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195 records · Page 9

NIAC Phase I Final Report Lunar South Pole Oxygen Pipeline (LSPOP)

The Lunar South Pole Oxygen Pipeline (LSPOP) Phase I NIAC, is to analyze the feasibility of constructing a pipeline at the Moon’s South Pole for transporting gaseous oxygen from point of generation to point of use. A lunar pipeline has never been pursued and will revolutionize lunar surface operations for the Artemis program and reduce cost and risk. Our starting concept is for a 5 km pipeline to transport oxygen gas from an oxygen production source, for example from our molten regolith electrolysis (MRE, currently at TRL 5, see references[1],[2],[3],[4],[5],[6] for technical discussions of the MRE process) extraction site, or any other source, to an oxygen storage/liquification plant near a lunar base. The pipeline is designed to: 1) be constructed robotically from regolith-derived metals with minimal material transferred from Earth, 2) be repairable robotically, 3) have an oxygen flow rate of ~2 kg/hour, which is commensurate with the NASA initial projected need of 10,000 kg/year, 4) operate with minimal power over the lifetime of the pipeline, with a goal of high operational reliability and the ability to survive in the lunar environment for > 10 years. We compare this concept to a pipeline concept with pipe produced on Earth and then transported to and assembled on the Moon. Both approaches will use earth-based compressors, valves, and fittings which are integrated into the pipeline on the Moon.

NIAC Phase I

First-Principles Investigation of Phase Transitions in RuNb, RuTa, and Ru-Nb-Ta Ultrahigh Temperature Shape Memory Alloys

Ultrahigh temperature shape memory alloys (UHT-SMAs) have transition temperatures above 600 C, and they have found applications for sensing and actuating devices in aerospace industry. Among very few such UHT-SMAs currently known are Ru-based alloys such as RuNb and RuTa, whose martensite structures and phase transitions are totally different from those of NiTi-based SMAs and were poorly understood. In this work, we carried out a systematical study of RuNb using first-principles total energy calculations and molecular dynamics (MD) simulations. The transition paths and mechanisms in cubic → tetragonal →monoclinic transitions are revealed. and the transition sequence and martensitic transition temperatures are determined (MTTs) by evaluating the Gibbs free energies using thermodynamic integration. The calculated MTTs are in very good agreement with the experimental data. We found that the monoclinic phase at the second transition has the 𝑃21/m symmetry instead of experimentally identified 𝑃2/m. Our calculations demonstrate that RuTa has very similar phase transitions to those of RuTa. Furthermore, we studied the Ru0.5Nb0.25Ta0.25 ternary. Our results can explain the measured significant drop of MTT (~ 200 C) in the second transition for Ru0.5Nb0.25Ta0.25 compared with those of RuNb and RuTa, while in the first transition its MTT is between MTTs of RuNb and RuTa. The insights gained by this study and the verified ab initio methods for accurate MTT calculations can be applied to fast screen and quantitatively design novel UHT-SMAs having similar properties with desirable MTTs and much reduced cost.

Zhigang Wu

The Evolution in Coma Molecular Composition of Comet C/2017 K2 (PanSTARRS) Across the H 2 O Sublimation Zone: ALMA Imaging of an H 2 O-Dominated Coma

We report a survey of molecular emission from cometary volatiles using the Atacama Large Millimeter/Submillimeter Array (ALMA) toward comet C/2017 K2 (PanSTARRS) carried out on UT 2022 September 21, 22, and 23 at a heliocentric distance r H 3 OH, and H 2 CO (along with continuum emission from dust) sampled molecular chemistry in C/2017 K2 at the inner edge of the H 2 O sublimation zone, the region from r H 2 O begins vigorously subliming and increasingly dominating comet activity, discerning parent from daughter or extended source species. This work presents spectrally integrated flux maps, production rates, and parent scale lengths for each molecule. CH 3 OH, CO, and HCN were produced within ~250 km of the nucleus, potentially including contributions from sublimation of icy grains. CS was consistent with production from CS 2 photolysis, and H 2 CO required production from extended sources in the coma. An ortho-to-para ratio of 2.9 ± 0.4 for H 2 CO was derived from simultaneously measured transitions of each spin species. The continuum was extended and spatially resolved, consistent with thermal emission from dust in the coma. Analysis of the continuum visibilities provided an upper limit on the nucleus diameter d <6.6 km and coma dust masses of (1.2-2.4) times10 11 kg.

Nathan X Roth

Thermal-Fluid Analysis of a Liquid-Cooled Battery Module for Electrified Aircraft

The development of safe, energy-dense batteries is critical to advancing hybrid electric and fully electrified aircraft propulsion. Achieving this capability requires a thermal management system that can maintain battery performance and safety under demanding operational conditions. The objective of this project is to support the maturation of next-generation lithium-ion batteries for electrified aircraft by conducting performance testing on integrated battery modules, specifically a 2-cell series configuration module housed within an aluminum enclosure. Designed to operate at a nominal 7.2 V with discharge rates up to 2.5C, the module will eventually be used to power an electric motor and DC-DC converter, generating substantial thermal loads that must be effectively managed to increase the usable energy and power density of electrified aircraft. To address these thermal challenges, this study presents the development and thermal-fluid analysis of a liquid-cooled thermal management system. While the full aircraft architecture utilizes an eight-string configuration, the present work evaluates a representative single-string water coolant loop to characterize baseline performance. The active cooling loop circulates water through a reservoir, pump, the battery module, and a variable area flow meter. Key performance metrics including component-level temperatures, mass flow rates, and pressure drops are quantified across the loop. Across discharge rates ranging from 0.5C to 2.5C, the active thermal loop consistently and effectively removed heat from the module, validating the design approach and confirming readiness for further development. The validated thermal performance indicates a path toward scalable battery modules that could enable energy and power dense systems for hybrid electric aircraft.

Electrified Aircraft

Guidelines for Schlieren Systems at Langley Research Center

The original Langley Working Paper (LWP 448) published on July 27th, 1967, provided guidance to NASA Langley Research Center personnel on how to set up conventional path-integrated schlieren flow visualization systems and what pitfalls could be expected with such setups. The guidance and information contained in the document continues to be used for schlieren setups at NASA Langley Research Center to this day. The most commonly used method of flow visualization in supersonic wind tunnels is the schlieren method, or method of striae. At the Langley Research Center, this method is so commonly used that it has come to be regarded somewhat as merely another piece of instrumentation which is to be maintained by service people, and which is too mysteriously complicated to be touched by tunnel personnel. This should not be the case. High-quality results from a schlieren system can only be obtained by having personnel on the tunnel staff who are well-informed on the subject and who have the time and the interest to do a good job of adjustment. This paper is a discussion in practical terms, of some of the points to be considered and the pitfalls that may be encountered in designing, setting up and using a working schlieren system. It is directed specifically toward helping specify and install a Z-type mirror system. It is hoped that the material will be of assistance to facilities throughout the Center and NASA and that users of the schlieren method will be inspired to the point of training people in the adjustment of the systems in use at their facilities.

Langley Working Papers

Artemis I Orion ESM Propulsion System Engine Performance

NASA's Orion spacecraft transports humans and cargo into cislunar space for the Artemis program. The European Service Module (ESM), supplied by ESA and its European industry partners, provides Orion with power and in-space propulsion. The Orion-ESM propulsion system is a bipropellant hypergolic propulsion system using monomethyl hydrazine (MMH) and nitrogen tetroxide (MON-3). Primary translational propulsion is provided by the Orbital Maneuvering System Engine(OMS-E), with backup translational propulsion provided by eight Auxiliary thrusters (AUX). Attitude control and small translational maneuvers are provided by twenty four Reaction Control System (RCS) engines. The 2022 Artemis I mission was the first integrated flight test of the Orion-ESM spacecraft and its propulsion system. The OMS-E used on Artemis I was a refurbished Space Shuttle OMS-E that previously flew on nineteen missions ranging from STS-41G in 1984 to STS-112 in 2002. The Auxiliary engines are modified Aerojet Rocketdyne R4D-11 engines produced specifically for the Orion program. The RCS engines are Ariane Group engines originally used for the Automated Transfer Vehicle (ATV) program. This paper will discuss the unique operational requirements for each engine on Orion and the development and qualification effort sat both the engine and system-level that were completed to enable a successful Artemis I mission. Next the paper will evaluate the in-flight performance of the engines during the Artemis I mission showing nominal performance as expected. Additionally, comparisons to models will be presented showing very good correlation. Finally, the paper will address the plan for the engines on future Orion missions and the evolution of the system operation.

Liquid Propulsion Systems

Artemis I Orion ESM Propulsion System Engine Performance

NASA's Orion spacecraft transports humans and cargo into cislunar space for the Artemis program. The European Service Module (ESM), supplied by ESA and its European industry partners, provides Orion with power and in-space propulsion. The Orion-ESM propulsion system is a bipropellant hypergolic propulsion system using monomethyl hydrazine (MMH) and nitrogen tetroxide (MON-3). Primary translational propulsion is provided by the Orbital Maneuvering System Engine(OMS-E), with backup translational propulsion provided by eight Auxiliary thrusters (AUX). Attitude control and small translational maneuvers are provided by twenty four Reaction Control System (RCS) engines. The 2022 Artemis I mission was the first integrated flight test of the Orion-ESM spacecraft and its propulsion system. The OMS-E used on Artemis I was a refurbished Space Shuttle OMS-E that previously flew on nineteen missions ranging from STS-41G in 1984 to STS-112 in 2002. The Auxiliary engines are modified Aerojet Rocketdyne R4D-11 engines produced specifically for the Orion program. The RCS engines are Ariane Group engines originally used for the Automated Transfer Vehicle (ATV) program. This paper will discuss the unique operational requirements for each engine on Orion and the development and qualification effort sat both the engine and system-level that were completed to enable a successful Artemis I mission. Next the paper will evaluate the in-flight performance of the engines during the Artemis I mission showing nominal performance as expected. Additionally, comparisons to models will be presented showing very good correlation. Finally, the paper will address the plan for the engines on future Orion missions and the evolution of the system operation.

Reuse

Technology Readiness Assessment for Stirling Power Convertor

Stirling-based power conversion system could represent a critical enabling technology for future NASA missions, offering significantly enhanced power efficiency over traditional thermoelectric systems. To ensure the successful infusion of this technology into deep space and planetary surface missions, a rigorous evaluation of its maturity and associated risks is essential. The objective of this Technology Readiness Assessment (TRA) is to determine the current technology readiness level (TRL) of the Stirling power convertor and identify key technical risks and challenges associated with its maturation and potential infusion into a targeted flight system. The evaluation process will rigorously follow the NASA TRA procedure: (1) determining the requirements that underpin the design, function, and performance; (2) finding and listing all new technology elements (NTEs) and critical technology elements (CTEs); (3) identifying the level of integration assumed for the assessment; and (4) assessing the TRL for each NTE and CTE. The overall subassembly TRL will then be determined via a roll-up using the “weakest link” criterion, culminating in a final (5) assessment of risks to further progression of maturity. This paper will present the results of a comprehensive technology readiness assessment (TRA) conducted on the Stirling-based dynamic power conversion subassembly, excluding the radioisotope heat source. The paper will also describe a detailed breakdown of the TRL roll-up and a matrix of identified risks and recommended mitigation paths, along with identified key technical risks and challenges to achieve the required long-duration performance. Key Words: Radioisotope Power Conversion, Technology Readiness Assessment

Radioisotope Power Conversion

A Review of Pump Package Assembly Anomalies and Demonstration to Gain Motor Controller Replacement Capability

The International Space Station (ISS) generates heat within the US modules from systems used to operate the station, maintain crew health, and conduct science experiments in the orbiting laboratory. The Internal Thermal Control System (ITCS) collects this heat in water loops and transfers it to the external ammonia system for rejection to space. The ITCS uses six Pump Package Assemblies (PPA) as the motive force to circulate the water within the Lab, Node 2, and Node 3 (Node 1 is parasitic to the Lab and Node 3 ITCS loops). In the life of ISS, 3 PPAs have had to be replaced and 2 PPAs are currently showing signs of degradation. The first PPA to fail in 2003 was due to early coolant chemistry issues; the remaining pump failures and current pump degradations are determined to be related to the Pump/Fan Motor Controller (PFMC), with their individual signatures all being unique to this point. The PFMC of one of the failed PPAs was returned and testing confirmed its sub-components to be the root cause of the PPA failure. Due to the relative size and weight of the standalone PFMC in comparison to the integrated assembly, it is desired, from a launch and on-orbit stowage perspective, to replace the PFMC component of the degraded PPA instead of the entire PPA. The PPA was not designed for this capability, so on the ground demonstrations are planned using crew tools to show that the PFMC can be replaced on-orbit while maintaining full functionality. This paper will focus on the signatures of the two most recent PPA failures and the two PPAs showing signs of degradation, in addition to presenting the findings from the PFMC demonstration effort.

Aaron Rodriguez

A Review of Pump Package Assembly Anomalies and Demonstration to Gain Motor Controller Replacement Capability

The International Space Station (ISS) generates heat within the US modules from systems used to operate the station, maintain crew health, and conduct science experiments in the orbiting laboratory. The Internal Thermal Control System (ITCS) collects this heat in water loops and transfers it to the external ammonia system for rejection to space. The ITCS uses six Pump Package Assemblies (PPA) as the motive force to circulate the water within the Lab, Node 2, and Node 3 (Node 1 is parasitic to the Lab and Node 3 ITCS loops). In the life of ISS, 3 PPAs have had to be replaced and 2 PPAs are currently showing signs of degradation. The first PPA to fail in 2003 was due to early coolant chemistry issues; the remaining pump failures and current pump degradations are determined to be related to the Pump/Fan Motor Controller (PFMC), with their individual signatures all being unique to this point. The PFMC of one of the failed PPAs was returned and testing confirmed its sub-components to be the root cause of the PPA failure. Due to the relative size and weight of the standalone PFMC in comparison to the integrated assembly, it is desired, from a launch and on-orbit stowage perspective, to replace the PFMC component of the degraded PPA instead of the entire PPA. The PPA was not designed for this capability, so on the ground demonstrations are planned using crew tools to show that the PFMC can be replaced on-orbit while maintaining full functionality. This paper will focus on the signatures of the two most recent PPA failures and the two PPAs showing signs of degradation, in addition to presenting the findings from the PFMC demonstration effort.

Aaron Rodriguez

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials

Plume Impingement Software Module for Real-Time Proximity Operations

Successfully executing proximity operations in space, such as docking or in-orbit servicing, requires sophisticated spacecraft design that accounts for induced environments. As a chaser vehicle’s attitude control thrusters fire, they create rarefied plumes that can impact the target vehicle, with the potential to overload components, exceed thermal limits, and spin the target vehicle out of control. High-fidelity simulations of the thruster plume impingement environment require the direct simulation Monte Carlo (DSMC) method, but DSMC is too computationally expensive to simulate proximity operations that involve thousands of thruster firings. For this analysis to be tractable, engineering models of the plume flowfield and impingement events are used to simulate these trajectories [1]. Currently, on-orbit plume impingement environments are modeled through an inefficient open-loop analysis cycle where the vehicle’s flight controller and plume impingement teams iterate on the trajectories until they pass the target vehicle’s plume requirements. As complex on-orbit missions evolve and become more frequent, lengthy design cycles will become operational bottlenecks. To address this gap, this work develops an advanced plume impingement module capable of operating at real-time scale that can be integrated with existing mission planning tools and onboard flight systems. The plume module leverages state-of-the-art plume simulation techniques [2] to deliver fast, physics-based impingement predictions in a software architecture that can be tailored to diverse proximity operations scenarios. A prototype of this plume impingement module is built to demonstrate the feasibility of real-time performance. This prototype completes plume impingement calculations in microseconds per target geometry mesh point. The software serves as a foundational capability for plume-aware trajectory design, operational risk assessment, and future autonomous decision-making systems.

Plume Impingement

Optimization of X-ray Absorbers for High-Resolution TES Detectors in NewATHENA X-IFU

NewATHENA’s X-ray Integral Field Unit (X-IFU) uses a large-format array of Transition Edge Sensor (TES) microcalorimeters coupled with absorbers made of gold and bismuth providing 4 eV FWHM resolution up to 7 keV in the 0.2- 12 keV band. X-ray absorbers must be thick enough for photon absorption, maintain low heat capacity for energy resolution, and have good thermalization properties. The X-IFU requires total Quantum Efficiency (QE) of 96%, 87%, and 63% at 1, 7, and 9.5 keV, respectively. Optimal thicknesses are 1.05 µm gold and 5.5 µm bismuth to achieve 0.731 pJ/K at 90 mK and 87% QE at 7 keV. While typical TES absorbers are 3-4 µm thick, producing the required 5.5 µm Bi absorbers via standard electroplating creates enlarged grains and surface roughness. The increased roughness and grain size variability produced with our standard recipe have resulted in instances of 1) low energy spectral tails 2) spectral broadening of the energy resolution and 3) thermal shorts between pixels when a large grain bridges the gap between absorbers. In this study, we have introduced a new fabrication process and altered the morphology of the thick Bi through changes in the electroplating process. The process changes are intended to address all three issues as well as reduce particulate contamination observed on the finished detector arrays.

Absorber

Hydrology Copilot: A Cloud-Native Ai System for Hydrological Data Analysis

The emergence of AI-driven Earth observation systems promises to broaden access to petabyte-scale geospatial data beyond domain specialists. However, translating this vision into operational scientific infrastructure requires addressing fundamental challenges in data virtualization, code transparency, and domain-specific reasoning. We present Hydrology Copilot, a cloud-native AI framework for natural-language-driven analysis of Earth observation data. To demonstrate operational capabilities at scale, we implement the system using NASA's North American Land Data Assimilation System version 3 (NLDAS-3), which provides surface meteorological forcing and land-surface model output across North and Central America at 1-km resolution, from which drought diagnostics are derived. The system integrates five core contributions: (1) scalable data virtualization using Kerchunk-based cloud optimized access, achieving a 1.5 to 4.6 times improvement in I/O latency across benchmark queries spanning regional single-day extractions (4.6 times speedup) to continental monthly aggregations (1.5 times speedup); (2) transparent code generation through Microsoft Azure AI Foundry agents that expose executable Python workflows for scientific verification; (3) persistent conversational memory enabling multi-turn analytical discourse across sessions; (4) intelligent query validation that enforces dataset boundaries and resolves ambiguous requests before execution; and (5) a multi-agent architecture coordinating query parsing, code generation, and visualization. We evaluate the system through drought-monitoring workflows, demonstrating reliable code generation, accurate results validated against reference computations and the operational U.S. Drought Monitor, and efficient operation across increasingly complex tasks. By bridging natural-language interfaces with rigorous hydrological analysis, Hydrology Copilot advances beyond proof-of-concept demonstrations to provide a deployable framework for operational Earth science applications.

Data virtualization

Concept to Reality: Contributions of the Langley Research Center to US Civil Aircraft of the 1990s

This document is intended to be a companion to NASA/SP-2000-4519, Partners in Freedom: Contributions of the Langley Research Center to U.S. Military Aircraft of the 1990s . Material included in the combined set of volumes provides informative and significant examples of the impact of Langley's research on U.S. civil and military aircraft of the 1990s. This volume, 'Concept to Reality: Contributions of the NASA Langley Research Center to U.S. Civil Aircraft of the 1990s', highlights significant Langley contributions to safety, cruise performance, takeoff and landing capabilities, structural integrity, crashworthiness, flight deck technologies, pilot-vehicle interfaces, flight characteristics, stall and spin behavior, computational design methods, and other challenging technical areas for civil aviation. The contents of this volume include descriptions of some of the more important applications of Langley research to current civil fixed-wing aircraft (rotary-wing aircraft are not included), including commercial airliners, business aircraft, and small personal-owner aircraft. In addition to discussions of specific aircraft applications, the document also covers contributions of Langley research to the operation of civil aircraft, which includes operating problems. This document is organized according to disciplinary technologies, for example, aerodynamics, structures, materials, and flight systems. Within each discussion, examples are cited where industry applied Langley technologies to specific aircraft that were in operational service during the 1990s and the early years of the new millennium. This document is intended to serve as a key reference for national policy makers, internal NASA policy makers, Congressional committees, the media, and the general public. Therefore, it has been written for a broad general audience and does not presume any significant technical expertise. An extensive bibliography is provided for technical specialists and others who desire a more in-depth discussion of the contributions.

NASA History Series

NASA Hybrid Thermally Efficient Core (HyTEC) Phase 2 Q3’GFY25 to Q2’GFY26 Unlimited Rights Annual Report for CLIN 1 and 2

The HyTEC Phase 2 Project focuses on the development and demonstration of high-power density, small engine core gas turbine engine technologies. The focus of HyTEC on these small engine core technologies will provide direct benefits to the next single-aisle class aircraft in terms of thermal efficiency, as well as integrate with other technologies, through increased hybridization, as they mature to provide substantial continuous fuel burn reductions during the aircraft lifecycle. These advances will strengthen the US position in the commercial aviation engine market and enable cost benefits in commercial aviation. In Government fiscal year 26 the HyTEC Project was closed and contract moved to the Subsonic Vehicle Technologies and Tools Project. GE Aerospace is executing two major work plans as part of the HyTEC Phase 2 contract. The first is Contract Line-Item Number (CLIN) 001 and its objective is to mature High Pressure Turbine (HPT) aerodynamics technology to TRL 5 through multiple rigs so that it may be incorporated into a complete TRL 6 evaluation and unlock learnings for the engine core demonstration as applicable. CLIN 002, the second work plan, is to design, procure and test a cost shared portion of technologies on the TRL6 Compact Core test vehicle. The compact core demonstrated through HyTEC Phase 2 along with the HPT rig TRL advancement directly matures the technologies being developed as part of the CFM RISE demonstrator program which is targeting a more than 20% fuel burn reduction at the engine level versus today’s state of the art. The RISE program’s objective is to advance both the novel Open Fan architecture, compact core technologies and advanced systems such as hybrid electric needed to achieve the desired fuel burn reduction to TRL6 ahead of a new product introduction in the single-aisle class aircraft in the 2030s timeframe.

gas turbine engine

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Robotics