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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 NTRS2004

Lab-On-a-Chip Application Development (LOCAD): Bridging Technology Readiness for Exploration

At Marshall Space Flight Center we have established a capability to investigate the use of microfluidics for space flight. The Lab-On-a-Chip Application Development (LOCAD) team has created a program for advancing Technology Readiness Levels (TRL) of 1 and 2 to TRL 6 and 7, quickly and economically for Lab-On-a-Chip (LOC) applications. Scientists and engineers can utilize LOCAD'S process to efficiently learn about microfluidics and determine if microfluidics is applicable to their needs. Once the applicability has been determined, LOCAD can then perform tests to develop the new fluidic protocols which are different from macro-scale chemical reaction protocols. With this information new micro-fluidic devices can be created and tested. Currently, LOCAD is focused on using microfluidics for both Environmental Monitoring & Control, and Medical Systems. Eventually, handheld portable units utilizing LOC technology will perform rapid tests to determine water quality, and microbial contamination levels. Since LOC technology is drastically reduced in physical size, it thereby reduces power, weight, volume, and sample requirements, a big advantage considering the resource constraints associated with spaceflight. Another one of LOCAD's current activities is the development of a microfluidic system to aid in the search for life on Mars.

Spearing, Scott F.↗
NASA NTRS2005

Development, Implementation and Application of Micromechanical Analysis Tools for Advanced High Temperature Composites

This document contains the final report to the NASA Glenn Research Center (GRC) for the research project entitled Development, Implementation, and Application of Micromechanical Analysis Tools for Advanced High-Temperature Composites. The research supporting this initiative has been conducted by Dr. Brett A. Bednarcyk, a Senior Scientist at OM in Brookpark, Ohio from the period of August 1998 to March 2005. Most of the work summarized herein involved development, implementation, and application of enhancements and new capabilities for NASA GRC's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) software package. When the project began, this software was at a low TRL (3-4) and at release version 2.0. Due to this project, the TRL of MAC/GMC has been raised to 7 and two new versions (3.0 and 4.0) have been released. The most important accomplishments with respect to MAC/GMC are: (1) A multi-scale framework has been built around the software, enabling coupled design and analysis from the global structure scale down to the micro fiber-matrix scale; (2) The software has been expanded to analyze smart materials; (3) State-of-the-art micromechanics theories have been implemented and validated within the code; (4) The damage, failure, and lifing capabilities of the code have been expanded from a very limited state to a vast degree of functionality and utility; and (5) The user flexibility of the code has been significantly enhanced. MAC/GMC is now the premier code for design and analysis of advanced composite and smart materials. It is a candidate for the 2005 NASA Software of the Year Award. The work completed over the course of the project is summarized below on a year by year basis. All publications resulting from the project are listed at the end of this report.

Source record↗
NASA NTRS2005

Vacuum Deployment and Testing of a 4-Quadrant Scalable Inflatable Solar Sail System

Solar sails reflect photons streaming from the sun and transfer momentum to the sail. The thrust, though small, is continuous and acts for the life of the mission without the need for propellant. Recent advances in materials and ultra-low mass gossamer structures have enabled a host of useful missions utilizing solar sail propulsion. The team of L'Garde, Jet Propulsion Laboratories, Ball Aerospace, and Langley Research Center, under the direction of the NASA In-Space Propulsion office, has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. The baseline design currently in development and testing was optimized around the 1 AU solar sentinel mission. Featuring inflatably deployed sub-T(sub g), rigidized beam components, the 10,000 sq m sail and support structure weighs only 47.5 kg, including margin, yielding an areal density of 4.8 g/sq m. Striped sail architecture, net/membrane sail design, and L'Garde's conical boom deployment technique allows scalability without high mass penalties. This same structural concept can be scaled to meet and exceed the requirements of a number of other useful NASA missions. This paper discusses the interim accomplishments of phase 3 of a 3-phase NASA program to advance the technology readiness level (TRL) of the solar sail system from 3 toward a technology readiness level of 6 in 2005. Under earlier phases of the program many test articles have been fabricated and tested successfully. Most notably an unprecedented 4-quadrant 10 m solar sail ground test article was fabricated, subjected to launch environment tests, and was successfully deployed under simulated space conditions at NASA Plum Brook s 30m vacuum facility. Phase 2 of the program has seen much development and testing of this design validating assumptions, mass estimates, and predicted mission scalability. Under Phase 3 a much larger 20 m square test article including subscale vane has been fabricated and tested. A 20 m system ambient deployment has been successfully conducted after enduring Delta-2 launch environment testing. The program will culminate in a vacuum deployment of a 20 m subscale test article at the NASA Glenn s Plum Brook 30 m vacuum test facility to bring the TRL level as close to 6 as possible in 1 g. This focused program will pave the way for a flight experiment of this highly efficient space propulsion technology.

Lichodziejewski, David↗
NASA NTRS2004

Secure, Mobile, Wireless Network Technology Designed, Developed, and Demonstrated

The inability to seamlessly disseminate data securely over a high-integrity, wireless broadband network has been identified as a primary technical barrier to providing an order-of-magnitude increase in aviation capacity and safety. Secure, autonomous communications to and from aircraft will enable advanced, automated, data-intensive air traffic management concepts, increase National Air Space (NAS) capacity, and potentially reduce the overall cost of air travel operations. For the first time ever, secure, mobile, network technology was designed, developed, and demonstrated with state-ofthe- art protocols and applications by a diverse, cooperative Government-industry team led by the NASA Glenn Research Center. This revolutionary technology solution will make fundamentally new airplane system capabilities possible by enabling secure, seamless network connections from platforms in motion (e.g., cars, ships, aircraft, and satellites) to existing terrestrial systems without the need for manual reconfiguration. Called Mobile Router, the new technology autonomously connects and configures networks as they traverse from one operating theater to another. The Mobile Router demonstration aboard the Neah Bay, a U.S. Coast Guard vessel stationed in Cleveland, Ohio, accomplished secure, seamless interoperability of mobile network systems across multiple domains without manual system reconfiguration. The Neah Bay was chosen because of its low cost and communications mission similarity to low-Earth-orbiting satellite platforms. This technology was successfully advanced from technology readiness level (TRL) 2 (concept and/or application formation) to TRL 6 (system model or prototype demonstration in a relevant environment). The secure, seamless interoperability offered by the Mobile Router and encryption device will enable several new, vehicle-specific and systemwide technologies to perform such things as remote, autonomous aircraft performance monitoring and early detection and mitigation of potential equipment malfunctions. As an additional benefit, team advancements were incorporated into open standards, ensuring technology transfer. Low-cost, commercial products incorporating the new technology are already available. Furthermore, these products are fully interoperable with legacy network technology equipment currently being used throughout the world.

Ivancic, William D.↗
NASA NTRS2005

Development of Inflatable Entry Systems Technologies

Achieving the objectives of NASA s Vision for Space Exploration will require the development of new technologies, which will in turn require higher fidelity modeling and analysis techniques, and innovative testing capabilities. Development of entry systems technologies can be especially difficult due to the lack of facilities and resources available to test these new technologies in mission relevant environments. This paper discusses the technology development process to bring inflatable aeroshell technology from Technology Readiness Level 2 (TRL-2) to TRL-7. This paper focuses mainly on two projects: Inflatable Reentry Vehicle Experiment (IRVE), and Inflatable Aeroshell and Thermal Protection System Development (IATD). The objectives of IRVE are to conduct an inflatable aeroshell flight test that demonstrates exoatmospheric deployment and inflation, reentry survivability and stability, and predictable drag performance. IATD will continue the development of the technology by conducting exploration specific trade studies and feeding forward those results into three more flight tests. Through an examination of these projects, and other potential projects, this paper discusses some of the risks, issues, and unexpected benefits associated with the development of inflatable entry systems technology.

Player, Charles J.↗
NASA NTRS1993

Formal Functional Test Designs: Bridging the Gap Between Test Requirements and Test Specifications

This presentation describes the testing life cycle, the purpose of the test design phase, and test design methods and gives an example application. Also included is a description of Test Representation Language (TRL), a summary of the language, and an example of an application of TRL. A sample test requirement and sample test design are included.

testing life cycle test design test requirements T↗
NASA NTRS2005

Reconfiguration of Analog Electronics for Extreme Environments: Problem or Solution?

This paper argues in favor of adaptive reconfiguration as a technique to expand the operational envelope of analog electronics for extreme environments (EE). In addition to hardening-by-process and hardening-by-design, "hardening-by-reconfiguration", when applicable, could be used to mitigate drifts, degradation, or damage on electronic devices (chips) in EE, by using re-configurable devices and an adaptive self-reconfiguration of their circuit topology. Conventional circuit design exploits device characteristics within a certain temperature/radiation range; when that is exceeded, the circuit function degrades. On a reconfigurable device, although component parameters change in EE, as long as devices still operate, albeit degraded, a new circuit design, suitable for new parameter values, may be mapped into the reconfigurable structure to recover the initial circuit function. Partly degraded resources are still used, while completely damaged resources are bypassed. Designs suitable for various environmental conditions can be determined prior to operation or can be determined in-situ, by adaptive reconfiguration algorithms running on built-in digital controllers. Laboratory demonstrations of this technique were performed by JPL in several independent experiments in which bulk CMOS reconfigurable devices were exposed to, and degraded by, low temperatures (approx. 196 C), high temperatures (approx.300 C) or radiation (300kRad TID), and then recovered by adaptive reconfiguration using evolutionary search algorithms. Taking this technology from Technology Readiness Level (TRL) 3 to TRL 5 is the target of a current NASA project.

Field Programmable Transistor Array (FPTA)↗
NASA NTRS2007

An Exploration Perspective of Beamed Energy Propulsion

The Vision for Exploration is currently focused on flying the Space Shuttle safely to complete our Space Station obligations, retiring the Shuttle in 2010, then returning humans to the Moon and learning how to proceed to Mars and beyond. The NASA budget still includes funds for science and aeronautics but the primary focus is on human exploration. Fiscal constraints have led to pursuing exploration vehicles that use heritage hardware, particularly existing boosters and engines, with the minimum modifications necessary to satisfy mission requirements. So, pursuit of immature technologies is not currently affordable by NASA. Beamed energy is one example of an immature technology, from a human exploration perspective, that may eventually provide significant benefits for human exploration of space, but likely not in the near future. Looking to the more distant future, this paper will examine some of the criteria that must be achieved by beamed energy propulsion to eventually contribute to human exploration of the solar system. The analysis focuses on some of the implications of increasing the payload fraction of a launch vehicle, with a quick look at trans-lunar injection. As one would expect, there is potential for benefit, and there are concerns. The analysis concludes with an assessment of the Technology Readiness Level (TRL) for some beamed energy propulsion components, indicating that TRL 2 is close to being completed.

Cole, John W.↗
NASA NTRS2008

NASA's Plans for Materials Science on ISS: Cooperative Utilization of the MSRR-MSL

The ISS Research Project draws Life (non-human) and Physical Sciences investigations on the ISS, free flyer and ground-based into one coordinated project. The project has two categories: I. Exploration Research Program: a) Utilizes the ISS as a low Technology Readiness Level (TRL) test bed for technology development, demonstration and problem resolution in the areas of life support, fire safety, power, propulsion, thermal management, materials technology, habitat design, etc.; b) Will include endorsement letters from other ETDP projects to show relevancy. II. Non-Exploration Research Program; a) Not directly related to supporting the human exploration program. Research conducted in the life (non-human) and physical sciences; b) The program will sustain, to the maximum extent practicable, the United States scientific expertise and research capability in fundamental microgravity research. Physical Sciences has about 44 grants, and Life Sciences has approximately 32 grants, mostly with universities, to conduct low TRL research; this includes grants to be awarded from the 2008 Fluid Physics and Life Science NRA's.

Chiaramonte, Francis↗
NASA NTRS2008

How Might the Ares V Change the Need for Future Mirror Technology

More Massive Missions do not need to be More Expensive. Simple, robust, low-risk, high-TRL mission is likely to be low cost. It is also likely to be more massive than a complex, high-risk, low TRL mission. The challenge will be to overcome human nature. Launch Date Constrained Missions Cost Less

Stahl, H. Philip↗
NASA NTRS2006

A Process for Technology Prioritization in a Competitive Environment

This slide presentation reviews NASA's process for prioritizing technology requirements where there is a competitive environment. The In-Space Propulsion Technology (ISPT) project is used to exemplify the process. The ISPT project focuses on the mid level Technology Readiness Level (TRL) for development. These are TRL's 4 through 6, (i.e. Technology Development and Technology Demonstration. The objective of the planning activity is to identify the current most likely date each technology is needed and create ISPT technology development schedules based on these dates. There is a minimum of 4 years between flight and pacing mission. The ISPT Project needed to identify the "pacing mission" for each technology in order to provide funding for each area. Graphic representations show the development of the process. A matrix shows which missions are currently receiving pull from the both the Solar System Exploration and the Sun-Solar System Connection Roadmaps. The timeframes of the pacing missions technologies are shown for various types of propulsion. A pacing mission that was in the near future serves to increase the priority for funding. Adaptations were made when budget reductions precluded the total implementation of the plan.

Stephens, Karen↗
NASA NTRS2006

Emerging Propulsion Technologies

The Emerging Propulsion Technologies (EPT) investment area is the newest area within the In-Space Propulsion Technology (ISPT) Project and strives to bridge technologies in the lower Technology Readiness Level (TRL) range (2 to 3) to the mid TRL range (4 to 6). A prioritization process, the Integrated In-Space Transportation Planning (IISTP), was developed and applied in FY01 to establish initial program priorities. The EPT investment area emerged for technologies that scored well in the IISTP but had a low technical maturity level. One particular technology, the Momentum-eXchange Electrodynamic-Reboost (MXER) tether, scored extraordinarily high and had broad applicability in the IISTP. However, its technical maturity was too low for ranking alongside technologies like the ion engine or aerocapture. Thus MXER tethers assumed top priority at EPT startup in FY03 with an aggressive schedule and adequate budget. It was originally envisioned that future technologies would enter the ISP portfolio through EPT, and EPT developed an EPT/ISP Entrance Process for future candidate ISP technologies. EPT has funded the following secondary, candidate ISP technologies at a low level: ultra-lightweight solar sails, general space/near-earth tether development, electrodynamic tether development, advanced electric propulsion, and in-space mechanism development. However, the scope of the ISPT program has focused over time to more closely match SMD needs and technology advancement successes. As a result, the funding for MXER and other EPT technologies is not currently available. Consequently, the MXER tether tasks and other EPT tasks were expected to phased out by November 2006. Presentation slides are presented which provide activity overviews for the aerocapture technology and emerging propulsion technology projects.

Keys, Andrew S.↗
NASA NTRS2009

Conclusions and Recommendations

This chapter provides a brief wrap-up of the task group report and focuses on the overall conclusions and recommendations for future work for the CAWAPI and VFE-2 facets beyond the task group. The overall conclusion is that the Technology Readiness Level (TRL) of CFD solvers has been improved in predicting the flow-physics of vortex-dominated flows during the work of the task group, by having flight and wind-tunnel data available for comparison. Moreover, like all good scientific studies, this task group has identified flight conditions on the F-16XL airplane or wind-tunnel test conditions for a specific leading-edge radius on the 65 delta-wing model where the TRL still needs to be increased.

Lamar, John E.↗
NASA NTRS2010

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗
NASA NTRS2010

Demonstration of an Aerocapture GN and C System Through Hardware-in-the-Loop Simulations

Aerocapture is an orbit insertion maneuver in which a spacecraft flies through a planetary atmosphere one time using drag force to decelerate and effect a hyperbolic to elliptical orbit change. Aerocapture employs a feedback Guidance, Navigation, and Control (GN&C) system to deliver the spacecraft into a precise postatmospheric orbit despite the uncertainties inherent in planetary atmosphere knowledge, entry targeting and aerodynamic predictions. Only small amounts of propellant are required for attitude control and orbit adjustments, thereby providing mass savings of hundreds to thousands of kilograms over conventional all-propulsive techniques. The Analytic Predictor Corrector (APC) guidance algorithm has been developed to steer the vehicle through the aerocapture maneuver using bank angle control. Through funding provided by NASA's In-Space Propulsion Technology Program, the operation of an aerocapture GN&C system has been demonstrated in high-fidelity simulations that include real-time hardware in the loop, thus increasing the Technology Readiness Level (TRL) of aerocapture GN&C. First, a non-real-time (NRT), 6-DOF trajectory simulation was developed for the aerocapture trajectory. The simulation included vehicle dynamics, gravity model, atmosphere model, aerodynamics model, inertial measurement unit (IMU) model, attitude control thruster torque models, and GN&C algorithms (including the APC aerocapture guidance). The simulation used the vehicle and mission parameters from the ST-9 mission. A 2000 case Monte Carlo simulation was performed and results show an aerocapture success rate of greater than 99.7%, greater than 95% of total delta-V required for orbit insertion is provided by aerodynamic drag, and post-aerocapture orbit plane wedge angle error is less than 0.5 deg (3-sigma). Then a real-time (RT), 6-DOF simulation for the aerocapture trajectory was developed which demonstrated the guidance software executing on a flight-like computer, interfacing with a simulated IMU and simulated thrusters, with vehicle dynamics provided by an external simulator. Five cases from the NRT simulations were run in the RT simulation environment. The results compare well to those of the NRT simulation thus verifying the RT simulation configuration. The results of the above described simulations show the aerocapture maneuver using the APC algorithm can be accomplished reliably and the algorithm is now at TRL-6. Flight validation is the next step for aerocapture technology development.

Masciarelli, James↗
NASA NTRS2010

Thermal Protection System (Heat Shield) Development - Advanced Development Project

The Orion Thermal Protection System (TPS) ADP was a 3 1/2 year effort to develop ablative TPS materials for the Orion crew capsule. The ADP was motivated by the lack of available ablative TPS's. The TPS ADP pursued a competitive phased development strategy with succeeding rounds of development, testing and down selections. The Project raised the technology readiness level (TRL) of 8 different TPS materials from 5 different commercial vendors, eventual down selecting to a single material system for the Orion heat shield. In addition to providing a heat shield material and design for Orion on time and on budget, the Project accomplished the following: 1) Re-invigorated TPS industry & re-established a NASA competency to respond to future TPS needs; 2) Identified a potentially catastrophic problem with the planned MSL heat shield, and provided a viable, high TRL alternate heat shield design option; and 3) Transferred mature heat shield material and design options to the commercial space industry, including TPS technology information for the SpaceX Dragon capsule.

Kowal, T. John↗
NASA NTRS2010

Autonomous GN and C for Spacecraft Exploration of Comets and Asteroids

A spacecraft guidance, navigation, and control (GN&C) system is needed to enable a spacecraft to descend to a surface, take a sample using a touch-and-go (TAG) sampling approach, and then safely ascend. At the time of this reporting, a flyable GN&C system that can accomplish these goals is beyond state of the art. This article describes AutoGNC, which is a GN&C system capable of addressing these goals, which has recently been developed and demonstrated to a maturity TRL-5-plus. The AutoGNC solution matures and integrates two previously existing JPL capabilities into a single unified GN&C system. The two capabilities are AutoNAV and GREX. AutoNAV is JPL s current flight navigation system, and is fairly mature with respect to flybys and rendezvous with small bodies, but is lacking capability for close surface proximity operations, sampling, and contact. G-REX is a suite of low-TRL algorithms and capabilities that enables spacecraft operations in close surface proximity and for performing sampling/contact. The development and integration of AutoNAV and G-REX components into AutoGNC provides a single, unified GN&C capability for addressing the autonomy, close-proximity, and sampling/contact aspects of small-body sample return missions. AutoGNC is an integrated capability comprising elements that were developed separately. The main algorithms and component capabilities that have been matured and integrated are autonomy for near-surface operations, terrain-relative navigation (TRN), real-time image-based feedback guidance and control, and six degrees of freedom (6DOF) control of the TAG sampling event. Autonomy is achieved based on an AutoGNC Executive written in Virtual Machine Language (VML) incorporating high-level control, data management, and fault protection. In descending to the surface, the AutoGNC system uses camera images to determine its position and velocity relative to the terrain. This capability for TRN leverages native capabilities of the original AutoNAV system, but required advancements that integrate the separate capabilities for shape modeling, state estimation, image rendering, defining a database of onboard maps, and performing real-time landmark recognition against the stored maps. The ability to use images to guide the spacecraft requires the capability for image-based feedback control. In Auto- GNC, navigation estimates are fed into an onboard guidance and control system that keeps the spacecraft guided along a desired path, as it descends towards its targeted landing or sampling site. Once near the site, AutoGNC achieves a prescribed guidance condition for TAG sampling (position/orientation, velocity), and a prescribed force profile on the sampling end-effector. A dedicated 6DOF TAG control then implements the ascent burn while recovering from sampling disturbances and induced attitude rates. The control also minimizes structural interactions with flexible solar panels and disallows any part of the spacecraft from making contact with the ground (other than the intended end-effector).

Carson, John M.↗
NASA NTRS2010

Large Spun Formed Friction-Stir Welded Tank Domes for Liquid Propellant Tanks Made from AA2195: A Technology Demonstration for the Next Generation of Heavy Lift Launchers

Improving structural efficiency while reducing manufacturing costs are key objectives when making future heavy-lift launchers more performing and cost efficient. The main enabling technologies are the application of advanced high performance materials as well as cost effective manufacture processes. This paper presents the status and main results of a joint industrial research & development effort to demonstrate TRL 6 of a novel manufacturing process for large liquid propellant tanks for launcher applications. Using high strength aluminium-lithium alloy combined with the spin forming manufacturing technique, this development aims at thinner wall thickness and weight savings up to 25% as well as a significant reduction in manufacturing effort. In this program, the concave spin forming process is used to manufacture tank domes from a single flat plate. Applied to aluminium alloy, this process allows reaching the highest possible material strength status T8, eliminating numerous welding steps which are typically necessary to assemble tank domes from 3D-curved panels. To minimize raw material costs for large diameter tank domes for launchers, the dome blank has been composed from standard plates welded together prior to spin forming by friction stir welding. After welding, the dome blank is contoured in order to meet the required wall thickness distribution. For achieving a material state of T8, also in the welding seams, the applied spin forming process allows the required cold stretching of the 3D-curved dome, with a subsequent ageing in a furnace. This combined manufacturing process has been demonstrated up to TRL 6 for tank domes with a 5.4 m diameter. In this paper, the manufacturing process as well as test results are presented. Plans are shown how this process could be applied to future heavy-lift launch vehicles developments, also for larger dome diameters.

Stachulla, M.↗