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NASA NTRS2016

3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing, and Future Work

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS), an orbiting laboratory 200 miles above the earth, provides a unique and incredible opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In particularly, additive manufacturing (or 3D printing) techniques can potentially be deployed in the space environment to enhance crew safety (by providing an on-demand part replacement capability) and decrease launch mass by reducing the number of spare components that must be launched for missions where cargo resupply is not a near-term option. In September 2014, NASA launched the 3D Printing in Zero G technology demonstration mission to the ISS to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on-orbit. The printer for this mission was designed and operated by the company Made In Space under a NASA SBIR (Small Business Innovation Research) phase III contract. The overarching objectives of the 3D print mission were to use ISS as a testbed to further maturation of enhancing technologies needed for long duration human exploration missions, introduce new materials and methods to fabricate structure in space, enable cost-effective manufacturing for structures and mechanisms made in low-unit production, and enable physical components to be manufactured in space on long duration missions if necessary. The 3D print unit for fused deposition modeling (FDM) of acrylonitrile butadiene styrene (ABS) was integrated into the ISS Microgravity Science Glovebox (MSG) in November 2014 and phase I printing operations took place from November through December of that year. Phase I flight operations yielded 14 unique parts (21 total specimens) that could be directly compared against ground-based prints of identical geometry manufactured using the printer prior to its launch to ISS. The 3DP unit functioned safely and produced specimens necessary to advance the understanding of the critical design and operational parameters for the FDM process as affected by the microgravity environment. From the standpoint of operations, 3DP demonstrated the ability to remove parts from the build-tray on-orbit, teleoperate the printer from the ground, perform critical maintenance functions within defined human factors limits, produce a functional tool that could be evaluated for form/fit/function, and uplink a new part file from the ground and produce it on the printer. The flight parts arrived at NASA Marshall Space Flight Center in Huntsville, Alabama in April 2015, where they underwent months of testing in the materials and processes laboratory. Ground and flight prints completed the following phases of testing: photographic/visual inspection, mass and density evaluation, structured light scanning, XRay and CT, mechanical testing, optical microscopy, scanning electron microscopy, and chemical analysis. This presentation will discuss the results of this testing as well as phase II operations for the printer, which took place in June and July of 2016. Lessons learned from the tech demo and their impacts on the design and development of the second generation 3D printer for ISS, the Additive Manufacturing Facility (AMF) by Made In Space will also be presented. In addition, progress in other elements of NASA's In Space Manufacturing (ISM) initiative such as the on-demand ISM utilization catalog, in-space Recycler ISS Technology Demonstration development, launch packaging recycling, in-space printable electronics, development of higher strength polymeric materials for 3D printing and Additive Construction by Mobile Emplacement (ACME) will also be addressed.

Prater, Tracie↗
NASA NTRS2016

Arcus: The X-Ray Grating Spectrometer Explorer

Arcus will be proposed to the NASA Explorer program as a free-flying satellite mission that will enable high-resolution soft X-ray spectroscopy (8-50 Angstroms) with unprecedented sensitivity-effective areas of greater than 500 sq cm and spectral resolution greater than 2500. The Arcus key science goals are (1) to determine how baryons cycle in and out of galaxies by measuring the effects of structure formation imprinted upon the hot gas that is predicted to lie in extended halos around galaxies, groups, and clusters, (2) to determine how black holes influence their surroundings by tracing the propagation of out-flowing mass, energy and momentum from the vicinity of the black hole out to large scales and (3) to understand how accretion forms and evolves stars and circumstellar disks by observing hot infalling and outflowing gas in these systems. Arcus relies upon grazing incidence silicon pore X-ray optics with the same 12m focal length (achieved using an extendable optical bench) that will be used for the ESA Athena mission. The focused X-rays from these optics will then be diffracted by high-efficiency off-plane reflection gratings that have already been demonstrated on sub-orbital rocked flights, imaging the results with flight-proven CCD detectors and electronics. The power and telemetry requirements on the spacecraft are modest. The majority of mission operations will not be complex, as most observations will be long (~100 ksec), uninterrupted, and pre-planned, although there will be limited capabilities to observe targets of opportunity, such as tidal disruption events or supernovae with a 3-5 day turnaround. After the end of prime science, we plan to allow guest observations to maximize the science return of Arcus to the community.

Instrumentation↗
NASA NTRS2015

An Overview of WFIRST-AFTA Coronagraph Modelling

The WFIRST/AFTA 2.4 m space telescope currently under study includes a stellar coronagraph for the imaging and spectral characterization of extrasolar planets. Based largely on performance predictions from end-to-end optical propagation modeling, promising coronagraphic methods were selected in late 2013 for further consideration for use on AFTA. Since those downselect analyses further modeling work has been done on evaluating refined coronagraph designs, wavefront sensing and control, detector representation, and time-dependent effects. Thermal, structural, ray trace, and diffraction propagation models are used in these studies. Presented here is the progress to date and plans for future analyses.

Krist, John↗
NASA NTRS2018

Output Measurement Equations for Flexible Aircraft Flight Dynamics

A summary of output measurement equations for onboard sensors used in flight testing of flexible aircraft is presented. These equations include the effects of structural flexibility and are considerably more complex than the standard equations for rigid-body aircraft. The output equations discussed include accelerations from linear accelerometers, strains, angular rates, angular accelerations, Euler angles, true airspeed, and air flow angles. The output equations are derived in full form and then simplified in some cases. Linearized output equations, suitable for state-space or transfer function models, are also developed. Example flight test data from the X-56A subscale aeroelastic demonstrator is discussed, for reference.

Grauer, Jared A.↗
NASA NTRS2019

Multi-Objective Optimal Control of the 6-DoF Aeroservoelastic Common Research Model with Aspect Ratio 13.5 Wing

A new 6-DoF aeroservoelastic (ASE) Common Research Model (CRM) provided by The Boeing Company with aspect ratio 13.5 and 17 control surfaces per wing is utilized to demonstrate combined tracking and optimal multi-objective control. The multi-objective controller is derived on the closed loop tracking controller, and utilizes state and gust estimates provided by an extended state observer. Various methods of model reduction useful for control and estimation are presented. A computationally efficient MATLAB/Simulink simulation is presented which includes actuator dynamics, rate and deflection saturation limits, and gust disturbance inputs. The platform is used to demonstrate excellent 6-DoF tracking control performance coupled with the multi-objective controller, which is shown to effectively reduce structural mode movement, wing root bending moment, and drag. State and gust estimation is also shown to perform well, even when derived and/or implemented with significantly fewer states than the original full-sized model.

Drew, Michael C.↗
NASA NTRS2019

Arcus: The Soft X-ray Grating Explorer

Arcus provides high-resolution soft X-ray spectroscopy in the 12-50 Å bandpass with unprecedented sensitivity, including spectral resolution > 2500 and effective area > 250 cm2. The three top science goals for Arcus are (1) to measure the effects of structure formation imprinted upon the hot baryons that are predicted to lie in extended halos around galaxies, (2) to trace the propagation of outflowing mass, energy, and momentum from the vicinity of the black hole to extragalactic scales as a measure of their feedback, and (3) to explore how stars form and evolve. Arcus uses the same 12 m focal length grazing-incidence Silicon Pore X-ray Optics (SPOs) that ESA has developed for the Athena mission; the focal length is achieved on orbit via an extendable optical bench. The focused X-rays from these optics are diffracted by high-efficiency Critical-Angle Transmission (CAT) gratings, and the results are imaged with flight-proven CCD detectors and electronics. Combined with the high-heritage NGIS LEOStar-2 spacecraft and launched into 4:1 lunar resonant orbit, Arcus provides high sensitivity and high efficiency observing of a wide range of astrophysical sources.

Randall K Smith↗
NASA NTRSDate not supplied

Aeroelastic Modeling and CFD Simulation of Wind-Tunnel Scale Aspect Ratio 13.5 Common Research Model

This paper presents an aeroelastic modeling and simulation study of an aspect ratio 13.5 wind-tunnel scale Common Research Model (CRM) with distributed flaps. A vortex-lattice VSPAERO model of the CRM model is developed. A transonic small disturbance/integral boundary layer correction method is implemented in the VSPAERO model to account for the transonic and viscous flow effects. The structural deformation of the CRM model is calculated using a NASTRAN equivalent beam model. The VSPAERO model is coupled to the NASTRAN equivalent beam model to provide a rapid aero-structural analysis. A validation of the VSPAERO aeroelastic model is conducted by comparing the results to FUN3D CFD aeroelastic simulation results. An aerodynamic database is generated using the developed VSPAERO aeroelastic model for the real-time drag optimization and maneuver load alleviation study of the wind-tunnel scale CRM model.

Aeroelastic Modeling↗
NASA NTRSDate not supplied

Sustainable Crop Cultivation in Space Analogs: A BRIDGES Methodology Perspective Through SpaCEA

Sustainable crop cultivation in space holds paramount significance for the support of life in future long-duration missions. This research explores the development and integration of innovative low-cost proof-of-concept (LC-POC) plant growth cabinets tailored for use in space analog missions. By outlining past and current efforts in space farming, this study introduces the SpaCEA Cabinet using BRIDGES framework, establishing a context for reproducible experiments and innovation in plant growth systems. The SpaCEA cabinets can either be delivered in flat packs or assembled on-site, employing cutting-edge methods like 3-D printing and laser cutting. The main objective is to assess how effectively these structures foster crop growth within analog environments while replicating conditions crucial for space exploration. Employing a multi-faceted approach encompassing technical and qualitative dimensions, this project integrates a qualitative investigation where representatives managing analog stations and analog astronauts will partake in interviews and questionnaires to discern specific requirements and challenges within these environments. Insights gained from these engagements will significantly define the final design parameters of updated SpaCEA plant growth cabinets. The practical applicability of these cabinets emphasizes ease of assembly and transportation, addressing the inherent spatial and logistical constraints associated with space missions. Furthermore, the BRIDGES framework ensures the standardization of hardware, software, and data-gathering elements within a unified structure, which utilizes cutting-edge manufacturing technologies for the prototyping and deployment of these cabinets. The anticipated outcomes of this research include the identification of key design considerations and technical specifications for plant growth cabinets tailored to space farming analog systems. This research is poised to contribute valuable knowledge to sustainable space exploration through the development of interoperable plant growth systems for analog environments, advancing research in space crop cultivation which will make up part of a larger bioregenerative life support system.

Advanced Life Support↗
NASA NTRSDate not supplied

Sustainable Crop Cultivation in Space Analogs: A BRIDGES Methodology Perspective Through SpaCEA

Sustainable crop cultivation in space holds paramount significance for the support of life in future long-duration missions. This research explores the development and integration of innovative low-cost proof-of-concept (LC-POC) plant growth cabinets tailored for use in space analog missions. By outlining past and current efforts in space farming, this study introduces the SpaCEA Cabinet using BRIDGES framework, establishing a context for reproducible experiments and innovation in plant growth systems. The SpaCEA cabinets can either be delivered in flat packs or assembled on-site, employing cutting-edge methods like 3-D printing and laser cutting. The main objective is to assess how effectively these structures foster crop growth within analog environments while replicating conditions crucial for space exploration. Employing a multi-faceted approach encompassing technical and qualitative dimensions, this project integrates a qualitative investigation where representatives managing analog stations and analog astronauts will partake in interviews and questionnaires to discern specific requirements and challenges within these environments. Insights gained from these engagements will significantly define the final design parameters of updated SpaCEA plant growth cabinets. The practical applicability of these cabinets emphasizes ease of assembly and transportation, addressing the inherent spatial and logistical constraints associated with space missions. Furthermore, the BRIDGES framework ensures the standardization of hardware, software, and data-gathering elements within a unified structure, which utilizes cutting-edge manufacturing technologies for the prototyping and deployment of these cabinets. The anticipated outcomes of this research include the identification of key design considerations and technical specifications for plant growth cabinets tailored to space farming analog systems. This research is poised to contribute valuable knowledge to sustainable space exploration through the development of interoperable plant growth systems for analog environments, advancing research in space crop cultivation which will make up part of a larger bioregenerative life support system.

Advanced Life Support↗
DOE OSTI2017

Study of a Novel Oscillating Surge Wave Energy Converter: Preprint

This study investigates the performance of an oscillating surge wave energy converter (OSWEC) that utilizes adjustable geometry as a means of controlling the hydrodynamic coefficients, a concept originally proposed by [1]. The body of the device consists of a bottom-hinged solid rectangular frame with five horizontal flaps spanning the interior of the frame. The flaps can rotate independently about their center of rotation within the frame like a large window shutter. Changing the orientation of the flaps alters the hydrodynamic coefficients and natural frequency of the device as well as the ability to shed or absorb structural loads accordingly. This ability may allow the device to operate in a wider range of sea states than other current wave energy converter designs. This paper presents and compares the results of numerical simulations and experimental testing of the OSWEC's response to regular waves with all five of the horizontal fin configurations sharing the same orientation of 0 degrees (fully closed interior) and 90 degrees (fully open). The numerical simulations were performed using WAMIT, which calculates hydrodynamic coefficients using a boundary element method code to solve the linear potential flow problem, and WEC-Sim, a MATLAB-based tool that simulates multibody devices in the time domain by solving the governing equations of motion. A 1:14 scale model of the device was built for experimental evaluation in an 8-m-long, 1-m wide wave tank, which supports a water depth of 0.7 m. The OSWEC motion in different wave conditions was measured with displacement sensors while nonlinear wave-structure interaction effects like slamming and overtopping were captured using a high-speed camera and used to understand differences between the simulation and experiments.

13 HYDRO ENERGY↗
DOE OSTI2017

Automated Proton Track Identification in MicroBooNE Using Gradient Boosted Decision Trees

MicroBooNE is a liquid argon time projection chamber (LArTPC) neutrino experiment that is currently running in the Booster Neutrino Beam at Fermilab. LArTPC technology allows for high-resolution, three-dimensional representations of neutrino interactions. A wide variety of software tools for automated reconstruction and selection of particle tracks in LArTPCs are actively being developed. Short, isolated proton tracks, the signal for low- momentum-transfer neutral current (NC) elastic events, are easily hidden in a large cosmic background. Detecting these low-energy tracks will allow us to probe interesting regions of the proton's spin structure. An effective method for selecting NC elastic events is to combine a highly efficient track reconstruction algorithm to find all candidate tracks with highly accurate particle identification using a machine learning algorithm. We present our work on particle track classification using gradient tree boosting software (XGBoost) and the performance on simulated neutrino data.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Laser ion-shotgun acceleration

Relativistic transparency induced by an ultra-intense laser ($5 \times 10^{22}$ W/cm$^2$) offers an attractive method for generating extreme electric (50 TV/m) and magnetic (0.5 MT) fields by enabling laser pulse propagation through a very dense and otherwise opaque material. A slowly evolving structure that effectively accelerates ions is generated by employing a target ($\sim 10$ $\mu$m thick) with a pre-filled channel that guides the laser pulse. As the pulse exits the channel driving a strong electron current, strong accelerating longitudinal and focusing transverse electric fields emerge at the rear side of the target. Three-dimensional kinetic simulations predict a low-diverging dense mono-energetic proton bunch with energies of 200-300 MeV. The charge in an opening angle of $10^{\circ}$ is tens of nC. This scheme potentially allows high repetition rate operation and relaxes laser contrast requirements.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

High temperature vibration resistant solderless electrical connections for planar surfaces

An electrical arrangement (10), including: a first conductor (12) having a first generally planar contact area (34); a second conductor (12) having a second generally planar contact area (40); an intermediate conductor (44) having a first faying area (84) overlying the first contact area and a second faying area (86) overlying the second contact area; a compression arrangement configured to compress the first faying area and the first contact area toward each other and to compress the second faying area and the second contact area toward each other; and a dimpling structure (46) effective to create plural contact points (74) between the first faying area and the first contact area and between the second faying area and the second contact area when the first and the second faying areas and the first and second contact areas are compressed toward each other by the compression arrangement.

McConkey, Joshua S.↗