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NASA NTRS2012

Design and Manufacturing Considerations for Shockproof and Corrosion-Immune Superelastic Nickel-Titanium Bearings for a Space Station Application

An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.

DellaCorte, Christopher↗

NASA NTRS2017

NASA Centennial Challenge: Three Dimensional (3D) Printed Habitat, Phase 2

The NASA Centennial Challenges: 3D-Printed Habitat Challenge seeks to develop the fundamental technologies necessary to manufacture an off-world habitat using mission recycled materials and/or local indigenous materials. The vision is that autonomous habitat manufacturing machines will someday be deployed to the Moon or Mars to construct shelters for human habitation. NASA and Bradley University, are holding a new US$ 2.5 million competition to design and build a 3-D printed habitat for deep space exploration, including the agency's journey to Mars. The multi-phase 3-D Printed Habitat Challenge, part of NASA's Centennial Challenges program, is designed to advance the additive construction technology needed to create sustainable housing solutions for Earth and beyond. The first phase of the competition ran through Sept. 27, 2015. This phase, a design competition, called on participants to develop state-of-the-art architectural concepts that take advantage of the unique capabilities 3-D printing offers. The top 3 prizes with a prize purse of $40,000 were awarded at the 2015 World Maker Faire in New York. The second phase of the competition is called the Structural Member Competition and it is divided into three levels happening in the spring and summer of 2017. The Compression Test Competition (Level 1) focuses on the fabrication technologies needed to manufacture structural components from a combination of indigenous materials and recyclables, or indigenous materials alone. For Level 1, teams will develop 3D printable materials, build a 3D printing machine, and print two specimens: a truncated cone and a cylinder. The Level 2 Beam Member Competition is the second of three sub-competitions within the overall Structural Member Competition. For Level 2, teams will print a beam that will be tested. The Level 3 Head to Head Competition is the third of three sub-competitions within the overall Structural Member Competition. For Level 3, teams will develop 3D printable materials, use a 3D printing machine, and print three compression specimens of the elected material, three flexural specimens of the elected material, and one dome structure. Tests conducted on the specimens and the dome structure will determine Level 3 scores and awards. On Earth these same habitat manufacturing capabilities could be used to produce housing wherever affordable housing is needed and access to conventional building materials and skills is limited. Terrestrially, it is envisioned that local indigenous materials (dirt, clay, sand, etc.) could be combined with readily available recyclable materials and used to construct semi-permanent shelters against environmental elements for human habitation. The goal of the 3D-Printed Habitat Challenge is to foster the development of new technologies necessary to additively manufacture a habitat using local indigenous materials with, or without, recyclable materials. This paper will summarize the Level 2 results of this NASA Centennial Challenge competition and it will discuss related technology advancement.

3D printing↗

NASA NTRSDate not supplied

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

As NASA prepares for Mars colonization, resource conservation will be critical for survival. Artificial Intelligence (AI) powered waste sorting technologies, already emerging on Earth, offer promising solutions for recycling and material recovery. These systems use advanced sensors and machine learning algorithms to identify and separate materials with remarkable accuracy. On Mars, where every item has significant value, efficient recycling will be essential to reduce resupply needs and support closed-loop life support systems. This paper explores how terrestrial AI-based trash sorting technologies can be adapted for Martian conditions, focusing on challenges such as the harsh surface environment, minimizing system mass, power, volume, and estimating waste composition. Addressing these issues will be key to enabling sustainable operations on the Red Planet.

Sorting↗

NASA NTRSDate not supplied

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

AI↗

NASA NTRS2017

Axiomatic Design of Space Life Support Systems

Systems engineering is an organized way to design and develop systems, but the initial system design concepts are usually seen as the products of unexplained but highly creative intuition. Axiomatic design is a mathematical approach to produce and compare system architectures. The two axioms are:- Maintain the independence of the functional requirements.- Minimize the information content (or complexity) of the design. The first axiom generates good system design structures and the second axiom ranks them. The closed system human life support architecture now implemented in the International Space Station has been essentially unchanged for fifty years. In contrast, brief missions such as Apollo and Shuttle have used open loop life support. As mission length increases, greater system closure and increased recycling become more cost-effective.Closure can be gradually increased, first recycling humidity condensate, then hygiene wastewater, urine, carbon dioxide, and water recovery brine. A long term space station or planetary base could implement nearly full closure, including food production. Dynamic systems theory supports the axioms by showing that fewer requirements, fewer subsystems, and fewer interconnections all increase system stability. If systems are too complex and interconnected, reliability is reduced and operations and maintenance become more difficult. Using axiomatic design shows how the mission duration and other requirements determine the best life support system design including the degree of closure.

Axiomatic design↗

NASA NTRS2002

Progress in the Development of a Continuous Adiabatic Demagnetization Refrigerator

We report on recent progress in the development of a continuous adiabatic demagnetization refrigerator (CADR). Continuous operation avoids the constraints of long hold times and short recycle times that lead to the generally large mass of single-shot ADRs, allowing us to achieve an order of magnitude larger cooling power per unit mass. Our current design goal is 10 micro W of cooling at 50 mK using a 6-10 K heat sink. The estimated mass is less than 10 kg, including magnetic shielding of each stage. The relatively high heat rejection capability allows it to operate with a mechanical cryocooler as part of a cryogen-free, low temperature cooling system. This has the advantages of long mission life and reduced complexity and cost. We have assembled a three-stage CADR and have demonstrated continuous cooling using a superfluid helium bath as the heat sink. The temperature stability is 8 micro K rms or better over the entire cycle, and the cooling power is 2.5 micro W at 60 mK rising to 10 micro W at 100 mK.

Shirron, Peter↗

NASA NTRS2004

A Continuous Adiabatic Demagnetization Refrigerator for Far-IR/Sub-mm Astronomy

We report on recent progress in the development of a continuous adiabatic demagnetization refrigerator (CADR). Continuous operation avoids the constraints of long hold times and short recycle times that lead to the generally large mass of single-shot ADRs, allowing us to achieve an order of magnitude larger cooling power per unit mass. Our current design goal is 10 microW of cooling at 50 mK using a 6-10 K heat sink. The estimated mass is less than 10 kg, including magnetic shielding of each stage. The relatively high heat rejection capability allows it to operate with a mechanical cryocooler as part of a cryogen-free, low temperature cooling system. This has the advantages of long mission life and reduced complexity and cost. We have assembled a three-stage CADR and have demonstrated continuous cooling using a superfluid helium bath as the heat sink. The temperature stability is 8 microK rms or better over the entire cycle, and the cooling power is 2.5 microW at 60 mK rising to 10 microW at 100 mK.

Shirron, Peter↗

NASA NTRS1997

NASA tests composters for space

For long term missions, composters may be an integral part of a life support system that provides edible food crops, extracts nutrients from plant biomass and removes contaminants from the recycling stream.

Plants/growth & development↗

NASA NTRS1985

The evolution of CELSS for lunar bases

A bioregenerative life support system designed to address the fundamental requirements of a functioning independent lunar base is presented in full. Issues to be discussed are associated with CELSS weight, volume and cost of operation. The fundamental CELSS component is a small, highly automated module containing plants which photosynthesize and provide the crew with food, water and oxygen. Hydrogen, nitrogen and carbon dioxide will be initially brought in from earth, recycled and their waste products conserved. As the insufficiency of buffers necessitates stringent cybernetic control, a stable state will be maintained by computer control. Through genetic engineering and carbon dioxide, temperature, and nutrient manipulation, plant productivity can be increased, while the area necessary for growth and illumination energy decreased. In addition, photosynthetic efficiency can be enhanced through lamp design, fiber optics and the use of appropriate wavelengths. Crop maintenance will be performed by robotics, as a means of preventing plant ailments.

Macelroy, R. D.↗

NASA NTRSDate not supplied

Harnessing Synthetic Communities and Microbial Recycling of Space Waste Streams for Biomanufacturing Applications

The long-term habitation of extraterrestrial environments such as the Moon or Mars presents significant challenges including supplying materials to sustain life. Off-world recycling of waste materials into biomanufacturer products may ameliorate this. Current literature highlights the need for efficient waste recycling systems to support the bioproduction of essential materials including foods, pharmaceuticals, and biomaterials. The study herein concerns itself with the investigation of three key aspects: 1) formulating an optimal wastewater media on which to grow recombinant microbes for bioproduction in space, 2) examining the potential for constructing stable and metabolically synergistic synthetic microbial communities for largescale and multi-tiered biomanufacturing, and 3) testing the efficacy of one such bioengineered enzyme, cutinase, on the degradation of PET plastics characteristic of those found in ISS waste as a model for recombinant recycling-based biomanufacturing of mission-critical substrates. Formulation of an optimal wastewater media involved growing several microorganisms on mixtures of synthetic planetary wastes representative of those found in space waste systems, combined with simple carbon sources derived from a physio-chemical CO conversion system to determine their growth potential. Potential synthetic microbial communities were conceptually designed, and their stability and metabolic synergism was evaluated within the context of co-cultures. Cutinase activity assays were utilized to determine the efficacy of bioengineered cutinase on PET plastic degradation. Findings will contribute to optimization of wastewater-based media formulations, data on stable synthetic microbial communities for bioproduction, and effective methods for measuring cutinase-based PET plastic degradation. These outcomes support the development of sustainable waste recycling systems for space habitation and aim to fill gaps in the current literature and proposing innovative solutions for waste recycling in space environments. By leveraging synthetic biology this study seeks to enhance the feasibility of long-term extraterrestrial habitation through sustainable resource management.

Bioprocessing↗

NASA NTRSDate not supplied

Analysis of Alternative Jettison Design Concepts for Deep-space Missions

The management of waste generated onboard spacecraft during future long-duration, deep-space missions will require different solutions from those currently implemented on the International Space Station, which consist exclusively of collecting, storing, and returning the waste to Earth. Alternative options for managing spacecraft waste are to process it for recycling and recovering resources, and to jettison it overboard. The waste generated during a deep-space mission is derived mainly from spacecraft logistics supplies, food and beverage residues, personal or scientific items used by the crew, and unused spare components. Uncontained and unprocessed trash is a health hazard and a habitat volume liability, which makes onboard long-term storage a nonviable option. Jettison of solid, processed waste appear, on the other hand, to be an effective solution for crewed deep-space missions, leading not only to volume reduction and habitat safening, but also to considerable mass savings in the spacecraft’s propulsion system. However, the disposal of trash overboard also creates a navigation hazard for spacecraft and the risk of collisions with planetary bodies. This paper investigates alternative jettison design concepts for L2 libration orbit, Mars conjunction-class, and Mars opposition-class missions.

Jurek Parodi↗

NASA NTRS1982

An atmospheric exposure chamber for small animals

The purpose of this project was to design a long-term environmental exposure chamber for small animals. This chamber is capable of producing hypoxic, normoxic and hyperoxic atmospheres which are closely regulated. The chamber, which is of the recycling type, is fashioned after clear plastic germ-free isolators. Oxygen concentration is set and controlled by a paramagnetic O2 analyzer and a 3-way solenoid valve. In this way either O2 or N2 may be provided to the system by way of negative O2 feedback. Relative humidity is maintained at 40-50 percent by a refrigeration type dryer. Carbon dioxide is absorbed by indicating soda lime. A diaphragm pump continuously circulates chamber gas at a high enough flow rate to prevent buildup of CO2 and humidity. This chamber has been used for numerous studies which involve prolonged exposure of small animals to various O2 concentrations.

Glaser, R. M.↗

NASA NTRS1985

Integrated Fuel Cell/Coal Gasifier

Powerplant design with low-temperature coal gasifier coupled to highly-exothermic fuel cell for efficient production of dc power eliminates need for oxygen in gasifier and achieves high fuel efficiency with recycling of waste heat from fuel cell.

Ferrall, J. F.↗

NASA NTRS2012

Water Treatment Systems for Long Spaceflights

Space exploration will require new life support systems to support the crew on journeys lasting from a few days to several weeks, or longer. These systems should also be designed to reduce the mass required to keep humans alive in space. Water accounts for about 80 percent of the daily mass intake required to keep a person alive. As a result, recycling water offers a high return on investment for space life support. Water recycling can also increase mission safety by providing an emergency supply of drinking water, where another supply is exhausted or contaminated. These technologies also increase safety by providing a lightweight backup to stored supplies, and they allow astronauts to meet daily drinking water requirements by recycling the water contained in their own urine. They also convert urine into concentrated brine that is biologically stable and nonthreatening, and can be safely stored onboard. This approach eliminates the need to have a dedicated vent to dump urine overboard. These needs are met by a system that provides a contaminant treatment pouch, referred to as a urine cell or contaminant cell, that converts urine or another liquid containing contaminants into a fortified drink, engineered to meet human hydration, electrolyte, and caloric requirements, using a variant of forward osmosis (FO) to draw water from a urine container into the concentrated fortified drink as part of a recycling stage. An activated carbon pretreatment removes most organic molecules. Salinity of the initial liquid mix (urine plus other) is synergistically used to enhance the precipitation of organic molecules so that activated carbon can remove most of the organics. A functional osmotic bag is then used to remove inorganic contaminants. If a contaminant is processed for which the saline content is different than optimal for precipitating organic molecules, the saline content of the liquid should be adjusted toward the optimal value for that contaminant. A first urine treatment method converts urine into a fortified sports drink, resembling Gatorade, using a first urine cell.

FLynn, Michael T.↗

NASA NTRS2019

Astronaut Mass Balance for Long Duration Missions

Human spaceflight logistics requirements are strongly driven by the daily living needs of the astronauts, including their biological functions. Oxygen, water and food are absolute requirements to sustain life and must be supplied at adequate rates. However, these rates can vary from day to day and from person to person. Beyond the body's immediate physical needs, water is also required for important health and hygiene functions within the spacecraft. Undesirable weight loss or gain aside, human waste product mass outputs will equal the inputs over time, resulting in an average astronaut mass balance. Best values, as well as range of variability for inputs and outputs are explored at both the individual physiological level and the spacecraft level. These values are important for design of life support and habitability systems as well as for mission planning of consumables. Current spacecraft life support systems are not fully closed loop, but the International Space Station (ISS) does recycle most of its air and water. The astronaut mass balances at the personal and vehicle level can have different impacts at different levels of system closure. Recommendations are made for a consistent set of values representing a realistic average astronaut mass balance over reasonable durations for exploration missions.

Ewert, Michael K.↗

NASA NTRS2011

Issues and Design Drivers for Deep Space Habitats

A cross-disciplinary team of scientists and engineers applied expertise gained in Lunar Lander development to the conceptual design of a long-duration, deep space habitat for Near Earth Asteroid (NEA) missions. The design reference mission involved two launches to assemble a 5-module vehicle for a 380-day round trip mission carrying 4 crew members. The conceptual design process yielded a number of interesting debates, some of which could be significant design drivers in a detailed Deep Space Habitat (DSH) design. These issues include: a) Launch loads: Potentially drives layout of equipment mounted to module floors or walls, and whether temporary internal structure is required to distribute launch loads to minimize shell mass; b) Unmanned loiter time: When added to an already lengthy mission, loiter time further drives risk and reliability, and poses issues for equipment shelf life such as material degradation or cryogenic fluids boil-off; c) Pointing and Visibility: A habitat embedded in a 5-module stack may drive Communications, Tracking, Guidance, and Navigation equipment out onto long booms to maintain line-of-sight visibility with targets. However, long booms will be more susceptible to disruption from exercise-induced vibration, potential damage during docking/undocking operations, and increased power distribution mass; d) Water: although it is assumed that a water processor will collect and recycle water, several interesting question were posed, such as: How much water to start with? Should potable water serve double-duty as radiation protection? And if so, should it be stowed in a single large tank, or smaller, portable containers? e) Design for repairability: one of the worst-case scenarios identified was a cabin depressurization that required suited repair from inside the module, potentially driving the need for long umbilical hoses or special equipment to allow smaller, mated modules to be used as safe havens for up to 180 days;

Anderson, Molly S.↗

NASA NTRS2010

Microbiological Tests Performed During the Design of the International Space Station ECLSS: Part 1, Bulk Phase Water and Wastewater

This slide presentation summarizes the studies performed to assess the bulk phase microbial community during the Space Station Water Recover Tests (WRT) from 1990-1998. These tests show that it is possible to recycle water from different sources including urine, and produce water that can exceed the quality of municpally produced tap water.

Roman, Monsi C.↗

NASA NTRS1980

Silicon web process development

A barrier crucible design which consistently maintains melt stability over long periods of time was successfully tested and used in long growth runs. The pellet feeder for melt replenishment was operated continuously for growth runs of up to 17 hours. The liquid level sensor comprising a laser/sensor system was operated, performed well, and meets the requirements for maintaining liquid level height during growth and melt replenishment. An automated feedback loop connecting the feed mechanism and the liquid level sensing system was designed and constructed and operated successfully for 3.5 hours demonstrating the feasibility of semi-automated dendritic web growth. The sensitivity of the cost of sheet, to variations in capital equipment cost and recycling dendrites was calculated and it was shown that these factors have relatively little impact on sheet cost. Dendrites from web which had gone all the way through the solar cell fabrication process, when melted and grown into web, produce crystals which show no degradation in cell efficiency. Material quality remains high and cells made from web grown at the start, during, and the end of a run from a replenished melt show comparable efficiencies.

Duncan, C. S.↗