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NASA NTRS2004

Medical/Scientific Illustration And Production Of Otological Health Awareness Materials

Over the past year, I have worked for my mentor, Beth Cooper, on a large variety of projects. Beth is the Manager of the Acoustical Testing Laboratory, which tests the acoustical emissions of payloads destined for the International Space Station. She is also responsible for educating, and developing new methods of educating, people of all occupational and educational backgrounds in hearing conservation. Beth spends much of her time developing new materials and strategies with which to train people and teach other people to train people in hearing conservation and noise emissions control. I have been helping Beth develop and market these materials by way of graphic design and scientific illustration. Last summer, I spent much of my time creating educational illustrations that visually explained particular concepts in Beth's presentations. Sometimes these illustrations were small "comics" while, at other times, they were an instructional series of illustrations. Since then, Beth and her lab have been developing and updating some materials which will be distributed free to hearing conservation and noise control professionals and others in related fields. I have helped with these projects by designing their packaging. In each instance, it was my responsibility to develop an aesthetically appealing package that would also, through its imagery, describe or summarize the contents of the product. I did this for 3 CD's (Auditory Demonstrations 11, MACSUG, and JeopEARdy) and saw them through their actual production and distribution. In addition to working with Beth, I work with the Imaging Technology Center on various imaging projects. Some of my activities include photo retouching and manipulation for videos and print. This summer, I also had the opportunity to develop a screen saver that would show of some of the photography contained on the soon-to-be-released "Highlights of the GRC Image Archives, vol. 2". I was also able to utilize my medical training to help several of ITC s videographers identify the best histological examples of cancerous cells for incorporation in one of their videos. Over the last part of this summer and then throughout the school year, I will be working with Beth to develop a "pre-packaged" lecture series about the physics of acoustics in the context of hearing conservation. These lectures will be used to teach people of all backgrounds the fundamental concepts involved in acoustical physics so they might be better aware of their own and others auditory health in and out of the work place, and, in the case of payload developers, to design and build more quiet science experiments for the ISS. Even though it may not seem as such, this project is precisely what I am learning to do as a student of the Cleveland Institute of Art's Medical Illustration Department. From my perspective, this project is about taking technical information and translating it into terms that anyone, regardless of background, can understand.

Hawes, Nicholas E.↗
NASA NTRSDate not supplied

Selection, Production, and Properties of Regolith Polymer Composites for Lunar Construction

NASA’s Artemis Program seeks to establish a long-term presence on the moon to enable scientific discoveries and utilization of lunar resources through public-private partnerships. Over the next decades, a lunar spaceport enabling regular transportation from and to Earth will need to be established to provide the services and facilities that are necessary to achieve this goal. Robotic construction technologies using in-situ materials must be developed to build up enabling infrastructure such as launch/landing pads, blast protection, power/communications towers, improved trafficability pathways and radiation protection shelters. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory at Swamp Works has partnered with AI SpaceFactory to develop the architectural and structural design of an unpressurized shelter. The shelter, called Lina, is designed to protect astronauts and surface assets from radiation, meteoroid impact, moon quakes and thermal gradients. Lina’s structural design criteria and the resulting structure design are detailed in separate papers. A Fused Filament Fabrication (FFF) construction process using regolith polymer composites has been developed. This paper presents the material formulations and selection rationale for each of the composite components. Formulations include 70:30, 80:20, and 85:15 wt.% mixture ratios of lunar mare simulant Black Point-1 (BP-1): Polylactic Acid (PLA), 80:20 Lunar Highlands Simulant (LHS-1): PLA and an 80:20 BP-1:PLA formulation with a processing aid/compatibilizer additive. Test samples were printed in simulated lunar dirty thermal vacuum conditions (~-180 °C, ~10 -3 torr). The test environment evolved throughout the duration of the print process. A series of tests were performed to characterize the mixture ratios achieved for each formulation, the off-gassing products during vacuum printing, the strength properties, and porosity of printed products. The LHS-1: PLA formulation yielded an advantageous combination of properties and was used in a final test that additively constructed a sub-scaled Lina on regolith simulant in dirty vacuum conditions.

lunar infrastructure↗
NASA NTRSDate not supplied

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

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

Optimization↗
NASA NTRSDate not supplied

An Optimization-Based Toolchain for Parametric Mechanism Design

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

Optimization↗
NASA NTRS2016

[EC5-Space Suit Assembly Team- Internship]

There were three main projects in this internship. The first pertained to the Bearing Dust Cycle Test, in particular automating the test to allow for easier administration. The second concerned modifying the communication system setup in the Z2 suit, where speakers and mics were adjusted to allow for more space in the helmet. And finally, the last project concerned the tensile strength testing of fabrics deemed as candidates for space suit materials and desired to be sent off for radiation testing. The major duties here are split up between the major projects detailed above. For the Bearing Dust Cycle Test, the first objective was to find a way to automate administration of the test, as the previous version was long and tedious to perform. In order to do this, it was necessary to introduce additional electronics and perform programming to control the automation. Once this was done, it would be necessary to update documents concerning the test setup, procedure, and potential hazards. Finally, I was tasked with running tests using the new system to confirm system performance. For the Z2 communication system modifications, it was necessary to investigate alternative speakers and microphones which may have better performance than those currently used in the suit. Further, new speaker and microphone positions needed to be identified to keep them out of the way of the suit user. Once this was done, appropriate hardware (such as speaker or microphone cases and holders) could be prototyped and fabricated. For the suit material strength testing, the first task was to gather and document various test fabrics to identify the best suit material candidates. Then, it was needed to prepare samples for testing to establish baseline measurements and specify a testing procedure. Once the data was fully collected, additional test samples would be prepared and sent off-site to undergo irradiation before being tested again to observe changes in strength performance. For the Bearing Dust Cycle Test, automation was achieved through use of a servo motor and code written in LabVIEW. With this a small electrical servo controller was constructed and added to the system. For the Z2 communication modifications speaker cases were developed and printed, and new speakers and mics were selected. This allowed us to move the speakers and mics to locations to remain out of the suit users way. For the suit material strength testing, five material candidates were identified and test samples were created. These samples underwent testing, and baseline test results were gathered, though these results are currently being investigated for accuracy. The main process efficiency developed during the course of this internship comes from automation of the Bearing Dust Cycle Test. In particular, many hours of human involvement and precise operation are replaced with a simple motor setup. Thus it is no longer required to man the test, saving valuable employee time. This internship has confirmed a few things for me, namely that I both want to work as an engineer for an aerospace firm and that in particular I want to work for the Johnson Space Center. I am also confirmed in my desire to work with electronics, though I was surprised to enjoy prototyping 3D CAD design as much as I did. Therefore, I will make an effort to build my skills in this area so that I can continue to design mechanical models. In fact, I found the process of hands-on prototyping to be perhaps the most fun aspect of my time working here. This internship has also furthered my excitement for continual education, and I will hopefully be pursuing a masters in my field in the near future.

Maicke, Andrew↗
NASA NTRSDate not supplied

Selection, Production, and Properties of Regolith Polymer Composites for Lunar Construction

NASA’s Artemis Program seeks to establish a long-term presence on the Moon to enable scientific exploration and expand the cis-lunar economy by utilizing lunar resources through public-private and international partnerships. Over the next decades, a lunar spaceport will need to be established to provide the services and facilities that are necessary to achieve this goal. Robotic construction technologies using in-situ materials must be developed to build up enabling infrastructure such as launch/landing pads, blast protection, power/communications infrastructure, improved roads, improved operational surfaces, and radiation protection shelters. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory at Swamp Works has partnered with SpaceFactory and LERA Consulting Structural Engineers to develop the architectural and structural design of an unpressurized lunar shelter. The shelter, called Lunar Infrastructure Asset (LINA), is designed to support 2.3 m of regolith overburden to protect astronauts and surface assets from radiation, meteoroid impact, thermal gradients/cycling, and to withstand moonquakes. LINA’s structural design criteria and the resulting structure design are detailed in separate papers. A Fused Filament Fabrication (FFF) construction process using regolith polymer composites has been developed and is detailed in a separate publication. This paper presents material formulations and selection rationale for each of the composite components that were examined. Formulations include 70:30, 80:20, and 85:15 wt.% mixture ratios of lunar mare simulant Black Point-1 (BP-1): Polylactic Acid (PLA), 80:20 Lunar Highlands Simulant-1 (LHS-1): PLA and an 80:20 BP-1: PLA formulation with a flow enhancer additive. Test samples were printed in simulated lunar dirty thermal vacuum conditions (-190 °C, 10-3 torr). A series of tests were performed on each formulation to characterize the achieved mixture ratio, mechanical strength properties, off-gassing products during vacuum printing, and porosity and density of printed products. The LHS-1: PLA formulation yielded an advantageous combination of properties and was used in a final test that additively constructed a sub-scaled LINA on regolith simulant in dirty vacuum conditions. The materials and construction process presented in this paper are considered to be at Technology Readiness Level (TRL) 5 with additional testing necessary to characterize long term lunar environmental exposure effects.

lunar infrastructure↗
NASA NTRS2005

Navier-Stokes Simulation of Airconditioning Facility of a Large Modem Computer Room

NASA recently assembled one of the world's fastest operational supercomputers to meet the agency's new high performance computing needs. This large-scale system, named Columbia, consists of 20 interconnected SGI Altix 512-processor systems, for a total of 10,240 Intel Itanium-2 processors. High-fidelity CFD simulations were performed for the NASA Advanced Supercomputing (NAS) computer room at Ames Research Center. The purpose of the simulations was to assess the adequacy of the existing air handling and conditioning system and make recommendations for changes in the design of the system if needed. The simulations were performed with NASA's OVERFLOW-2 CFD code which utilizes overset structured grids. A new set of boundary conditions were developed and added to the flow solver for modeling the roomls air-conditioning and proper cooling of the equipment. Boundary condition parameters for the flow solver are based on cooler CFM (flow rate) ratings and some reasonable assumptions of flow and heat transfer data for the floor and central processing units (CPU) . The geometry modeling from blue prints and grid generation were handled by the NASA Ames software package Chimera Grid Tools (CGT). This geometric model was developed as a CGT-scripted template, which can be easily modified to accommodate any changes in shape and size of the room, locations and dimensions of the CPU racks, disk racks, coolers, power distribution units, and mass-storage system. The compute nodes are grouped in pairs of racks with an aisle in the middle. High-speed connection cables connect the racks with overhead cable trays. The cool air from the cooling units is pumped into the computer room from a sub-floor through perforated floor tiles. The CPU cooling fans draw cool air from the floor tiles, which run along the outside length of each rack, and eject warm air into the center isle between the racks. This warm air is eventually drawn into the cooling units located near the walls of the room. One major concern is that the hot air ejected to the middle isle might recirculate back into the cool rack side and cause thermal short-cycling. The simulations analyzed and addressed the following important elements of the computer room: 1) High-temperature build-up in certain regions of the room; 2) Areas of low air circulation in the room; 3) Potential short-cycling of the computer rack cooling system; 4) Effectiveness of the perforated cooling floor tiles; 5) Effect of changes in various aspects of the cooling units. Detailed flow visualization is performed to show temperature distribution, air-flow streamlines and velocities in the computer room.

Source record↗
NASA NTRS2013

Three-Dimensional (3D) Additive Construction: Printing with Regolith

Three dimensional (3D) printing is a new and booming topic in many realms of research and engineering technology. When it comes to space science and aerospace engineering, it can be useful in numerous ways. As humans travel deeper into space and farther from Earth, sending large quantities of needed supplies from Earth for a mission becomes astronomically expensive and less plausible. In order to reach further to new places, In Situ Resource Utilization (ISRU), a project that pushes for technologies to use materials already present in the destination's environment, is necessary. By using materials already available in space such as regolith from the Moon, Mars, or an asteroid's surface, fewer materials need to be brought into space on a launched vehicle. This allows a vehicle to be filled with more necessary supplies for a deep space mission that may not be found in space, like food and fuel. This project's main objective was to develop a 3D printer that uses regolith to "print" large structures, such as a dome, to be used as a heat shield upon a vehicle's reentry into the atmosphere or even a habitat. 3D printing is a growing technology that uses many different methods to mix, heat, and mold a material into a specific shape. In order to heat the regolith enough to stick together into a solid shape, it must be sintered at each layer of material that is laid. Sintering is a process that heats and compresses a powdered material until it fuses into a solid, which requires a lot of energy input. As an alternative, a polymer can be mixed with the regolith before or as it is sent to the 3D printer head to be placed in the specific shape. The addition of the polymer, which melts and binds at much lower temperatures than sintering temperatures, greatly decreases the required heating temperature and energy input. The main task of the project was to identify a functional material for the printer. The first step was to find a miscible. polymer/solvent solution. This solution was added to the regolith and the solvent was evaporated essentially leaving polymer-coated regolith particles. This material would be sent through the printer head and heated layer by layer to melt the polymer and bind the regolith. This method was one of many in a large goal to utilize materials in space with a custom-made 3D printer that builds dome-shaped habitats and other essential equipment for future deep space missions.

Tsoras, Alexandra↗
NASA NTRS2010

Planning for Plume Diagnostics for Ground Testing of J-2X Engines at the SSC

John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.

SaintCyr, William W.↗
NASA NTRS2001

Using Wearable Computers in Shuttle Processing: A Feasibility Study

Shuttle processing operations are performed following prescribed instructions compiled in a Work Authorization Document (WAD). Until very recently, WADs were printed so that they could be properly executed, including the buy off of each and every step by the appropriate authorizing agent. However, with the development of EPICs, Maximo, and PeopleSoft applications, some of these documents are now available in electronic format; hence, it is possible for technicians and engineers to access them on line and buy off the steps electronically. To take full advantage of these developments, technicians need access to such documents at the point of job execution. Body wearable computers present an opportunity to develop a WAD delivery system that enables access while preserving technician's mobility, safety levels, and quality of work done. The primary objectives of this project were to determine if body wearable computers are a feasible delivery system for WADs. More specifically, identify and recommend specific brands of body wearable computers readily available on the market. Thus, this effort has field-tested this technology in two areas of shuttle processing, and it has examined the usability of the technology. Results of two field tests and a Human Factors Usability Test are presented. Section 2 provides a description of the body wearable computer technology. Section 3 presents the test at the Space Shuttle Main Engine (SSME) Shop. Section 4 presents the results of the integration test at the Solid Rocket Boosters Assembly and Refurbishing Facility (SRBARF). Section 5 presents the results of the usability test done at the Operations Support Building (OSB).

Centeno, Martha A.↗
NASA NTRS2013

Kennedy Space Center: Swamp Works

When I began my internship with the Granular Mechanics and Regolith Operations laboratory (GMRO), also known as Swamp Works, I was given the unique opportunity to shadow many teams working on various projects, and decide what projects I wanted to take part in. Before I go into details of my experiences at Swamp Works, I would like to take a moment to explain what I discovered Swamp Works to be. Swamp Works is a family of hardworking, dedicated, and driven people from various backgrounds and skill sets. These people all work to advance technologies and make science fiction science fact through means of rapid prototyping. They support and encourage failure as an option when learning new things, as long as lesson learned from said failure. In fact, their motto states "Fail, Fast, Forward." What this means is, not if but when one fails he or she must do so quickly and spring forward from the failure so that his or her progress is not delayed. With this acceptance, it provided me the confidence to dive into a multitude of projects working in various fields and with a wide range of skill sets. The first project I joined was Badger. My motivation for taking on this project was the opportunity I would have to obtain valuable experience working with 3D modeling and 3D printing technologies. Badger was a digging apparatus to be used in a highly dusty environment in a material known as Regolith. Regolith is a scientific term for the dirt or top soil found on planetary bodies. Regolith contains a large quantity of sediments less than lOppm and as a result poses a challenge of keeping it out of any cracks and crevices. Furthermore, regolith can create high levels of electrostatic energy, which can prove damaging to sensitive electrical hardware. With these characteristics in mind, I decided to take on the task of designing and manufacturing a dust proof cover for the sensitive electrical hardware. When I began this project, I did not have the slightest idea as to how to use 3D modeling software or a means of manufacturing a viable product. As I went along with variants of the design, I became very proficient with a 3D modeling program known as CREO 2.0. Upon completion of my 3D design, I then had the task of manufacturing and having, in my hands, a usable model. To do this I had to work with additive printing technologies also known as 3D printing. Through my experiences working with Badger, I realized that 3D modeling is the focal point in much of engineering. With this in mind, I have embraced this fact and decided to further my experience with this software so that I may become a more valuable asset to any firm later in my career. Mid-way through work with Badger, I picked up another project in which I found much interest. I ha~ the opportunity to work side by side with a materials and composites guru in manufacturing carbon composite coupons (test strips) for performing stress, strain, and sheer analysis on. Being from a surfing, kiteboarding, and other water sport background I have always been interested in board design. With this in mind, it is no wonder why I found interest in such a project. I had the opportunity to refine Mold preparatory, composite layup, and composite curing techniques. Following manufacturing of these composite strips, I then performed various stress tests and logged my results. With these results, future teams could create lighter, stronger, and more cost effective composite structures for use in varieties of applications. After my experiences with materials and composites testing, I have obtained crucial appreciation for detailed documentation and analysis that material sciences involve. However, as interesting as composite materials testing has been, I do not feel this is where my future career lies. Another, more on the side, project I have been involved in is building a 626 cubic foot regolith containment chamber for doing full scale testing of robotic systems. This chamber is built of high strength aluminum scaffold materials, 80/20, and massive panels of Lexan. Once the chamber is completed, it is be filled with 120 tons of regolith and dubbed the largest regolith test chamber in the world. Through my experiences with building "Big Bin" as we called it, I discovered my demand for engaging and hands on activities. Through all of my incredible experiences working with the Swamp Works at Kennedy Space Center; I have obtained crucial knowledge, insights, and experiences that have fuelled, shaped, and will continue to drive me toward my ultimate goal of obtaining not only a degree in Engineering, but obtaining a job that I can call a career. I want to give much thanks to all of those who mentored me along my journey, and to all who made this opportunity a reality.

DeFilippo, Anthony Robert↗
NASA NTRS1991

Optical studies in the holographic ground station

The Holographic Group System (HGS) Facility in rooms 22 & 123, Building 4708 has been developed to provide for ground based research in determining pre-flight parameters and analyzing the results from space experiments. The University of Alabama, Huntsville (UAH) has researched the analysis aspects of the HGS and reports their findings here. Some of the results presented here also occur in the Facility Operating Procedure (FOP), which contains instructions for power up, operation, and powerdown of the Fluid Experiment System (FES) Holographic Ground System (HGS) Test Facility for the purpose of optically recording fluid and/or crystal behavior in a test article during ground based testing through the construction of holograms and recording of videotape. The alignment of the optical bench components, holographic reconstruction and and microscopy alignment sections were also included in the document for continuity even though they are not used until after optical recording of the test article) setup of support subsystems and the Automated Holography System (AHS) computer. The HGS provides optical recording and monitoring during GCEL runs or development testing of potential FES flight hardware or software. This recording/monitoring can be via 70mm holographic film, standard videotape, or digitized images on computer disk. All optical bench functions necessary to construct holograms will be under the control of the AHS personal computer (PC). These include type of exposure, time intervals between exposures, exposure length, film frame identification, film advancement, film platen evacuation and repressurization, light source diffuser introduction, and control of realtime video monitoring. The completed sequence of hologram types (single exposure, diffuse double exposure, etc.) and their time of occurrence can be displayed, printed, or stored on floppy disk posttest for the user.

Workman, Gary L.↗
NASA NTRS2013

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an assortment of "post-processing" methods to locally alter properties (such as coating, heat treating, work hardening, shot peening, etching, anodizing, among others). Building the final part in an additive process allows for the development of an entirely new class of metals, so-called "functionally graded metals" or "gradient alloys." By carefully blending feedstock materials with different properties in an AM process, hardware can be developed with properties that cannot be obtained using other techniques but with the added benefit of the net-shaped fabrication that AM allows.

Hofmann, Douglas C.↗
NASA NTRS1997

Monitoring with Trackers Based on Semi-Quantitative Models

In three years of NASA-sponsored research preceding this project, we successfully developed a technology for: (1) building qualitative and semi-quantitative models from libraries of model-fragments, (2) simulating these models to predict future behaviors with the guarantee that all possible behaviors are covered, (3) assimilating observations into behaviors, shrinking uncertainty so that incorrect models are eventually refuted and correct models make stronger predictions for the future. In our object-oriented framework, a tracker is an object which embodies the hypothesis that the available observation stream is consistent with a particular behavior of a particular model. The tracker maintains its own status (consistent, superceded, or refuted), and answers questions about its explanation for past observations and its predictions for the future. In the MIMIC approach to monitoring of continuous systems, a number of trackers are active in parallel, representing alternate hypotheses about the behavior of a system. This approach is motivated by the need to avoid 'system accidents' [Perrow, 1985] due to operator fixation on a single hypothesis, as for example at Three Mile Island. As we began to address these issues, we focused on three major research directions that we planned to pursue over a three-year project: (1) tractable qualitative simulation, (2) semiquantitative inference, and (3) tracking set management. Unfortunately, funding limitations made it impossible to continue past year one. Nonetheless, we made major progress in the first two of these areas. Progress in the third area as slower because the graduate student working on that aspect of the project decided to leave school and take a job in industry. I enclosed a set of abstract of selected papers on the work describe below. Several papers that draw on the research supported during this period appeared in print after the grant period ended.

Kuipers, Benjamin↗
NASA NTRSDate not supplied

Virtual Fit Assessment: Validation using Historical Spacesuit Fit Data

Virtual fit tests using 3D body scans have provided a cost-effective means to predictively assess spacesuit fit for the current and future astronaut population. However, fit is a complex issue influenced by physical interferences, subjective preference, and many other factors. Fit can substantially differ between the type of hardware, environmental conditions, and tasks being performed. Namely, fit changes across different contexts, such as 3D printed mockup evaluations, pressurized one-g suited test events, neutral buoyancy and other training events, and flight extravehicular activities (EVA). These challenges make it difficult to validate virtual fit frameworks to physical suit sizing. This study proposes a new method of validation using the wealth of historically archived suit fit data. Physically Assessed Fit (PAF) data was assessed from astronauts and test volunteers who wore the legacy Extravehicular Mobility Unit (EMU). The data was collected during the past decades at NASA and considered to be most reliable and dependable. Each participant was 3D scanned for body shape and spacesuit-critical dimensions were measured per NASA guidelines. The participants’ size preference for hard upper torso (HUT) assembly was retrieved from their pressurized suit fit check records. Fit assessments were also updated after one-g EVA training, neutral buoyancy training, and EVA flights. Virtually Assessed Fit (VAF) was done by overlaying the CAD model of a HUT with the 3D body scans of the PAF participants. Each body scan was iteratively adjusted for the position inside the HUT to minimize the suit-to-body contact interference while satisfying a set of prescribed requirements. Then the residual contact area, depth, and volume were quantified as VAF metrics. This process was repeated for the different HUT sizes, including medium, large, and extra-large. Statistical modeling is currently in progress and will be presented at the conference. A statistical classifier will be developed to predict a fit probability for different HUT sizes as a function of the corresponding person’s VAF metrics. The HUT size with the highest fit probability will constitute the most likely size selection for the person, and the prediction will be compared against the corresponding PAF data. The participant data will be randomly pre-grouped into either a model development or validation subset. While the model development subset will be used to build the probability model, the validation subset will be used to assess the model accuracy. Also, the locations and magnitudes of suit-body-contacts will be estimated from VAF. This information can identify the critical suit geometry and body shape features that influence suit fit. The variations found in PAF size selections by subjects with similar VAF metrics will allow for investigations into subjective preferences, for example, tight versus loose fit. Overall, this study is expected to provide a structured validation of a virtual suit fit framework, which has not been possible in the past. The outcome can also provide useful insights and potential limitations for interpreting virtual fit tests for future spacesuit designs and population accommodation.

Han Kim↗
NASA NTRS2013

Planetary Protection Bioburden Analysis Program

This program is a Microsoft Access program that performed statistical analysis of the colony counts from assays performed on the Mars Science Laboratory (MSL) spacecraft to determine the bioburden density, 3-sigma biodensity, and the total bioburdens required for the MSL prelaunch reports. It also contains numerous tools that report the data in various ways to simplify the reports required. The program performs all the calculations directly in the MS Access program. Prior to this development, the data was exported to large Excel files that had to be cut and pasted to provide the desired results. The program contains a main menu and a number of submenus. Analyses can be performed by using either all the assays, or only the accountable assays that will be used in the final analysis. There are three options on the first menu: either calculate using (1) the old MER (Mars Exploration Rover) statistics, (2) the MSL statistics for all the assays, or This software implements penetration limit equations for common micrometeoroid and orbital debris (MMOD) shield configurations, windows, and thermal protection systems. Allowable MMOD risk is formulated in terms of the probability of penetration (PNP) of the spacecraft pressure hull. For calculating the risk, spacecraft geometry models, mission profiles, debris environment models, and penetration limit equations for installed shielding configurations are required. Risk assessment software such as NASA's BUMPERII is used to calculate mission PNP; however, they are unsuitable for use in shield design and preliminary analysis studies. The software defines a single equation for the design and performance evaluation of common MMOD shielding configurations, windows, and thermal protection systems, along with a description of their validity range and guidelines for their application. Recommendations are based on preliminary reviews of fundamental assumptions, and accuracy in predicting experimental impact test results. The software is programmed in Visual Basic for Applications for installation as a simple add-in for Microsoft Excel. The user is directed to a graphical user interface (GUI) that requires user inputs and provides solutions directly in Microsoft Excel workbooks. This work was done by Shannon Ryan of the USRA Lunar and Planetary Institute for Johnson Space Center. Further information is contained in a TSP (see page 1). MSC- 24582-1 Micrometeoroid and Orbital Debris (MMOD) Shield Ballistic Limit Analysis Program Lyndon B. Johnson Space Center, Houston, Texas Commercially, because it is so generic, Enigma can be used for almost any project that requires engineering visualization, model building, or animation. Models in Enigma can be exported to many other formats for use in other applications as well. Educationally, Enigma is being used to allow university students to visualize robotic algorithms in a simulation mode before using them with actual hardware. This work was done by David Shores and Sharon P. Goza of Johnson Space Center; Cheyenne McKeegan, Rick Easley, Janet Way, and Shonn Everett of MEI Technologies; Mark Manning of PTI; and Mark Guerra, Ray Kraesig, and William Leu of Tietronix Software, Inc. For further information, contact the JSC Innovation Partnerships Office at (281) 483-3809. MSC-24211-1 Spitzer Telemetry Processing System NASA's Jet Propulsion Laboratory, Pasadena, California The Spitzer Telemetry Processing System (SirtfTlmProc) was designed to address objectives of JPL's Multi-mission Image Processing Lab (MIPL) in processing spacecraft telemetry and distributing the resulting data to the science community. To minimize costs and maximize operability, the software design focused on automated error recovery, performance, and information management. The system processes telemetry from the Spitzer spacecraft and delivers Level 0 products to the Spitzer Science Center. SirtfTlmProc is a unique system with automated error notification and recovery, with a real-time continuous service that can go quiescent after periods of inactivity. The software can process 2 GB of telemetry and deliver Level 0 science products to the end user in four hours. It provides analysis tools so the operator can manage the system and troubleshoot problems. It automates telemetry processing in order to reduce staffing costs. This work was done by Alice Stanboli, Elmain M. Martinez, and James M. McAuley of Caltech for NASA's Jet Propulsion Laboratory. For more information, contact iaoffice @jpl.nasa.gov. This software is available for commercial licensing. Please contact Dan Broderick at Daniel.F. Broderick@jpl.nasa.gov. Refer to NPO-47803. NASA Tech Briefs, September 2013 29 This rapid response computer program predicts Orbiter Wing Leading Edge (WLE) damage caused by ice or foam impact during a Space Shuttle launch (Program "IMPACT2"). The program was developed after the Columbia accident in order to assess quickly WLE damage due to ice, foam, or metal impact (if any) during a Shuttle launch. IMPACT2 simulates an impact event in a few minutes for foam impactors, and in seconds for ice and metal impactors. The damage criterion is derived from results obtained from one sophisticated commercial program, which requires hours to carry out simulations of the same impact events. The program was designed to run much faster than the commercial program with prediction of projectile threshold velocities within 10 to 15% of commercial-program values. The mathematical model involves coupling of Orbiter wing normal modes of vibration to nonlinear or linear springmass models. IMPACT2 solves nonlinear or linear impact problems using classical normal modes of vibration of a target, and nonlinear/ linear time-domain equations for the projectile. Impact loads and stresses developed in the target are computed as functions of time. This model is novel because of its speed of execution. A typical model of foam, or other projectile characterized by material nonlinearities, impacting an RCC panel is executed in minutes instead of hours needed by the commercial programs. Target damage due to impact can be assessed quickly, provided that target vibration modes and allowable stress are known. This work was done by Robert Clark, Jr., Paul Cotter, and Constantine Michalopoulos of The Boeing Company for Johnson Space Center. For further information, contact the JSC Innovation Partnerships Office at (281) 483-3809. MSC-24988-1 Wing Leading Edge RCC Rapid Response Damage Prediction Tool (IMPACT2) Lyndon B. Johnson Space Center, Houston, Texas (3) the MSL statistics for only the accountable assays. Other options on the main menu include a data editing form and utility programs that produce various reports requested by the microbiologists and the project, and tools to generate the groupings for the final analyses. The analyses can be carried out in three ways: Each assay can be treated separately, the assays can be collectively treated for the whole zone as a group, or the assays can be collected in groups designated by the JPL Planetary Protection Manager. The latter approach was used to generate the final report because assays on the same equipment or similar equipment can be assumed to have been exposed to the same environment and cleaning. Thus, the statistics are improved by having a larger population, thereby reducing the standard deviation by the square root of N. For each method mentioned above, three reports are available. The first is a detailed report including all the data. This version was very useful in verifying the calculations. The second is a brief report that is similar to the full detailed report, but does not print out the data. The third is a grand total and summary report in which each assay requires only one line. For the first and second reports, most of the calculations are performed in the report section itself. For the third, all the calculations are performed directly in the query bound to the report. All the numerical results were verified by comparing them with Excel templates, then exporting the data from the Planetary Protection Analysis program to Excel.

Beaudet, Robert A.↗