microshutter Arrays for Large-Format Imaging and Spectroscopy; Detection of Carbon Monoxide Using Polymer-Composite Films with a Porphyrin-Functionalized Polypyrrole; Enhanced-Adhesion Multiwalled Carbon Nanotubes on Titanium Substrates for Stray Light Control; Three-Dimensional Porous Particles Composed of Curved, Two-Dimensional, Nano-Sized Layers for Li-Ion Batteries 23 Ultra-Lightweight; and Ultra-Lightweight Nanocomposite Foams and Sandwich Structures for Space Structure Applications.

Source record↗
NASA NTRS2022

Multiscale Progressive Failure Analysis of 3D Woven Composites

Application of three-dimensional (3D) woven composites is growing as an alternative to the use of ply-based composite materials. However, the design, analysis, modeling, and optimization of these materials is more challenging due to their complex and inherently multiscale geometries. Herein, a multiscale modeling procedure, based on efficient, semi-analytical micromechanical theories rather than the traditional finite element approach, is presented and applied to a 3D woven carbon–epoxy composite. A crack-band progressive damage model was employed for the matrix constituent to capture the globally observed nonlinear response. Realistic microstructural dimensions and tow-fiber volume fractions were determined from detailed X-ray computed tomography (CT) and scanning electron microscopy data. Pre-existing binder-tow disbonds and weft-tow waviness, observed in X-ray CT scans of the composite, were also included in the model. The results were compared with experimental data for the in-plane tensile and shear behavior of the composite. The tensile predictions exhibited good correlations with the test data. While the model was able to capture the less brittle nature of the in-plane shear response, quantitative measures were underpredicted to some degree.

3D woven composites↗
NASA NTRS2024

Characterization of NUW-LHT-5m, A Lunar Highland Simulant

A new simulant of the lunar highlands regolith, NUW-LHT-5M, was designed by NASA and manufactured by Washington Mills. The simulant was based on Apollo 16 data and is a member of the NU-LHT-series. NASA’s Marshall Space Flight Center and Johnson Space Center have already purchased 3 metric tons of the simulant for advanced engineering work. In support of engineering uses of the simulant, we provided measurements of the simulant including: mineral abundance and composition, liberation, X-ray fluorescence (XRF), ferrous iron, carbon, sulfur, 60 element inductively coupled plasma (ICP), loss on ignition, particle size, both 2D and 3D particle shape, specific surface area, shear, cohesion, internal friction, helium pycnometry, minimum index density, tap density, magnetic susceptibility, cryogenic and high temperature permittivity, visible and near-infrared (VNIR) and middle infra-red spectroscopy (MIR), differential scanning calorimetry (DSC), viscosity, thermal diffusivity, thermal conductivity, thermal gravimetric analysis (TGA), evolved gas analysis (EGA), and spark sintering. For the crystalline components the design of the simulant called for two rocks from the Stillwater Complex, Montana: 17.6 wt% norite, 37.7% anorthosite, and 4.7 wt% olivine from an unspecified commercial source. The other 40% of the simulant was a high calcium (An100), vesicular glass that Washington Mills made specifically for the simulant. Fabrication and quality control processes for both the glass and the simulant are described. Importantly, most of the graphs and tables presented herein provide values for both the new simulant and data for the older NASA mare simulant, JSC-1A. Finally, we discussed the current limitations of NUW-LT-5M and most other lunar regolith simulants to replicate the lunar material.

lunar regolith simulant↗
NASA NTRS2015

Application of Pinniped Vibrissae to Aeropropulsion

Vibrissae of Phoca Vitulina (Harbor Seal) and Mirounga Angustirostris (Elephant Seal) possessundulations along their length. Harbor Seal Vibrissae were shown to reduce vortex induced vibrations and reduce dragcompared to appropriately scaled cylinders and ellipses. Samples of Harbor Seal vibrissae, Elephant Seal vibrissae andCalifornia Sea Lion vibrissae were collected from the Marine Mammal Center in California. CT scanning, microscopy and3D scanning techniques were utilized to characterize the whiskers. Computational fluid dynamics simulations of thewhiskers were carried out to compare them to an ellipse and a cylinder. Leading edge parameters from the whiskerswere used to create a 3D profile based on a modern power turbine blade. The NASA SW-2 facility was used to performwind tunnel cascade testing on the 'Seal Blades'. Computational Fluid Dynamics simulations were used to studyincidence angles from -37 to +10 degrees on the aerodynamic performance of the Seal Blade. The tests and simulationswere conducted at a Reynolds number of 100,000. The Seal Blades showed consistent performance improvements overthe baseline configuration. It was determined that a fuel burn reduction of approximately 5 could be achieved for a fixedwing aircraft. Noise reduction potential is also explored

vortex induced vibration↗
NASA NTRS2016

3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing, and Future Work

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS), an orbiting laboratory 200 miles above the earth, provides a unique and incredible opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In particularly, additive manufacturing (or 3D printing) techniques can potentially be deployed in the space environment to enhance crew safety (by providing an on-demand part replacement capability) and decrease launch mass by reducing the number of spare components that must be launched for missions where cargo resupply is not a near-term option. In September 2014, NASA launched the 3D Printing in Zero G technology demonstration mission to the ISS to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on-orbit. The printer for this mission was designed and operated by the company Made In Space under a NASA SBIR (Small Business Innovation Research) phase III contract. The overarching objectives of the 3D print mission were to use ISS as a testbed to further maturation of enhancing technologies needed for long duration human exploration missions, introduce new materials and methods to fabricate structure in space, enable cost-effective manufacturing for structures and mechanisms made in low-unit production, and enable physical components to be manufactured in space on long duration missions if necessary. The 3D print unit for fused deposition modeling (FDM) of acrylonitrile butadiene styrene (ABS) was integrated into the ISS Microgravity Science Glovebox (MSG) in November 2014 and phase I printing operations took place from November through December of that year. Phase I flight operations yielded 14 unique parts (21 total specimens) that could be directly compared against ground-based prints of identical geometry manufactured using the printer prior to its launch to ISS. The 3DP unit functioned safely and produced specimens necessary to advance the understanding of the critical design and operational parameters for the FDM process as affected by the microgravity environment. From the standpoint of operations, 3DP demonstrated the ability to remove parts from the build-tray on-orbit, teleoperate the printer from the ground, perform critical maintenance functions within defined human factors limits, produce a functional tool that could be evaluated for form/fit/function, and uplink a new part file from the ground and produce it on the printer. The flight parts arrived at NASA Marshall Space Flight Center in Huntsville, Alabama in April 2015, where they underwent months of testing in the materials and processes laboratory. Ground and flight prints completed the following phases of testing: photographic/visual inspection, mass and density evaluation, structured light scanning, XRay and CT, mechanical testing, optical microscopy, scanning electron microscopy, and chemical analysis. This presentation will discuss the results of this testing as well as phase II operations for the printer, which took place in June and July of 2016. Lessons learned from the tech demo and their impacts on the design and development of the second generation 3D printer for ISS, the Additive Manufacturing Facility (AMF) by Made In Space will also be presented. In addition, progress in other elements of NASA's In Space Manufacturing (ISM) initiative such as the on-demand ISM utilization catalog, in-space Recycler ISS Technology Demonstration development, launch packaging recycling, in-space printable electronics, development of higher strength polymeric materials for 3D printing and Additive Construction by Mobile Emplacement (ACME) will also be addressed.

Prater, Tracie↗
NASA NTRS2005

Computed Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

In friction stir welding (FSW), a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and is carried with the macro-flow of the weld metal. By using CT images, a 3-dimensional (3D) image of the lead flow pattern can be reconstructed. CT imaging was found to be a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

Schneider, Judy↗
NASA NTRS2014

Use of 2d-video Disdrometer to Derive Mean Density-size and Ze-SR Relations: Four Snow Cases from the Light Precipitation Validation Experiment

The application of the 2D-video disdrometer to measure fall speed and snow size distribution and to derive liquid equivalent snow rate, mean density-size and reflectivity-snow rate power law is described. Inversion of the methodology proposed by Böhm provides the pathway to use measured fall speed, area ratio and '3D' size measurement to estimate the mass of each particle. Four snow cases from the Light Precipitation Validation Experiment are analyzed with supporting data from other instruments such as Precipitation Occurrence Sensor System (POSS), Snow Video Imager (SVI), a network of seven snow gauges and three scanning C9 band radars. The radar-based snow accumulations using the 2DVD-derived Ze-SR relation are in good agreement with a network of seven snow gauges and outperform the accumulations derived from a climatological Ze-SR relation used by the Finnish Meteorological Institute (FMI). The normalized bias between radar-derived and gauge accumulation is reduced from 96% when using the fixed FMI relation to 28% when using the Ze-SR relations based on 2DVD data. The normalized standard error is also reduced significantly from 66% to 31%. For two of the days with widely different coefficients of the Ze-SR power law, the reflectivity structure showed significant differences in spatial variability. Liquid water path estimates from radiometric data also showed significant differences between the two cases. Examination of SVI particle images at the measurement site corroborated these differences in terms of unrimed versus rimed snow particles. The findings reported herein support the application of Böhm's methodology for deriving the mean density-size and Ze-SR power laws using data from 2D-video disdrometer.

radar↗
NASA NTRS2018

Freeze Casting of LAGP for 3D Textured Solid-State Structural Electrolytes

In this study, all-solid-state structural lithium-ion batteries, a type of load bearing electrochemical energy storage that provides systems-level weight savings is being pursued for the realization of inherently safe next generation hybrid-electric and all-electric green aerospace propulsion systems. Currently investigated all-solid-state batteries do not meet the requirements for specific power and mechanical stability. To address these issues, freeze casting of lithium aluminum germanium phosphate (LAGP) electrolyte material has been explored for the creation of a textured 3D electrolyte scaffold with large interfacial surface area for high power discharge and hierarchical porosity for accommodation of active material volume changes during electrochemical cycling. We report the effects of freeze casting processing parameters on the microstructural development and mechanical performance of the scaffolds, characterized through scanning electron microscopy and ring-on-ring mechanical testing. Slurry composition and casting parameters such as solids loading, casting speed, tape angle, and temperature gradients have been modified to determine the impact on density, lamellar morphology, and final load-bearing performance.

ceramics↗
NASA NTRS2003

Exploring Asteroid Interiors: The Deep Interior Mission Concept

Deep Interior is a mission to determine the geophysical properties of near-Earth objects, including the first volumetric image of the interior of an asteroid. Radio reflection tomography will image the 3D distribution of complex dielectric properties within the ~1 km rendezvous target and hence map structural, density or compositional variations. Laser altimetry and visible imaging will provide high-resolution surface topography. Smart surface pods culminating in blast experiments, imaged by the high frame rate camera and scanned by lidar, will characterize active mechanical behavior and structure of surface materials, expose unweathered surface for NIR analysis, and may enable some characterization of bulk seismic response. Multiple flybys en route to this target will characterize a diversity of asteroids, probing their interiors with non-tomographic radar reflectance experiments. Deep Interior is a natural follow-up to the NEARShoemaker mission and will provide essential guidance for future in situ asteroid and comet exploration. While our goal is to learn the interior geology of small bodies and how their surfaces behave, the resulting science will enable pragmatic technologies required of hazard mitigation and resource utilization.

Asphaug, E.↗