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Sustaining Thermal Protection Systems Needed for Uranus Probes

Summary: Achieving Uranus in-situ science objectives through deploying probes in the atmosphere requires thermal protection systems capable of withstanding extreme entry environments. NASA’s 3-D Woven based thermal protection systems (TPS), developed specifically to meet this challenge, are mature, efficient, and capable of withstanding such entry. These science-enabling capabilities need to be sustained, otherwise mission implementation risk may increase to the point that the mission is untenable. The heatshield technology has been developed in concert with industry, and manufacturing processes have been technology transferred. Current technology readiness does not guarantee future availability. Sustainment requires maintaining expertise within NASA as well as ensuring that proven industrial expertise and capabilities will be readily available in the future. A constant awareness and risk assessment followed by risk mitigation are required. The scientific community needs to be aware of these challenges. It needs to engage NASA to ensure these capabilities will be available when needed. As was the case with the atrophy of heritage carbon phenolic that led to developing the 3-D Woven capabilities, our vigilance is again needed to sustain these enabling TPS capabilities for Uranus and for other missions. Background: NASA invested in and developed Heatshield for Extreme Entry Environment Technology (HEEET) TPS that was matured to TRL 6 in 2019 as a tiled system with seams and gap-fillers. Manufacturing readiness included development of specialized looms, molding, and infusion processes using commercial partners. In support of the Mars Sample Return mission, a single-layer, seamless, single-piece variant referred to as 3MDCP (3-D woven Mid-Density Carbon-Phenolic) was developed and is limited to a 1.3m maximum diameter scale due to weaving width limitations of 80”. Molding techniques developed to transform a flat, 2”-thick 3-D woven preform into a sphere-cone shape prior to phenolic resin infusion has been demonstrated. A team at NASA Ames is currently working with industry to demonstrate infusion at full-scale. By 2026, 3MDCP will be at a high level of maturity in technical, manufacturing, and integration readiness as well as material characterization. HEEET and 3MDCP for Uranus Entry: Several system studies have evaluated and baselined 3-D Woven TPS for Uranus entry, both HEEET as well as 3MDCP. If the aeroshell carrying the descent probe is 1.3m or less, then 3MDCP is a very capable and the most mass-efficient choice. If the aeroshell is bigger than 1.3m diameter, then HEEET can meet the mission need as it allows for an aeroshell of any diameter. HEEET and 3MDCP are capable of Saturn in-situ science missions prioritized in the New Frontiers-5 draft Announcement of Opportunity (AO) and if Saturn is the mission of choice, there is a pathway for sustaining the capability. Capability Sustainment: Given NASA’s current budgetary constraints, the postponement of the next New Frontiers AO to no earlier than 2026 and the unknown delay in starting the UOP flagship effort point to potential gap years for the HEEET and 3MDCP capabilities. The first step in capability sustainment is to understand the risks as they emerge, assess those risks, and develop plans to mitigate them. Keeping the science community, who are interested in UOP as well as the larger Giant Planet missions, informed of the emerging challenges requires continuous risk assessment/mitigation. Without these steps, atrophy is more likely within the industrial partners with which NASA has partnered. This presentation will provide more details as well as steps NASA can take to minimize the impact to the UOP mission.

Ethiraj Venkatapathy↗

Spaceflight KID Readout Electronics Development for PRIMA

We present the design and testing of spaceflight multiplexing kinetic inductance detector (KID) readout electronics for the PRobe far-Infrared Mission for Astrophysics (PRIMA). PRIMA is a mission proposed to the 2023 NASA Astrophysics Probe Explorer (APEX) Announcement of Opportunity that will answer fundamental questions about the formation of planetary systems, as well as the formation and evolution of stars, supermassive black holes, and dust over cosmic time. The readout electronics for PRIMA must be compatible with operation at Earth-Sun L2 and capable of multiplexing more than 1000 detectors over 2 GHz bandwidth while consuming around 30 W per readout chain. The electronics must also be capable of switching between the two instruments, which have different readout bands,: the hyperspectral imager (PRIMAger, 2.5-5.0 GHz) and the spectrometer (FIRESS, 0.4-2.4 GHz). We present the driving requirements, design, and measured performance of a laboratory brassboard system.

Sumit Dahal↗

Cryogenic Fluid Management Technologies Enabling for the Artemis Program and Beyond

NASA is endeavoring on an ambitious return to the Moon and eventually on to Mars through the Artemis Program leveraging innovative technologies to establish sustainable exploration architectures collaborating with US commercial and international partners[1]. Future NASA architectures have baselined cryogenic propulsion systems to support lunar missions and ultimately future missions to Mars. NASA has been investing in maturing CFM active and passive storage, transfer, and gauging technologies over the last decade plus primarily focused on ground development with a few small-scale microgravity fluid experiments. Recently, NASA created a Cryogenic Fluid Management (CFM)Technology Roadmap identifying the critical gaps requiring further development to reach a technology readiness level (TRL) of 6 prior to infusion to flight applications. To address the technology gaps the Space Technology Mission Directorate(STMD)strategically plans to invest in a diversified CFM portfolio approach through ground and flight demonstrations ,collaborating with international partners, and leveraging Public Private Partnerships (PPPs) opportunities with US industry through the Tipping Point and Announcement of Collaborative Opportunities (ACO) solicitations. Once proven, these system capabilities will enable the high performing cryogenic propellant systems needed for the Artemis Program and beyond.

Cryogenic Fluid Management↗

Cryogenic Fluid Management for the Artemis Program and Beyond

NASA is endeavoring on an ambitious return to the Moon and eventually on to Mars through the Artemis Program leveraging innovative technologies to establish sustainable exploration architectures collaborating with US commercial and international partners [1]. Future NASA architectures have baselined cryogenic propulsion systems to support lunar missions and ultimately future missions to Mars. NASA has been investing in maturing CFM active and passive storage, transfer, and gauging technologies over the last decade plus primarily focused on ground development with a few small-scale microgravity fluid experiments. Recently, NASA created a Cryogenic Fluid Management (CFM) Technology Roadmap identifying the critical gaps requiring further development to reach a technology readiness level (TRL) of 6 prior to infusion to flight applications. To address the technology gaps the Space Technology Mission Directorate (STMD) strategically plans to invest in a diversified CFM portfolio approach through ground and flight demonstrations, collaborating with international partners, and leveraging Public Private Partnerships (PPPs) opportunities with US industry through the Tipping Point and Announcement of Collaborative Opportunities (ACO) solicitations. Once proven, these system capabilities will enable the high performing cryogenic propellant systems needed for the Artemis Program and beyond.

Cryogenic Fluid Management↗

2015 Annual Report for the Flight Opportunities Program

Welcome to this third edition of the Flight Opportunities program annual report. In this edition, we continue our story of pathfinding NASA's role in the partnership with the U.S. commercial space and space technology R&D communities to advance national space interests and develop technologies critical to NASA's future missions. 2015 was the year in which a planned change to our payload solicitation strategy saw its first tangible result. As you might remember from our 2014 annual report, in 2015 we set out to facilitate a more direct interaction between flight providers and technology developers by providing fixed funding awards to researchers to directly purchase the flight service(s) that best meet their needs. The selection and award of the first six REDDI-F1 flight grants to non-U.S. government researchers was an important milestone in this regard. From now on, using the REDDI-F1 solicitation appendix, the program will enable non-U.S. government researchers to directly purchase flight services on the emerging suborbital market. The same (or similar) commercial flight services will be available to NASA and other U.S. government agencies (OGA) through commercial contracts that NASA has established through our program. For the latter, our program is available to provide campaign management services, similar to the role we play(ed) for technology payloads remaining in our pool from earlier selections. The full impact of this broader strategic change will likely become more visible in the years ahead as our legacy pool gets depleted and we have implemented a new NASA- and OGA-specific call for proposals. One observation that can already be made after two rounds of REDDI-F1 solicitations is that through this change, the list of commercial flight service providers of interest to non-U.S. government researchers has grown from five in 2014 to nine in 2015. On the industry development front, our Announcement of Collaborative Opportunities (ACO) solicitation was promoted to an STMD-wide solicitation and released in 2015 in combination with the Tipping Point solicitation. A total of 22 awards was announced in November 2015, 12 of which are ACO awards, and six of these are funded by Flight Opportunities. Through these ACO awards, the program funds NASA technical expertise and NASA test facilities to aid industry partners in maturing key space technologies, in our case focusing on small launch vehicle technology development. Flight test activity in 2015 saw a steady 13 campaigns with 31 payload-flights (29 unique payloads). Thirteen new payloads were selected into the program in FY2015, and 14 payloads completed flight testing, bringing the total number of completed technology demonstration payloads to 69. Overall, we are pleased with the evolution and growth of the Flight Opportunities program and look forward to continued success in our partnership with the technology R&D community and the commercial space sector.

Flight Testing↗

New Directions in NASA's Biological Crystal Growth Program on the International Space Station

NASA's Biological Crystal Growth Program (BCG) on the International Space Station (ISS) is changing direction from the study of crystallization to an emphasis on producing crystals for structure determination in leading problems in structural biology. The program will consist of two phases. The first phase is during assembly of the ISS and will primarily utilize payloads that currently fly in the orbiter middeck but can be adapted for ISS. The second phase begins after assembly of the ISS is complete and BCG payloads will occupy part of the Biotechnology Facility aboard the ISS. Two types of BCG payloads will be flown. One will emphasize the production of crystals for structure determination back on Earth. These types of payloads will allow hundreds of crystallization conditions to be tested. The second type of payload will be designed to study the crystallization process with the primary aim of assisting the structural biology efforts. Access to these facilities will be through the NASA BCG Guest Investigators program, the NASA Research Announcement, and other opportunities currently being formulated. Details of the crystallization hardware, the application procedures, and the operational aspects of the program will be described.

Kundrot, Craig E.↗

New Directions in NASA's Biological Crystal Growth Program on the International Space Station

NASA's Biological Crystal Growth Program (BCG) on the International Space Station (ISS) is changing direction from the study of crystallization to an emphasis on producing crystals for structure determination in leading problems in structural biology. The program will consist of two phases. The first phase is during assembly of the ISS and will primarily utilize payloads that currently fly in the orbiter middeck but can be adapted for ISS. The second phase begins after assembly of the ISS is complete and BCG payloads will occupy part of the Biotechnology Facility aboard the ISS. Two types of BCG payloads will be flown. One will emphasize the production of crystals for structure determination back on Earth. These types of payloads will allow hundreds of crystallization conditions to be tested. The second type of payload will be designed to study the crystallization process with the primary aim of assisting the structural biology efforts. Access to these facilities will be through the NASA BCG Guest Investigators program, the NASA Research Announcement, and other opportunities currently being formulated. Details of the crystallization hardware, the application procedures, and the operational aspects of the program will be described.

Kundrot, Craig E.↗

XII Recontres De Blois

In the initial awarding of the grant, we had difficulty phasing our proposed support of graduate students, postdoctoral fellows and young US scientists with the meeting schedule and the grant cycle. Initially, the grant arrived too late to support the meeting. The following year, a combination of the renewal process and the meeting announcement prevented us from announcing the support opportunity sufficiently in advance to allow us to make awards and provide support. As described in the initial proposal, the Moriond and Blois meetings are a unique opportunity for younger researchers to make oral presentations of their work at an international venue. As noted above, the phasing of meetings combined with the difficulty of arranging foreign travel for scientists at other institutions precluded the possibility of supporting the proposed meetings and providing young US scientists and post-doctoral fellows support to attend these meetings.

Kaluzienski, Louis↗

A Web 2.0 and OGC Standards Enabled Sensor Web Architecture for Global Earth Observing System of Systems

This paper will describe the progress of a 3 year research award from the NASA Earth Science Technology Office (ESTO) that began October 1, 2006, in response to a NASA Announcement of Research Opportunity on the topic of sensor webs. The key goal of this research is to prototype an interoperable sensor architecture that will enable interoperability between a heterogeneous set of space-based, Unmanned Aerial System (UAS)-based and ground based sensors. Among the key capabilities being pursued is the ability to automatically discover and task the sensors via the Internet and to automatically discover and assemble the necessary science processing algorithms into workflows in order to transform the sensor data into valuable science products. Our first set of sensor web demonstrations will prototype science products useful in managing wildfires and will use such assets as the Earth Observing 1 spacecraft, managed out of NASA/GSFC, a UASbased instrument, managed out of Ames and some automated ground weather stations, managed by the Forest Service. Also, we are collaborating with some of the other ESTO awardees to expand this demonstration and create synergy between our research efforts. Finally, we are making use of Open Geospatial Consortium (OGC) Sensor Web Enablement (SWE) suite of standards and some Web 2.0 capabilities to Beverage emerging technologies and standards. This research will demonstrate and validate a path for rapid, low cost sensor integration, which is not tied to a particular system, and thus be able to absorb new assets in an easily evolvable, coordinated manner. This in turn will help to facilitate the United States contribution to the Global Earth Observation System of Systems (GEOSS), as agreed by the U.S. and 60 other countries at the third Earth Observation Summit held in February of 2005.

Mandl, Daniel↗

Airborne Measurements in Support of the NASA Atmospheric Carbon and Transport - America (ACT-America) Mission

NASA announced the research opportunity Earth Venture Suborbital -2 (EVS-2) mission in support of the NASA's science strategic goals and objectives in 2013. Penn State University, NASA Langley Research Center (LaRC), and other academic institutions, government agencies, and industrial companies together formulated and proposed the Atmospheric Carbon and Transport -America (ACT -America) suborbital mission, which was subsequently selected for implementation. The airborne measurements that are part of ACT-America will provide a unique set of remote and in-situ measurements of CO2 over North America at spatial and temporal scales not previously available to the science community and this will greatly enhance our understanding of the carbon cycle. ACT -America will consist of five airborne campaigns, covering all four seasons, to measure regional atmospheric carbon distributions and to evaluate the accuracy of atmospheric transport models used to assess carbon sinks and sources under fair and stormy weather conditions. This coordinated mission will measure atmospheric carbon in the three most important regions of the continental US carbon balance: Northeast, Midwest, and South. Data will be collected using 2 airborne platforms (NASA Wallops' C-130 and NASA Langley's B-200) with both in-situ and lidar instruments, along with instrumented ground towers and under flights of the Orbiting Carbon Observatory (OCO-2) satellite. This presentation provides an overview of the ACT-America instruments, with particular emphasis on the airborne CO2and backscatter lidars, and the, rationale, approach, and anticipated results from this mission.

Meadows, Byron↗

ATLAS LINKS Electronically Steered Aperture Array System

NASA GSFC and ATLAS Space Operations, Inc. are collaborating through the Space Technology Announcement of Collaborative Opportunity (NASA solicitation NNH17ZOA001K) to advance the state of technology of ATLAS LINKS electronically steered aperture array system. ATLAS LINKS system is a state-of-the-art lightweight, high-performance electronically steered aperture array system. This collaboration provides the opportunity to explore the value of ATLAS technology in supporting NASA Near Earth missions.

Altunc, Serhat↗

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗

Lunar Commercial Development Infographic

This infographic captures Commercial Landers and Rovers presented in the dates that the companies said in public sources that they plan to deploy their vehicles to the Moon and includes NASA activities (Gateway, Orion, PPP Announcement of Collaborative Opportunity), CLPS, and private investors (Bigelow, Blue Origin, SpaceX). This image is expected to change over time to reflect changes in company's plans as they develop their spacecraft. All images used are public domain except for SpaceX and Bigelow images.

Lynn D Harper↗

Lunar Lander Fuel Cell (LLFC) ACO

This is the one-page status report for the STMD Announcement for Collaborative Opportunity (ACO) Lunar Lander Fuel Cell (LLFC) task to be presented at the fiscal year 2020 (FY20) Game Changing Development (GCD) Annual Review.

Fuel Cell↗

ACO Dust Mitigation for Flexible Solar Arrays (DMFlex)

• Announcement of Collaborative Opportunity (ACO) with SSLMaxar • Purpose: • Evaluate blanket solar arrays with mechanical actuation for dust removal • Evaluate vibratory shaking and electrostatic methods for efficacy in simulated lunar environment • Goal is to develop dust mitigation for solar arrays • To maintain solar array operational capability over time • Avoid replacement costs • Extend mission durations

solar arrays↗

2022 TDM Review - Colorado Power Electronics (CPE)-NASA PPUP

This is the presentation of the Colorado Power Electronics Power Processing Unit Prototype (PPUP) Announcement of Collaborations Opportunity (ACO) project. The presentation will be given to the Technology Demonstration Mission (TDM) Annual Review process on March 1, 2022. The purpose of the project is to complete the technology development of a PPU that can operate multiple Hall thrusters over a range of power conditions of interest for NASA science missions.

Eric Pencil↗

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed– A Robotic Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, a 3-axis robotic positioning system, and a regolith bin. For the REACT project, a pellet extruder and feed hopper have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

Moon↗