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NASA NTRSDate not supplied

In Space Manufacturing and Extraterrestrial Construction: How Did We Get Here?Where Are We? Where Should We Be Going? THE CHALLENGE: Will We Be Ready?

NASA has held multiple workshops and sought inputs from a broad spectrum of sources, including international partners, other space agencies, industry, large and small businesses, academia, and private citizens to develop its Moon to Mars Strategy and Objectives. The goals and objectives set forth in the resulting documents are “designed to achieve the vision to create a blueprint for sustained human presence and exploration throughout the solar system.” The objectives were categorized into four distinct tracks: Operations, Infrastructure, Transportation and Habitation, and Science. In addition, common themes across the objectives were captured under Recurring Tenets. Within the Infrastructure category, several objectives directly address the need for manufacturing and construction on the lunar surface to support continuous human lunar presence and a robust lunar economy. In exploring the vision for creation of on-demand infrastructure on the lunar surface and beyond, this presentation will examine the development of these capabilities, starting in the late 1990’s and early 2000’s, up to the current state, and offer a perspective on the challenges facing operational implementation of these technologies. In the early 2000’s, the destination was the Moon. The International Space Station (ISS) was to be the test bed for demonstration of in space manufacturing technologies. Additive construction was in its infancy. These pioneering initiatives, having begun primarily under NASA’s Office of Biological and Physical Research In Situ Fabrication and Repair (ISFAR) Project, were short-lived. It was not until the early 2010’s that in space manufacturing and later extraterrestrial construction experienced renewed interest and support. At this time, the destination was Mars. This period saw the initial in space additive manufacturing experiments on the ISS, creation of a roadmap for development of in space manufacturing technologies, and development of additive construction systems for terrestrial use at scale. The period also included NASA’s 3D Printed Mars Habitat Centennial Challenge, which catalyzed interest in extraterrestrial construction. With NASA’s announcement of the intention to return to the Moon, and the subsequent release of the Artemis Accords in 2020, and the commensurate Moon to Mars Strategy, NASA’s Space Technology Mission Directorate initiated the Lunar Surface Innovation Initiative (LSII). The LSII has spurred technology development and maturation efforts across a spectrum of capabilities that would be needed to live on the lunar surface. The presentation will provide an overview of current technology developments in the areas of in space manufacturing and extraterrestrial construction. Looking forward from the current state, a perspective will be offered on capabilities that are still needed to “institutionalize” in space manufacturing and extraterrestrial construction to achieve the vision of NASA’s Moon to Mars Strategy. Finally, a challenge will be posed to the community to accelerate the development of these capabilities. When the explorers of the future need these enabling capabilities, will they be ready?

Raymond G Clinton Jr.↗

NASA NTRS2023

Analysis of the Solid Products from the OSCAR and the AOWG Trash Processing Systems

Two trash conversion systems that process space logistical trash for conversion into gases and liquids have minor solid product formation consisting of primarily high carbon ash, inorganic salts, and aluminum metal flakes. These solid products necessarily comprise part of the system output because the thermal degradation processes intentionally operate at temperatures below aluminum vaporization and do not convert all solid inorganics or carbon-based compounds into gaseous compounds (i.e., CO 2 or CH 4 ). The two systems included the Orbital Syngas/Commodity Augmentation Reactor (OSCAR) combustion system funded by the NASA Space Technology Mission Directorate (STMD) located at NASA’s Kennedy Space Center, and the Advanced Organic Waste Gasifier (AOWG) steam reforming system developed by Pioneer Astronautics in Lakewood, Colorado, and funded by the NASA Small Business Innovation Research (SBIR) Exploration Systems Development Mission Directorate (ESDMD). OSCAR residual solids were collected from suborbital flight and ground-based laboratory testing, while all AOWG samples were collected from ground testing. This report discusses the solid product characterization, including elemental analyses performed with scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS), and a surface chemistry performed with x-ray photoelectron spectroscopy (XPS). A particle size analysis was performed with sieves, followed by SEM analyses. These analyses were performed to elucidate what high value products can be extracted or utilized from the solid products for follow on infusion into chemical feedstocks, manufacturing additives, or in-situ construction-based material needs.

OSCAR↗

NASA NTRS1990

Factors affecting the perception of transparent motion

It is possible to create a perception of transparency by combining patterns having different motions. Two particular combination rules, have specific interpretations in terms of physical phenomena: additive (specular reflection) and multiplicative (shadow illumination). Arbitrary combination rules applied to random patterns generate percepts in which the motions of the two patterns are visible, but have super-imposed noise. It is also possible to combine the patterns (using an exclusive-OR rule) so that only noise is visible. Within a one-dimensional family of combination rules which include addition and multiplication, there is a range where smooth motions are seen with no superimposed noise; this range is centered about the additive combination. This result suggests that the motion system deals with a linear representation of luminance, and is consistent with the analysis of motion by linear sensors. This research gives tentative validation the use in beam splitters (which combine images additively) in the construction of heads-up aviation displays. Further work is needed to determine if the superiority of additive combination generalizes to the case of full-color imagery (there are results in the literature suggesting that subtractive color mixture yields the best legibility of overlapping alphanumerics).

Mulligan, Jeffrey B.↗

NASA NTRS1991

A strongly goal-directed close-range vision system for spacecraft docking

In this presentation, we will propose a strongly goal-oriented stereo vision system to establish proper docking approach motions for automated rendezvous and capture (AR&C). From an input sequence of stereo video image pairs, the system produces a current best estimate of: contact position; contact vector; contact velocity; and contact orientation. The processing demands imposed by this particular problem and its environment dictate a special case solution; such a system should necessarily be, in some sense, minimalist. By this we mean the system should construct a scene description just sufficiently rich to solve the problem at hand and should do no more processing than is absolutely necessary. In addition, the imaging resolution should be just sufficient. Extracting additional information and constructing higher level scene representations wastes energy and computational resources and injects an unnecessary degree of complexity, increasing the likelihood of malfunction. We therefore take a departure from most prior stereopsis work, including our own, and propose a system based on associative memory. The purpose of the memory is to immediately associate a set of motor commands with a set of input visual patterns in the two cameras. That is, rather than explicitly computing point correspondences and object positions in world coordinates and trying to reason forward from this information to a plan of action, we are trying to capture the essence of reflex behavior through the action of associative memory. The explicit construction of point correspondences and 3D scene descriptions, followed by online velocity and point of impact calculations, is prohibitively expensive from a computational point of view for the problem at hand. Learned patterns on the four image planes, left and right at two discrete but closely spaced instants in time, will be bused directly to infer the spacecraft reaction. This will be a continuing online process as the docking collar approaches.

Boyer, Kim L.↗

NASA NTRS1993

Capacitive Proximity Sensors With Additional Driven Shields

Improved capacitive proximity sensors constructed by incorporating one or more additional driven shield(s). Sensitivity and range of sensor altered by adjusting driving signal(s) applied to shield(s). Includes sensing electrode and driven isolating shield that correspond to sensing electrode and driven shield.

Mcconnell, Robert L.↗

NASA NTRS1985

Vegetation canopy discrimination and biomass assessment using multipolarized airborne SAR

Multipolarized airborne Synthetic Aperture Radar (SAR) data were acquired over a largely agricultural test site near Macomb, Illinois, in conjunction with the Shuttle Imaging Radar (SIR-B) experiment in October 1984. The NASA/JPL L-band SAR operating at 1.225 GHz made a series of daily overflights with azimuth view angles both parallel and orthogonal to those of SIR-B. The SAR data was digitally recorded in the quadpolarization configuration. An extensive set of ground measurements were obtained throughout the test site and include biophysical and soil measurements of approximately 400 agricultural fields. Preliminary evaluation of some of the airborne SAR imagery indicates a great potential for crop discrimination and assessment of canopy condition. False color composites constructed from the combination of three linear polarizations (HH, VV, and HV) were found to be clearly superior to any single polarization for purposes of crop classification. In addition, an image constructed using the HH return to modulate intensity and the phase difference between HH and VV returns to modulate chroma indicates a clear capability for assessment of canopy height and/or biomass. In particular, corn fields heavily damaged by infestations of corn borer are readily distinguished from noninfested fields.

Ulaby, F. T.↗

DOE OSTI2023

Ultrastrong colloidal crystal metamaterials engineered with DNA

Lattice-based constructs, often made by additive manufacturing, are attractive for many applications. Typically, such constructs are made from microscale or larger elements; however, smaller nanoscale components can lead to more unusual properties, including greater strength, lighter weight, and unprecedented resiliencies. Here, solid and hollow nanoparticles (nanoframes and nanocages; frame size: ~15 nanometers) were assembled into colloidal crystals using DNA, and their mechanical strengths were studied. Nanosolid, nanocage, and nanoframe lattices with identical crystal symmetries exhibit markedly different specific stiffnesses and strengths. Unexpectedly, the nanoframe lattice is approximately six times stronger than the nanosolid lattice. Nanomechanical experiments, electron microscopy, and finite element analysis show that this property results from the buckling, densification, and size-dependent strain hardening of nanoframe lattices. Last, these unusual open architectures show that lattices with structural elements as small as 15 nanometers can retain a high degree of strength, and as such, they represent target components for making and exploring a variety of miniaturized devices.

42 ENGINEERING↗

NASA NTRS2004

Research Performed within the Non-Destructive Evaluation Team at NASA Glenn Research Center

Non-destructive testing is essential in many fields of manufacturing and research in order to perform reliable examination of potentially damaged materials and parts without destroying the inherent structure of the materials. Thus, the Non-Destructive Evaluation (NDE) Team at NASA Glenn Research Center partakes in various projects to improve materials testing equipment as well as analyze materials, material defects, and material deficiencies. Due to the array of projects within the NDE Team at this time, five research aims were supplemental to some current projects. A literature survey of "DE and testing methodologies as related to rocks was performed. Also, Mars Expedition Rover technology was assessed to understand the requirements for instrumentation in harsh space environments (e.g. temperature). Potential instrumentation and technologies were also considered and documented. The literature survey provided background and potential sources for a proposal to acquire funding for ultrasonic instrumentation on board a future Mars expedition. The laboratory uses a Santec Systems AcousticScope AS200 acoustography system. Labview code was written within the current program in order to improve the current performance of the acoustography system. A sample of Reinforced Carbon/Carbon (RCC) material from the leading edge of the space shuttle underwent various non-destructive tests (guided wave scanning, thermography, computed tomography, real time x-ray, etc.) in order to characterize its structure and examine possible defects. Guided wave scan data of a ceramic matrix composite (CMC) panel was reanalyzed utilizing image correlations and signal processing variables. Additional guided wave scans and thermography were also performed on the CMC panel. These reevaluated data and images will be used in future presentations and publications. An additional axis for the guided wave scanner was designed, constructed, and implemented. This additional axis allowed incremental spacing of the previously fixed transducers for ultrasonic velocity measurements.

Burns, Erin A.↗

DOE OSTI2021

Additive manufacturing print-heads for exotic material applications

Described herein is an additive manufacturing apparatus that is well-suited for constructing piezoelectric sensors. The additive manufacturing apparatus includes an extrusion nozzle formed of a conductive material such as aluminum. The extrusion nozzle has a channel by way of which printing material exits the extrusion nozzle, wherein a build plate is configured to receive the printing material responsive to the printing material exiting the extrusion nozzle. An arc suppressor formed of a semiconductor is coupled to the extrusion nozzle and is configured to dissipate excess charge that would otherwise exist on the extrusion nozzle when a relatively high bias voltage is applied to the extrusion nozzle. Thus, the arc suppressor mitigates arcing between the extrusion nozzle and the build plate. Arc suppressing gas is also optionally introduced into a printing region, thereby further mitigating arcing between the extrusion nozzle and the build plate.

Washburn, Cody M.↗

DOE OSTI2022

Additively manufactured cryogenic microchannel distillation device for air separation

Abstract The efficiency of air separation is tested using three different small‐scale cryogenic distillation columns. The performance of a random packed column is compared to the performance of two microchannel distillation (MCD) columns that use thin wicking structures and gas flow channels to achieve process intensification. The MCD columns tested include a plate‐type layered column and an additively manufactured porous honeycomb (AMPH) column. For columns with 25.4 cm of active height and run under similar conditions, the packed, plate‐type layering, and AMPH columns achieved approximate height equivalent of a theoretical plate (HETP) values of 5.5, 3.7, and 3.2 cm for nitrogen, and 5.9, 4.9, and 3.3 cm for argon. The AMPH column can produce up to 0.4 SLM of more than 90% purity oxygen with 12 W of cooling lift. These results demonstrate the feasibility of using additive manufacturing to construct MCD devices and pave a way for constructing novel MCD designs.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Application of Linear Additive Conditions for Near-Infrared Diffuse Reflectance Absorption Spectroscopy

Determining the homogeneity of material mixing in real time during product processing is critical for quality control. According to the Kubelka–Munk (K-M) function of diffuse reflectance absorption spectrum, absorbance (A) is approximately linear with the content of the components when the sample scattering coefficient (S) is in a certain range. The S is determined by the particle size of powder samples. Therefore, this study determined particle size ranges that satisfy linear additivity in near-infrared diffuse reflectance spectroscopy (NIRDRS). Thus, the proposed NIRDRS analysis technique can be used to determine the homogeneity of material mixes or analyze the percentages of the components in the mixture. In this study, vitamin B3 and vitamin C were used for preparing mixed samples with varying percentages. The experimental results revealed that linear additivity is satisfied when the powder particle size is in the range of less than 280, 280–450, and 450–900 μm. When the confidence level is 0.01, the actual mixed spectra are not significantly different from the “simulated mixed spectra” constructed by linear addition, with their relative deviations less than 1.08%. The absolute errors of the actual and analytic percentages were within 2.98% for each component in the mixtures. The above conclusions also hold for sorghum, which has a complex material composition. Statistical models cannot analyze the percentages of components in the mixture. In contrast, linear addition and direct calibration approach avoids the use of a large number of samples for statistical modeling and analyze the percentages of mixed samples. Meanwhile, it can be used to discriminate and analyze the material mixing uniformity by building a mechanistic model.

Feng, Zhiyue↗

DOE OSTI2023

EUI Benchmarks for Net-Zero Energy Buildings in India

In our study we present EUI benchmarks for NZEBs for six building types across residential and non-residential typologies and for India's five climate zones. This approach is similar to the simulation-based benchmarks used by the B3 program in Minnesota, the Cal-Arch methodology in California, and the US Solar Decathlon approach, which combine simulations with actual building data. Of the six building types we explore one in detail with a range of operation scenarios, specifically narrowing down the EUI benchmarks for mixed-mode building operation and for variable temperature set-points as prescribed in the National Building Code of India.The contribution of this work is to provide rigorous end-use level EUI benchmarks for six building types, and to describe a method for simulation-based EUI benchmarks for mixed-mode operation with variable setpoints to highlight the difference between the standard approach used for the five building types and the On-Site Construction Worker Housing which additionally has the mixed-mode variable setpoint approach.On-Site Construction Worker Housings are typically poorly constructed temporary structures, without adequate thermal comfort, It is critical to provide adequate thermal comfort to protect people from the warming effects of climate change, and to discover super efficient and cost-effective ways to do so.The methodology used for the On-Site Construction Worker Housing (CWH) results in an 80% acceptability according to the India Model for Adaptive Comfort in the National Building Code of India. EUIs of all six buildings are 60% lower than the minimum compliance with India's Energy Conservation Building Codes, providing benchmarks for efficiency levels. The end-use level EUI benchmarks are now provided to over 1800 Solar Decathlon India participants so that they can compare the performance of their NZEB designs.In particular, the CWH results provide an insight into the importance of the mixed-mode operation with variable temperature set-points. The results from the simulation study show that for an NZEB target, the EUI with standard thermal comfort model and without mixed operation is 58.26 kWh/m2*year, while that with the variable set-points of the adaptive model with mixed mode operation is 24.23 kWh/m2*year. This is a 58% reduction in EUI. Given that many building types including residential, and non-residential operate in mixed mode, it is important to take this work further to develop mixed-mode operation NZEB benchmarks so that the carbon intensity of these buildings could be lower than the standard thermal comfort model approach.

benchmarking↗

DOE OSTI2024

Abelian combinatorial gauge symmetry

Combinatorial gauge symmetry is a principle that allows us to construct lattice gauge theories with two key and distinguishing properties: a) only one- and two-body interactions are needed; and b) the symmetry is exact rather than emergent in an effective or perturbative limit. The ground state exhibits topological order for a range of parameters. This paper is a generalization of the construction to any finite Abelian group. In addition to the general mathematical construction, we present a physical implementation in superconducting wire arrays, which offers a route to the experimental realization of lattice gauge theories with static Hamiltonians.

Yu, Hongji↗

NASA NTRSDate not supplied

Voxel Based Three-Dimensional Topology Optimization of Heat Exchanger Fins

Increasing interest in novel aircraft propulsion systems and potential for unwanted heat generation, or capture and reuse of waste heat, may require increasingly lightweight and high performing heat exchangers. Advances in manufacturing technologies have shown potential to create complex designs, but design tools need more flexibility. This study utilizes genetic algorithm-driven topology optimization to develop high performance heat exchanger fins for critical applications such as aerospace. The solid domain is generated using voxel representation where a voxel value of 1 indicates the solid domain and a voxel value of 0 refers to the fluid domain. The use of voxel representation somewhat matches the digitization of a model that is required to fabricate using additive manufacturing, and also allows for a highly unconstrained geometry. To test the topology optimization approach, a three-dimensional(3D)baseline offset strip fin geometry in steady laminar flow(Reynolds number = 215)with conjugate heat transfer(simultaneous solution of solid and fluid temperature fields)is optimized. New designs are generated using the genetic algorithm (GA) and sent to evaluation by the CFD software OpenFOAM; then the GA sorts and selects the reproduction pool for the following generation. This process is repeated for 60 generations. The study also investigates the effect off in material on the performance of the GA and the resulting designs. The results show that the optimal designs have overall performance improvement of 18% relative to the baseline. Additionally, a fin constructed of a lower conductivity material (such as an Inconel super alloy that might be necessary for waste heat recovery applications)results in lower overall performance improvement (11%)and optimal designs with higher pressure drop relative to their baseline, and relative to optimal designs produced using higher conductivity materials.

3D Optimization↗

NASA NTRS1993

Active control of buildings during earthquakes

The objective of this report is to provide an overview of the different types of control systems used in buildings, to discuss the problems associated with current active control mechanisms, and to show the cost-effectiveness of applying active control to buildings. In addition, a small case study investigates the feasibility and benefits of using embedded actuators in buildings. Use of embedded actuators could solve many of the current problems associated with active control by providing a wider bandwidth of control, quicker speed of response, increased reliability and reduced power requirement. Though embedded actuators have not been developed for buildings, they have previously been used in space structures. Many similarities exist between large civil and aerospace structures indicating that direct transfer of concepts between the two disciplines may be possible. In particular, much of the Controls-Structures Interaction (CSI) technology currently being developed could be beneficially applied to civil structures. While several buildings with active control systems have been constructed in Japan, additional research and experimental verification are necessary before active control systems become widely accepted and implemented.

Vance, Vicki L.↗

NASA NTRS2003

Development of a Dynamically Configurable, Object-Oriented Framework for Distributed, Multi-modal Computational Aerospace Systems Simulation: Second Year Progress Report

Mesh generation has long been recognized as a bottleneck in the CFD process. While much research on automating the volume mesh generation process have been relatively successful,these methods rely on appropriate initial surface triangulation to work properly. Surface discretization has been one of the least automated steps in computational simulation due to its dependence on implicitly defined CAD surfaces and curves. Differences in CAD peometry engines manifest themselves in discrepancies in their interpretation of the same entities. This lack of "good" geometry causes significant problems for mesh generators, requiring users to "repair" the CAD geometry before mesh generation. The problem is exacerbated when CAD geometry is translated to other forms (e.g., IGES )which do not include important topological and construction information in addition to entity geometry. One technique to avoid these problems is to access the CAD geometry directly from the mesh generating software, rather than through files. By accessing the geometry model (not a discretized version) in its native environment, t h s a proach avoids translation to a format which can deplete the model of topological information. Our approach to enable models developed in the Denali software environment to directly access CAD geometry and functions is through an Application Programming Interface (API) known as CAPRI. CAPRI provides a layer of indirection through which CAD-specific data may be accessed by an application program using CAD-system neutral C and FORTRAN language function calls. CAPRI supports a general set of CAD operations such as truth testing, geometry construction and entity queries.

Afjeh, Abdollah A.↗

DOE OSTI2023

Design and construction of a compact, high-repetition-rate ultrafast electron diffraction instrument

We present the design and performance of a compact ultrafast electron diffraction instrument. The diffractometer provides a means of examining time-resolved ultrafast dynamical properties of solids. The system’s utilization is discussed in terms of instrument parameters and diffraction data from selected condensed matter samples. Here, the difractometer’s performance is highlighted in terms of detection sensitivity, instrumental temporal resolution, and the electron beam transverse coherence length. Following specific details of the construction, we present a practical discussion of parameters such as repetition rate and provide advice on general construction approaches for laboratory-based, keV ultrafast electron diffractometers. In addition, design guidance for constructing a compact electron gun source that is well-suited for studying diffraction from hard condensed matter is given. A unique data acquisition scheme, utilizing high laser repetition rates, is presented.

47 OTHER INSTRUMENTATION↗

NASA NTRS2013

Silicon Heat Pipe Array

Improved methods of heat dissipation are required for modern, high-power density electronic systems. As increased functionality is progressively compacted into decreasing volumes, this need will be exacerbated. High-performance chip power is predicted to increase monotonically and rapidly with time. Systems utilizing these chips are currently reliant upon decades of old cooling technology. Heat pipes offer a solution to this problem. Heat pipes are passive, self-contained, two-phase heat dissipation devices. Heat conducted into the device through a wick structure converts the working fluid into a vapor, which then releases the heat via condensation after being transported away from the heat source. Heat pipes have high thermal conductivities, are inexpensive, and have been utilized in previous space missions. However, the cylindrical geometry of commercial heat pipes is a poor fit to the planar geometries of microelectronic assemblies, the copper that commercial heat pipes are typically constructed of is a poor CTE (coefficient of thermal expansion) match to the semiconductor die utilized in these assemblies, and the functionality and reliability of heat pipes in general is strongly dependent on the orientation of the assembly with respect to the gravity vector. What is needed is a planar, semiconductor-based heat pipe array that can be used for cooling of generic MCM (multichip module) assemblies that can also function in all orientations. Such a structure would not only have applications in the cooling of space electronics, but would have commercial applications as well (e.g. cooling of microprocessors and high-power laser diodes). This technology is an improvement over existing heat pipe designs due to the finer porosity of the wick, which enhances capillary pumping pressure, resulting in greater effective thermal conductivity and performance in any orientation with respect to the gravity vector. In addition, it is constructed of silicon, and thus is better suited for the cooling of semiconductor devices.

Yee, Karl Y.↗