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NASA NTRS1990

Nylon and teflon scribe effect on NBR to Chemlok 233 and NBR to NBR bond interfaces

A study was requested by Manufacturing Engineering to determine what effects marking with nylon (6/6) and Teflon scribes may have on subsequent bonding. Witness panel bond specimens were fabricated by the development lab to test both acrylonitrile butadiene rubber (NBR) to Chemlok and NBR to NBR after controlled exposure. The nylon rod used as a scribe tool demonstrates virtually no bond deterioration when used to scribe lines on either the Chemlok to NBR surfaces or the NBR to NBR interface. Lab test results indicate that the nylon rod-exposed samples produce tensile and peel values very similar to the control samples and the Teflon exposed samples produce tensile and peel values much lower than the control samples. Visual observation of the failure surfaces of the tested samples shows that Teflon scribing produces an obvious contamination to the surface and the nylon produces no effect. Photographs of test samples are provided. It is concluded that Teflon stock used as a scribe tool on a Chemlok 233 to NBR surface or an NBR to NBR surface has a detrimental effect on the bond integrity on either of these bond interfaces. Therefore, it is recommended that the nylon rod continue to be used where a scribe line is required in the redesigned solid rocket motor segment insulation layup operations. The use of Teflon scribes should not be considered.

Jensen, S. K.↗

NASA NTRS2024

Wind Tunnel Test of A Scale Model of A Venus Probe to Determine Aeroacoustics Environment

The Zephyr probe for NASA’s DAVINCI project is being designed to fly to Venus and collect measurements to characterize the Venusian atmosphere while it descends towards the surface. Despite a slow descent speed as the probe approaches the surface, the very dense atmosphere means the vibro-acoustic environment that the probe must withstand could be very harsh. A wind tunnel test campaign was conducted to characterize the surface-pressure fluctuations (acoustics) on the external surface of the probe during the descent. The goal was to provide forcing functions for vibro-acoustic analysis of all instruments inside the probe. A 25% scale-model of the Zephyr probe was manufactured, instrumented with 18 microphones, and tested in two wind tunnels located in the Fluid Mechanics Lab at NASA Ames Research Center at velocities ranging from 13 m/s to 48 m/s. Trip strips were added to the model to ensure a turbulent boundary layer on the model. Microphones were located appropriately to provide spectra of pressure fluctuations in regions with different flow characteristics as well as for calculating various two-point statistics. The acoustic spectra measured in the wind tunnel tests were scaled up to flight-scale using the estimated flight trajectory information. Besides fluctuating surface-pressure measurements, hot-film velocity measurements as well as smoke-laser flow visualization were conducted to better understand the flow around the probe. Lastly, several different geometry configurations were tested to see whether any reduction in acoustic levels could be achieved, but none of the configurations that were tested offered significant improvements. The flow visualization showed 3 primary flow regimes on the model: an attached turbulent boundary layer on the front of the model, a region of separated flow upstream of the flared lip, and a large, separated wake at the rear of the model. The acoustic spectra generally show three different shapes corresponding to these flow regions, with the highest levels seen at the rear of the model, and directly in front of the drag plate. The scaled overall levels of pressure fluctuations were found to be high: in the range of 130dB to 155dB.

planetary probe↗

NASA NTRS2013

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗

NASA NTRS2004

Advanced Manufacturing Techniques Demonstrated for Fabricating Developmental Hardware

NASA Glenn Research Center's Engineering Development Division has been working in support of innovative gas turbine engine systems under development by Glenn's Combustion Branch. These one-of-a-kind components require operation under extreme conditions. High-temperature ceramics were chosen for fabrication was because of the hostile operating environment. During the designing process, it became apparent that traditional machining techniques would not be adequate to produce the small, intricate features for the conceptual design, which was to be produced by stacking over a dozen thin layers with many small features that would then be aligned and bonded together into a one-piece unit. Instead of using traditional machining, we produced computer models in Pro/ENGINEER (Parametric Technology Corporation (PTC), Needham, MA) to the specifications of the research engineer. The computer models were exported in stereolithography standard (STL) format and used to produce full-size rapid prototype polymer models. These semi-opaque plastic models were used for visualization and design verification. The computer models also were exported in International Graphics Exchange Specification (IGES) format and sent to Glenn's Thermal/Fluids Design & Analysis Branch and Applied Structural Mechanics Branch for profiling heat transfer and mechanical strength analysis.

Redding, Chip↗

NASA NTRS2007

Automated Eddy Current Inspection on Space Shuttle Hardware

Over the life time of the Space Shuttle program, metal parts used for the Reusable Solid Rocket Motors (RSRMs) have been nondestructively inspected for cracks and surface breaking discontinuities using magnetic particle (steel) and penetrant methods. Although these inspections adequately screened for critical sized cracks in most regions of the hardware, it became apparent after detection of several sub-critical flaws that the processes were very dependent on operator attentiveness and training. Throughout the 1990's, eddy current inspections were added to areas that had either limited visual access or were more fracture critical. In the late 1990's. a project was initiated to upgrade NDE inspections with the overall objective of improving inspection reliability and control. An automated eddy current inspection system was installed in 2001. A figure shows one of the inspection bays with the robotic axis of the system highlighted. The system was programmed to inspect the various case, nozzle, and igniter metal components that make up an RSRM. both steel and aluminum. For the past few years, the automated inspection system has been a part of the baseline inspection process for steel components. Although the majority of the RSRM metal part inventory ts free of detectable surface flaws, a few small, sub-critical manufacturing defects have been detected with the automated system. This paper will summarize the benefits that have been realized with the current automated eddy current system, as well as the flaws that have been detected.

Hartmann, John↗

NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗

NASA NTRS1990

An approach for relating the results of quantitative nondestructive evaluation to intrinsic properties of high-performance materials

One of the most difficult problems the manufacturing community has faced during recent years has been to accurately assess the physical state of anisotropic high-performance materials by nondestructive means. In order to advance the design of ultrasonic nondestructive testing systems, a more fundamental understanding of how ultrasonic waves travel and interact within the anisotropic material is needed. The relationship between the ultrasonic and engineering parameters needs to be explored to understand their mutual dependence. One common denominator is provided by the elastic constants. The preparation of specific graphite/epoxy samples to be used in the experimental investigation of the anisotropic properties (through the measurement of the elastic stiffness constants) is discussed. Accurate measurements of these constants will depend upon knowledge of refraction effects as well as the direction of group velocity propagation. The continuing effort for the development of improved visualization techniques for physical parameters is discussed. Group velocity images are presented and discussed. In order to fully understand the relationship between the ultrasonic and the common engineering parameters, the physical interpretation of the linear elastic coefficients (the quantities that relate applied stresses to resulting strains) are discussed. This discussion builds a more intuitional understanding of how the ultrasonic parameters are related to the traditional engineering parameters.

Miller, James G.↗

NASA NTRS2021

Romie: A Domain-Independent Tool for Computer-Aided Robust Operations Management

Romie is a decision support tool based on AI's latest advances in the domain of robust scheduling. Unlike all its predecessors, the tool allows to (i) visually model the operational problem and context entirely (ii) optimize to find near-optimal schedules while taking uncertainty into account and deals with (iii) a combination of various {key performance indicators (KPIs). It comes with a web user interface. Part or all of the modelled activities may be associated to random variables describing their stochastic durations, in order to produce schedules that are robust w.r.t. temporal uncertainty. Hence, depending on the pursued KPIs, the schedules maximize a combination of the following terms: the probability of satisfying the problem constraints, the expected return/efficiency, the expected outcome quality, and even the operators' wellness by minimizing its expected extra-hours. Initially developed for spatial exploration and demonstration in the context of Mars analog missions, this versatile tool is here applied to operations management in both biotechnology manufacturing and robots parametrization in a cave exploration context.

Chien, Steve A.↗

NASA NTRS1947

Effect of Fuel on Performance of a Single Combustor of an I-16 Turbojet Engine at Simulated Altitude Conditions

As part of a study of the effects of fuel composition on the combustor performance of a turbojet engine, an investigation was made in a single I-16 combustor with the standard I-16 injection nozzle, supplied by the engine manufacturer, at simulated altitude conditions. The 10 fuels investigated included hydrocarbons of the paraffin olefin, naphthene, and aromatic classes having a boiling range from 113 degrees to 655 degrees F. They were hot-acid octane, diisobutylene, methylcyclohexane, benzene, xylene, 62-octane gasoline, kerosene, solvent 2, and Diesel fuel oil. The fuels were tested at combustor conditions simulating I-16 turbojet operation at an altitude of 45,000 feet and at a rotor speed of 12,200 rpm. At these conditions the combustor-inlet air temperature, static pressure, and velocity were 60 degrees F., 12.3 inches of mercury absolute, and 112 feet per second respectively, and were held approximately constant for the investigation. The reproducibility of the data is shown by check runs taken each day during the investigation. The combustion in the exhaust elbow was visually observed for each fuel investigated.

Zettle, Eugene V↗

NASA NTRS1990

Phase compatibilities of YBa2Cu3O(9-delta) type structure in quintenary systems Y-Ba-Cu-O-X (impurity)

Electrical transport properties of the oxidic high T(sub c) superconductors are significantly affected by the presence of minor amounts of various elements adventing as impurities, e.g., from the chemical environment during manufacturing. YBa2Cu3O(9-delta) is prone to an extinction of the superconductivity on (partial) substitution of all four elemental components. E.g., Pr (for Y), La (for Ba), Zn (for Cu) or peroxygroup (for O) substituents will alter some of the superconductivity preconditions, like mixed valence state in Cu3O7/O(9-delta) network or structural distortion of the network. Although various pseudoternary chemical equilibrium phase diagrams of the Y(O)-Ba(O)-Cu(O) system now are available, no consensus is generally shown, however, this is partly due to lack of compatible definitions of the equilibrium conditions. Less information is available about the phase compatibilities in the appropriate quaternary phase diagram (including oxygen) and virtually no information exists about any pentenary phase diagrams (including one impurity). Unfortunately, complexity of such systems, stemming both from number of quaternary or pentenary compounds and from visualizing the five-component phase system, limits this presentation to more or less close surroundings of the YBa2Cu3O(9-delta) type phase in appropriate pseudoquaternary or pseudopseudoternary diagrams, involving Y-Ba-Cu and O, O-CO2, alkaline metals, Mg and alkaline earths, and Sc and most of the 3-d and 4-f elements. The systems were investigated by means of x ray diffraction, neutron diffraction and chemical analytical methods on samples prepared by sol-gel technique from citrates. The superconductivity was characterized by measuring the diamagnetic susceptibility by SQUID.

Karen, P.↗

NASA NTRS1981

A Solution in Search of Problems

Ferrofluids offered vast-problem solving potential. Under license for the NASA technology, Dr. Ronald Moskowitz and Dr. Ronald Rosensweig formed Ferrofluids Corporation. First problem they found a solution for was related to the manufacture of semiconductor "chips" for use in electronic systems. They developed a magnetic seal composed of ferrofluid and a magnetic circuit. Magnetic field confines the ferrofluid in the regions between the stationary elements and the rotary shaft of the seal. Result is a series of liquid barriers that totally bar passage of contaminants. Seal is virtually wear-proof and has a lifetime measured in billions of shaft revolutions. It has reduced maintenance, minimizes "downtime" of production equipment, and reduces the cost of expensive materials that had previously been lost through seal failures. Products based on ferrofluid are exclusion seals for computer disc drives and inertia dampers for stepper motors. Uses are performance-improving, failure-reducing coolants for hi-fi loudspeakers. Other applications include analytical instrumentation, medical equipment, industrial processes, silicon crystal growing furnaces, plasma processes, fusion research, visual displays, and automated machine tools.

Source record↗

NASA NTRSDate not supplied

A Virtual Reality Planning Environment for High-Risk, High-Latency Teleoperation

In-Space Servicing, Assembly, and Manufacturing has the potential to enable larger-scale and longer-lived infrastructure projects in space. Servicing in particular has the potential to vastly increase the usable lifetimes of satellites, both newly launched and existing. However, some of these servicing tasks require delicate manipulation and, to apply to existing satellites, need to be able to operate on structures that were not designed for servicing and, in some cases, where the exact shape of the structure is not known in advance. For this reason, human-in-the-loop ground-based teleoperation is the only option for some missions. Ground-based teleoperation presents its own difficulties. In addition to the challenge of performing delicate operations in constrained spaces, communication with the servicing platform is subject to a variable time delay on the order of 2-7 seconds, and the only visual feedback comes from camera views with limited situational awareness and viewing angles.

Teleoperation↗

NASA NTRS2013

Evaluation of Delamination Onset and Growth Characterization Methods under Mode I Fatigue Loading

Double-cantilevered beam specimens of IM7/8552 graphite/epoxy from two different manufacturers were tested in static and fatigue to compare the material characterization data and to evaluate a proposed ASTM standard for generating Paris Law equations for delamination growth. Static results were used to generate compliance calibration constants for reducing the fatigue data, and a delamination resistance curve, GIR, for each material. Specimens were tested in fatigue at different initial cyclic GImax levels to determine a delamination onset curve and the delamination growth rate. The delamination onset curve equations were similar for the two sources. Delamination growth rate was calculated by plotting da/dN versus GImax on a log-log scale and fitting a Paris Law. Two different data reduction methods were used to calculate da/dN. To determine the effects of fiber-bridging, growth results were normalized by the delamination resistance curves. Paris Law exponents decreased by 31% to 37% after normalizing the data. Visual data records from the fatigue tests were used to calculate individual compliance constants from the fatigue data. The resulting da/dN versus GImax plots showed improved repeatability for each source, compared to using averaged static data. The Paris Law expressions for the two sources showed the closest agreement using the individually fit compliance data.

Murri, Gretchen B.↗

NASA NTRSDate not supplied

Tomography Analysis of Orion Artemis 1 Heatshield Sample

The Orion spacecraft, under NASA's Artemis program, is an integral step in humanity's ambitions of deep space exploration, including our return to the Moon and subsequent mission to Mars. The performance of Orion's heatshield is central to ensuring the safety and success of such missions. This presentation offers a comprehensive overview of the process used in and findings derived from tomography scans of an Artemis 1 heatshield sample executed at the Lawrence Berkeley National Laboratory's Advanced Light Source. These tomography scans captured high-resolution X-Ray images of the heatshield's microstructure, allowing advanced imaging to be employed for 3D image segmentation and visualization of the sample. The Porous Media Analysis (PuMA) software stands central to our analysis, offering robust computational algorithms and methodologies to digitally compute properties of the heatshield material. The presentation discusses the following derived metrics: - Volume fractions, representing the spatial distribution and amounts of various components throughout the heatshield’s depth. - Porosity and crack distributions, offering insights into the void space within the material, critical for understanding the heatshield's structural integrity. - Fiber orientation, detailing the alignment and arrangement of fibers, significant for material orthotropy. - Permeability estimates, quantifying the passage of gas through the material, relevant for re-entry conditions and pyrolysis gasses. One distinctive feature of this study is the comparative evaluation against data obtained from tomography scans of the Exploration Flight Test-1 (EFT-1) heatshield. Such a comparison offers multiple insights, including evaluation of the consistency and repeatability of manufacturing processes as well as understanding of any evolutionary changes in heatshield design or material properties.

Micro-tomography↗

NASA NTRS2021

State of the Industry: UAS Sensor Review

This report is a follow on from HF Designworks’ 2018 report on state of the present and state of the art sensor technologies as they related to Ground Based Detect and Avoid (GBDAA) systems for Unmanned Aircraft Systems (UAS). In this update, HF Designworks again looks to UAS test sites, manufacturers, vendors, and users to identify the latest sensor technologies covering not just GBDAA, but additional UAS sensor types; including airborne. For this latest report, the following sensor types were reviewed, as well as a few that don’t quite fit within the following categories: Electro-Optical / Infrared (EO/IR), LiDAR, RADAR, Radiofrequency (RF) scanner, Acoustic, and Other. From our interviews and research with various organizations and individuals, we found both interesting new technologies as well as improvements to many technologies first reviewed in 2018. Compared with our 2018 findings, many of the new technologies have helped produce sensors that are smaller, lighter, require less power, and have better range and resolution than those discussed in 2018. However, challenges still exist. There is no single currently available and FAA approved sensor suite that can adequately provide complete detect and avoid capabilities to meet the needs of UAS beyond visual line of sight (BVLOS) in the civilian airspace.

unmanned aircraft systems↗

NASA NTRS1991

Ageing airplane repair assessment program for Airbus A300

Summary as a result of a commitment between the FAA and ATA the Airworthiness Assurance Task Force (AATF) steering committee requested the transport aircraft manufacturers to develop a program to assess the repairs on in-service aircraft since recent Supplemental Structural Inspection Programs (SSIP) had not been addressed to assessing repairs. The intent of the assessment program is to remove all existing ambiguities and to achieve a sufficient level of safety across the fleet by applying actual fatigue and damage tolerance criteria defined by FAR 25.571 to repaired structures. A general three stage program has been developed with major aircraft manufacturers and airlines cooperation including area/component classification, repair categorization and inspection/removal requirement establishment which is the basis for model specific repair assessment programs. This paper describes the current status of the repair categorization activities and includes all details about the methodologies developed for determination of the inspection program for the skin on pressurized fuselages. For inspection threshold determination two methods are defined based on fatigue life approach, i.e. a simplified and a detailed method. The detailed method considers 15 different parameters to assess the influences of material, geometry, size, location, aircraft usage and workmanship on the fatigue life of the repair and the original structure. For definition of the inspection intervals a general method is developed which applies to all concerned repairs. For this the initial flaw concept is used by considering 6 parameters and the detectable flaw sizes depending on proposed nondestructive inspection methods. An alternative method is provided for small repairs allowing visual inspection with shorter intervals.

Aging Aircraft↗

NASA NTRS1996

Welding rework data acquisition and automation

Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these.

Romine, Peter L.↗

NASA NTRS2012

Fast Paced, Low Cost Projects at MSFC

What does an orbiting microsatellite, a robotic lander and a ruggedized camera and telescope have in common? They are all fast paced, low cost projects managed by Marshall Space Flight Center (MSFC) teamed with successful industry partners. MSFC has long been synonymous with human space flight large propulsion programs, engineering acumen and risk intolerance. However, there is a growing portfolio/product line within MSFC that focuses on these smaller, fast paced projects. While launching anything into space is expensive, using a managed risk posture, holding to schedule and keeping costs low by stopping at egood enough f were key elements to their success. Risk is defined as the possibility of loss or failure per Merriam Webster. The National Aeronautics and Space Administration (NASA) defines risk using procedural requirement 8705.4 and establishes eclasses f to discern the acceptable risk per a project. It states a Class D risk has a medium to significant risk of not achieving mission success. MSFC, along with industry partners, has created a niche in Class D efforts. How did the big, cautious MSFC succeed on these projects that embodied the antithesis of its heritage in human space flight? A key factor toward these successful projects was innovative industry partners such as Dynetics Corporation, University of Alabama in Huntsville (UAHuntsville), Johns Hopkins Applied Physics Laboratory (JHU APL), Teledyne Brown Engineering (TBE), Von Braun Center for Science and Innovation (VCSI), SAIC, and Jacobs. Fast Affordable Satellite Technology (FastSat HSV01) is a low earth orbit microsatellite that houses six instruments with the primary scientific objective of earth observation and technology demonstration. The team was comprised of Dynetics, UAHuntsvile, SAIC, Goddard Space Flight Center (GSFC) and VCSI with the United States Air Force Space Test Program as the customer. The team completed design, development, manufacturing, environmental test and integration in one year. FastSat HSV01 also deployed a Poly Picosatellite Orbital Deployer (PPOD) for a separate nano ]satellite class spacecraft (Cubesat: Nano Sail Demonstration) in partnership with Ames Research Center. The Robotic lunar lander is a MSFC JHU APL partnership that led to the development of a flexible architecture for landers to support robotic missions to a wide range of lunar and asteroid destinations. The team started with the goal of meeting NASA agency directives that led to the creation of a test bed focusing on GN&C and software to demonstrate the descent and landing on any airless body for the final 30 to 60 meters. The team created a complex technology demonstration as well as Guidance Control and Navigation (GN&C) algorithms providing autonomous control of the lander. The team uses a green propellant of 90% hydrogen peroxide and has completed 18 successful test flights. The International Space Station (ISS) SERVIR Environmental Research and Visualization System (ISERV) is a technology demonstration payload to assist the SERVIR project with environmental monitoring for disaster relief and humanitarian efforts. The ISERV project was a partnership with TBE. The ISERV payload consists of a commercial off the shelf camera, telescope, and MSFC developed power distribution box and interfaces on ISS with the Window Observational Research Facility in the US Lab. MSFC has identified three key areas that enabled the low cost mission success to include culture, partnering, and cost/schedule control. This paper will briefly discuss these three Class D efforts, FastSat HSV-01, the Robotic Lunar Lander and the ISERV camera system, the lessons learned, their successes and challenges.

Watson-Morgan, Lisa↗