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NASA NTRS1979

An economic analysis of a commercial approach to the design and fabrication of a space power system

This paper discusses a commercial approach to the design and fabrication of an economical space power system. With the advent of the space shuttle, steps can be taken to back away from the presently used space qualified approach in order to reduce cost of space hardware by incorporating, where possible, commercial design, fabrication, and quality assurance methods. Cost reductions are projected through the conceptual design of a 2 kW space power system built with the capability for having serviceability. The approach to system costing that has been used takes into account both the constraints of operation in space and commercial production engineering approaches. The cost of this power system reflects a variety of cost/benefit tradeoffs that would reduce system cost as a function of system reliability requirements, complexity, and the impact of rigid specifications. A breakdown of the system design, documentation, fabrication and reliability and quality assurance cost estimates are detailed.

Putney, Z.↗

NASA NTRS2002

Space Ops 2002: Bringing Space Operations into the 21st Century. Track 3: Operations, Mission Planning and Control. 2nd Generation Reusable Launch Vehicle-Concepts for Flight Operations

With the successful implementation of the International Space Station (ISS), the National Aeronautics and Space Administration (NASA) enters a new era of opportunity for scientific research. The ISS provides a working laboratory in space, with tremendous capabilities for scientific research. Utilization of these capabilities requires a launch system capable of routinely transporting crew and logistics to/from the ISS, as well as supporting ISS assembly and maintenance tasks. The Space Shuttle serves as NASA's launch system for performing these functions. The Space Shuttle also serves as NASA's launch system for supporting other science and servicing missions that require a human presence in space. The Space Shuttle provides proof that reusable launch vehicles are technically and physically implementable. However, a couple of problems faced by NASA are the prohibitive cost of operating and maintaining the Space Shuttle and its relative inability to support high launch rates. The 2nd Generation Reusable Launch Vehicle (2nd Gen RLV) is NASA's solution to this problem. The 2nd Gen RLV will provide a robust launch system with increased safety, improved reliability and performance, and less cost. The improved performance and reduced costs of the 2nd Gen RLV will free up resources currently spent on launch services. These resource savings can then be applied to scientific research, which in turn can be supported by the higher launch rate capability of the 2nd Gen RLV. The result is a win - win situation for science and NASA. While meeting NASA's needs, the 2nd Gen RLV also provides the United States aerospace industry with a commercially viable launch capability. One of the keys to achieving the goals of the 2nd Gen RLV is to develop and implement new technologies and processes in the area of flight operations. NASA's experience in operating the Space Shuttle and the ISS has brought to light several areas where automation can be used to augment or eliminate functions performed by crew and ground controllers. This experience has also identified the need for new approaches to staffing and training for both crew and ground controllers. This paper provides a brief overview of the mission capabilities provided by the 2nd Gen RLV, a description of NASA's approach to developing the 2nd Gen RLV, a discussion of operations concepts, and a list of challenges to implementing those concepts.

Hagopian, Jeff↗

NASA NTRSDate not supplied

NASA Small Spacecraft Technology (SST) Program - Recent and Upcoming Technology Demonstrations and Development Efforts

The Small Spacecraft Technology (SST) program within NASA’s Space Technology Mission Directorate, expands the ability to execute unique missions through rapid development and demonstration of capabilities for small spacecraft applicable to exploration, science and the commercial space sector. Through targeted development and frequent in space testing, the program: • Enables execution of missions at much lower cost than previously possible • Substantially reduces the time required for development of spacecraft • Enables new mission architectures through the use of small spacecraft • Expands the reach of small spacecraft to new destinations and challenging new environments • Enables the augmentation of existing assets and future missions with supporting small spacecraft. The program achieves its objectives through: • Identification and investment in the development of new subsystem technologies to enhance or expand the capabilities of small spacecraft • Sponsorship of flight demonstrations of new technologies, capabilities and applications for small spacecraft • Promotion of the use of small spacecraft as platforms for testing and demonstrating technologies and capabilities that might have more general applications in larger-scale spacecraft and systems Technologies funded by the program that are key to advancing the utility and capability of small spacecraft were demonstrated in 2022 and 2023. Notable on-orbit demonstrations include the following. • The Cislunar Autonomous Positioning System Technology Operations and Navigation Experiment’s (CAPSTONE) navigation technology that was demonstrated for the first time in 2023 could provide autonomous onboard navigation information for future lunar missions, minimizing or eliminating human-in-the-loop mission operations. • The optical communications technology also demonstrated in 2023 by the TeraByte InfraRed Delivery (TBIRD) payload that launched on Pathfinder Technology Demonstrator-3, achieved 200 gigabit per second (Gbps) throughput on a space-to-ground optical link between a satellite in orbit and Earth, the highest data rate ever achieved by optical communications technology. • The precision laser pointing performance of NASA’s CubeSat Infrared CrossLink A (CLICK) spacecraft’s fine steering mirror control system was successfully demonstrated. This element of the laser communications system will be used to demonstrate two-way crosslink communication in low-Earth orbit by CLICK B/C anticipated to launch in late 2024. Investments in subsystem technology development through funding to university, industry, and other government partners in a number of areas will be discussed. Among others, topic areas include propulsion, autonomous swarm technology, edge computing, and thermal control. Additionally, the status of the CubeSat-alternative platform, DiskSat, strategies for accelerating the demonstration of technology payloads via the Realizing Rapid, Reduced-cost high-Risk Research (R5) project, and the status of recently completed and upcoming on-orbit demonstrations will also be presented.

Roger C Hunter↗

NASA NTRS2015

Iodine Propulsion Advantages for Low Cost Mission Applications and the Iodine Satellite (ISAT) Technology Demonstration

The NASA Marshall Space Flight Center Science and Technology Office is continuously exploring technology options to increase performance or reduce cost and risk to future NASA missions including science and exploration. Electric propulsion is a prevalent technology known to reduce mission costs by reduction in launch costs and spacecraft mass through increased post launch propulsion performance. The exploration of alternative propellants for electric propulsion continues to be of interest to the community. Iodine testing has demonstrated comparable performance to xenon. However, iodine has a higher storage density resulting in higher ΔV capability for volume constrained systems. Iodine's unique properties also allow for unpressurized storage yet sublimation with minimal power requirements to produce required gas flow rates. These characteristics make iodine an ideal propellant for secondary spacecraft. A range of mission have been evaluated with a focus on low-cost applications. Results highlight the potential for significant cost reduction over state of the art. Based on the potential, NASA has been developing the iodine Satellite for a near-term iodine Hall propulsion technology demonstration. Mission applications and progress of the iodine Satellite project are presented.

Dankanich, John W.↗

NASA NTRS1996

Calcium kinetics with microgram stable isotope doses and saliva sampling

Studies of calcium kinetics require administration of tracer doses of calcium and subsequent repeated sampling of biological fluids. This study was designed to develop techniques that would allow estimation of calcium kinetics by using small (micrograms) doses of isotopes instead of the more common large (mg) doses to minimize tracer perturbation of the system and reduce cost, and to explore the use of saliva sampling as an alternative to blood sampling. Subjects received an oral dose (133 micrograms) of 43Ca and an i.v. dose (7.7 micrograms) of 46Ca. Isotopic enrichment in blood, urine, saliva and feces was well above thermal ionization mass spectrometry measurement precision up to 170 h after dosing. Fractional calcium absorptions determined from isotopic ratios in blood, urine and saliva were similar. Compartmental modeling revealed that kinetic parameters determined from serum or saliva data were similar, decreasing the necessity for blood samples. It is concluded from these results that calcium kinetics can be assessed with micrograms doses of stable isotopes, thereby reducing tracer costs and with saliva samples, thereby reducing the amount of blood needed.

Clinical Trial↗

NASA NTRS1992

The design of a long-range megatransport aircraft

Aircraft manufacturers are examining the market and feasibility of long-range passenger aircraft carrying more than 600 passengers. These aircraft would carry travelers at reduced cost and, at the same time, reduce congestion around major airports. The design of a large, long-range transport involves broad issues such as: the integration of airport terminal facilities; passenger loading and unloading; trade-offs between aircraft size and the cost to reconfigure these existing facilities; and, defeating the 'square-cube' law. Thirteen Purdue design teams generated RFP's that defined passenger capability and range, based upon team perception of market needs and infrastructure constraints. Turbofan engines were designed by each group to power these aircraft. The design problem and the variety of solutions developed are reviewed.

Weisshaar, Terrence A.↗

NASA NTRS2009

CCSDS Spacecraft Monitor and Control Mission Operations Interoperability Prototype

We are entering a new era in space exploration. Reduced operating budgets require innovative solutions to leverage existing systems to implement the capabilities of future missions. Custom solutions to fulfill mission objectives are no longer viable. Can NASA adopt international standards to reduce costs and increase interoperability with other space agencies? Can legacy systems be leveraged in a service oriented architecture (SOA) to further reduce operations costs? The Operations Technology Facility (OTF) at the Johnson Space Center (JSC) is collaborating with Deutsches Zentrum fur Luft- und Raumfahrt (DLR) to answer these very questions. The Mission Operations and Information Management Services Area (MOIMS) Spacecraft Monitor and Control (SM&C) Working Group within the Consultative Committee for Space Data Systems (CCSDS) is developing the Mission Operations standards to address this problem space. The set of proposed standards presents a service oriented architecture to increase the level of interoperability among space agencies. The OTF and DLR are developing independent implementations of the standards as part of an interoperability prototype. This prototype will address three key components: validation of the SM&C Mission Operations protocol, exploration of the Object Management Group (OMG) Data Distribution Service (DDS), and the incorporation of legacy systems in a SOA. The OTF will implement the service providers described in the SM&C Mission Operation standards to create a portal for interaction with a spacecraft simulator. DLR will implement the service consumers to perform the monitor and control of the spacecraft. The specifications insulate the applications from the underlying transport layer. We will gain experience with a DDS transport layer as we delegate responsibility to the middleware and explore transport bridges to connect disparate middleware products. A SOA facilitates the reuse of software components. The prototype will leverage the capabilities of existing legacy systems. Various custom applications and middleware solutions will be combined into one system providing the illusion of a set of homogenous services. This paper will document our journey as we implement the interoperability prototype. The team consists of software engineers with experience on the current command, telemetry and messaging systems that support the International Space Station (ISS) and Space Shuttle programs. Emphasis will be on the objectives, results and potential cost saving benefits.

Lucord, Steve↗

NASA NTRS1991

Ground support system methodology and architecture

A synergistic approach to systems test and support is explored. A building block architecture provides transportability of data, procedures, and knowledge. The synergistic approach also lowers cost and risk for life cycle of a program. The determination of design errors at the earliest phase reduces cost of vehicle ownership. Distributed scaleable architecture is based on industry standards maximizing transparency and maintainability. Autonomous control structure provides for distributed and segmented systems. Control of interfaces maximizes compatibility and reuse, reducing long term program cost. Intelligent data management architecture also reduces analysis time and cost (automation).

Schoen, P. D.↗

NASA NTRS1984

On-orbit maintenance and repair - New era in space research and industrialization

During the seventies, NASA was developing a multifunction, economical spacecraft complete with ground and spaceborne support equipment, software, and necessary documentation to facilitate a large variety of space missions on a routine and cost effective basis. In order to reduce costs and time requirements, research was conducted to identify new approaches to a reusable, low-cost spacecraft design. The result of these studies was the development of the Multimission Modular Spacecraft (MMS). Three MMS spacecraft are currently operating in orbit. These spacecraft include the two Landsat-D earth resources satellites, Landsat-4 and -5, and the Solar Maximum Mission (SMM) spacecraft. Attention is given to details regarding the MMS, the STS-41C SMM repair mission, and failure modes and component degradation.

Cepollina, F.↗

NASA NTRS1992

Ground Robotic Hand Applications for the Space Program study (GRASP)

This document reports on a NASA-STDP effort to address research interests of the NASA Kennedy Space Center (KSC) through a study entitled, Ground Robotic-Hand Applications for the Space Program (GRASP). The primary objective of the GRASP study was to identify beneficial applications of specialized end-effectors and robotic hand devices for automating any ground operations which are performed at the Kennedy Space Center. Thus, operations for expendable vehicles, the Space Shuttle and its components, and all payloads were included in the study. Typical benefits of automating operations, or augmenting human operators performing physical tasks, include: reduced costs; enhanced safety and reliability; and reduced processing turnaround time.

Grissom, William A.↗

NASA NTRS1993

The design of a long range megatransport aircraft

Megatransport objectives and constraints are briefly reviewed, and certain solutions developed by student design teams at Perdue University are summarized. Particular attention is given to the market needs and the economic risks involved in such a project; and the different approaches taken to solve the problem and difficulties faced by the design teams. A long range megatransport aircraft is aimed at carrying more than 600 passengers at reduced cost, and at the same time, reducing airport and airway congestion. The design effort must take into account airport terminal facilities; passenger loading and unloading; and defeating the 'square-cube' law to design large structures.

Weisshaar, T. A.↗

NASA NTRS2004

Charge to Road Map Development Sessions

Develop a road map for new standard Model applications radiation belt models. Model applications: Spacecraft and instruments. Reduce risk. Reduce cost. Improve performance. Increase system lifetime. Reduce risk to astronauts.

Barth, Janet↗

NASA NTRS2011

Numerical Relativity for Space-Based Gravitational Wave Astronomy

In the next decade, gravitational wave instruments in space may provide high-precision measurements of gravitational-wave signals from strong sources, such as black holes. Currently variations on the original Laser Interferometer Space Antenna mission concepts are under study in the hope of reducing costs. Even the observations of a reduced instrument may place strong demands on numerical relativity capabilities. Possible advances in the coming years may fuel a new generation of codes ready to confront these challenges.

Baker, John G.↗

NASA NTRS1983

Satellite drag prediction effects on Shuttle mission planning

Long-term factors, along with Shuttle performance limitations, are considered in order to illustrate the need for more reliable long-term drag (meaning 'solar cycle') prediction techniques. Such techniques would make it possible to confidently plan dual-objective Shuttle flights, which maximize Shuttle cargo loadings and thus reduce costs. In describing the coupled mission concept, it is pointed out that by deploying one payload while retrieving or servicing another, the Space Transportation System can maximize the usefulness of the Shuttle and reduce the cost per customer. It is shown here that the proposed mission coupling LDEF (Long Duration Exposure Facility) with ST (Space Telescope) must be rejected since the Shuttle performance limitations prohibit deployment of the ST at even 315 n mi with a subsequent LDEF retrieval. If, however, it were possible to predict solar cycles, then, depending on the prediction, a mission of this type could be feasible.

Young, K. A.↗

NASA NTRS2020

Building the RS-25 Engine for NASA’s Next Generation of Exploration.

NASA is aggressively pursuing a human lunar return to the Moon with the Artemis Program. The Space Launch System (SLS) is critical to the transportation architecture, providing both crew and cargo capability. To accelerate SLS development, NASA settled on space shuttle heritage propulsion technologies. Early missions will use repurposed RS-25 engines from the Shuttle Program adapted to SLS requirements. For future missions, however, NASA and engine contractor Aerojet Rocketdyne are restarting RS-25 production with a goal of using the latest manufacturing technologies to produce an RS-25 variant that will cost at least 30 percent less than the shuttle-era engines developed and flown for almost 30 years. The prospect of restarting the production line on these engines after many years and modifying the engine to reduce cost and better match the needs of the SLS vehicle presented unique challenges and opportunities for NASA and Aerojet Rocketdyne. NASA and AR are now deep into the process of adapting 16 RS-25 engines for the first four SLS Artemis flights and building the first RS-25 “Restart” engines for future Artemis missions. In addition to navigating programmatic, technical, and logistical challenges with the current RS-25 production work, NASA and AR have partnered to pursue new methods of building this engine through advanced manufacturing techniques to further reduce the cost and schedule required to build each RS-25 engine to contribute to the long-term affordability of the SLS vehicle. This presentation will discuss the goals for the restart program, the challenges, and results to date.

Jessica Jean Wood↗

NASA NTRS2016

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Gradl, Paul↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗