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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

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.

Manufacturing↗

NASA NTRSDate not supplied

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

Robotics↗

NASA NTRS1974

Space-shuttle interfaces/utilization. Earth Observatory Satellite system definition study (EOS)

The economic aspects of space shuttle application to a representative Earth Observatory Satellite (EOS) operational mission in the various candidate Shuttle modes of launch, retrieval, and resupply are discussed. System maintenance of the same mission capability using a conventional launch vehicle is also considered. The studies are based on application of sophisticated Monte Carlo mission simulation program developed originally for studies of in-space servicing of a military satellite system. The program has been modified to permit evaluation of space shuttle application to low altitude EOS missions in all three modes. The conclusions generated by the EOS system study are developed.

Source record↗

NASA NTRS1988

Automation and robotics

The Autonomous Systems focus on the automation of control systems for the Space Station and mission operations. Telerobotics focuses on automation for in-space servicing, assembly, and repair. The Autonomous Systems and Telerobotics each have a planned sequence of integrated demonstrations showing the evolutionary advance of the state-of-the-art. Progress is briefly described for each area of concern.

Montemerlo, Melvin↗

NASA NTRS1989

Telerobotic research for in-space structural assembly and servicing

The paper reviews Langley's Telerobotic Technology Program and the recent and planned research in automated space assembly. Research areas include multiple manipulator coordination and control, automatic modes, evaluation of control modalities for teleoperated tasks, active sensing for world modeling and control, and architectures for distributed telerobotic systems. Studies of master/slave teleoperators performing representative space tasks showed that current teleoperator systems can be used to accomplish remote space operations. These studies also identified that research is required to improve the systems to reduce operator workload and task completion time. Closed-loop noncontact and contact sensor based control for automatic acquisition, positioning, and active compliance have been developed. A control structure for multiple manipulator coordination and control with manual, shared, and automatic modes performing space type tasks is being evaluated.

Meintel, Alfred J., Jr.↗

NASA NTRS1990

The role of Space Station Freedom in the Human Exploration Initiative

Exploration accommodation requirements for Space Station Freedom (SSF) and mission-supporting capabilities have been studied. For supporting the Human Exploration Initiative (HEI), SSF will accommodate two functions with augmentations to the baseline Assembly Complete configuration. First, it will be an earth-orbiting transportation node providing facilities and resources (crew, power, communications) for space vehicle assembly, testing, processing and postflight servicing. Second, it will be an in-space laboratory for science research and technology development. The evolutionary design of SSF will allow the on-orbit addition of pressurized laboratory and habitation modules, power generation equipment, truss structure, and unpressurized vehicle processing platforms.

Ahlf, P. R.↗

NASA NTRS1990

Technology and Mars exploration

The currently envisioned technology needs of the Space Exploration Initiative are surveyed. Earth-to-orbit transportation technology requirements are summarized. Space transportation needs regarding aerobraking, space-based engines, autonomous landing, autonomous rendezvous and docking, vehicle structures and cryogenic tankage, artificial gravity, nuclear propulsion, nuclear thermal propulsion, and nuclear electric propulsion. For in-space operations, cryogenic fluid systems, in-space assembly and construction, and vehicle processing and servicing are addressed. For surface operations on the moon and Mars, space nuclear power, resource utilization, planetary rovers, surface solar power, and surface habitats and construction are discussed. Regenerative life support, radiation protection, extravehicle activity, are considered along with factors pertaining to scientific activity in space and information systems and communications.

Mankins, John C.↗

NASA NTRS1987

Orbital fluid servicing and resupply operations

The capability to reservice spacecraft and satellites with expendable fluids will provide significant increases in the usability, operational efficiency and cost effectiveness of in-space systems. Initial resupply will be accomplished from the Orbiter cargo bay starting with monopropellant servicing which will eventually be extended to servicing of bipropellants and pressurants. Other fluids, such as freon, ammonia, methanol, superfluid helium, and liquid/gaseous nitrogen may also need to be resupplied once a space station becomes a reality. These fluids/gases are required for subsystem working fluid replacement and payload/experiment fluid replenishment. A logistics module operating on a 90 day schedule is planned for space station servicing. Resupplying hundreds of thousands of pounds of cryogenic propellants and reactants for users such as the Orbital Transfer Vehicle (OTV) also represents future logistics challenges. Implementation of on-orbit fluid transfer requires solving many problems including fluid management in the low-g environment, system docking and interface mating, configuration of user friendly avionics to monitor and control the entire servicing operation, and minimized maintenance and enhanced reliability. Candidate fluid transfer methods and possible gas transfer methods are discussed, and preliminary storable monopropellant and bipropellant tanker designs are summarized.

Eberhardt, R. N.↗

NASA NTRSDate not supplied

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 f rom 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-f light 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↗

NASA NTRS1982

Space Shuttle Orbiter auxiliary power unit

The Space Shuttle Orbiter auxiliary power units (APUs) provide hydraulic power for the Orbiter vehicle control surfaces (rudder/speed brake, body flap, and elevon actuation systems), main engine gimbaling during ascent, landing gear deployment and steering and braking during landing. Operation occurs during launch/ascent, in-space exercise, reentry/descent, and landing/rollout. Operational effectiveness of the APU is predicated on reliable, failure-free operation during each flight, mission life (reusability) and serviceability between flights (turnaround). Along with the accumulating flight data base, the status and results of efforts to achieve these long-run objectives is presented.

Mckenna, R.↗

NASA NTRS1990

Orbital storage and supply of subcritical liquid nitrogen

Subcritical cryogenic fluid management has long been recognized as an enabling technology for key propulsion applications, such as space transfer vehicles (STV) and the on-orbit cryogenic fuel depots which will provide STV servicing capability. The LeRC Cryogenic Fluids Technology Office (CFTO), under the sponsorship of OAST, has the responsibility of developing the required technology via a balanced program involving analytical modeling, ground based testing, and in-space experimentation. Topics covered in viewgraph form include: cryogenic management technologies; nitrogen storage and supply; cryogenic nitrogen cooling capability; and LN2 system demonstration technical objectives.

Aydelott, John C.↗

NASA NTRS1984

OTV fluid mangement systems

Design, performance, and technology issues associated with reduced gravity propellant management for orbital transfer vehicles (OTV's) are reviewed. The in-space cryogenic management state-of-technology significantly affects the overall confidence level associated with a resupply mission and propulsion performance. Cryogen resupply sequences, timelines, controls, and associated crew involvement are all affected by the technology state. Additionally, OTV propellant tankage configurations, tankage thermodynamic conditions, acceleration environment, propulsion interfaces, and instrumentation are significant factors. Basic propellant transfer phases examined that drive orbital servicing requirements include: (1) tankage preconditioning; (2) tankage chilldown; and (3) propellant fill. Propellant management support of the OTV propulsion phases includes engine restart requirements and orbital coast between engine burns. Technology activities in support of identified technology issues are reviewed.

Hastings, L.↗

NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗

NASA NTRS1978

New luster for space robots and automation

Consideration is given to the potential role of robotics and automation in space transportation systems. Automation development requirements are defined for projects in space exploration, global services, space utilization, and space transport. In each category the potential automation of ground operations, on-board spacecraft operations, and in-space handling is noted. The major developments of space robot technology are noted for the 1967-1978 period. Economic aspects of ground-operation, ground command, and mission operations are noted.

Heer, E.↗

NASA NTRS1985

BASD: SIRTF Telescope Instrument Changeout and Cryogen Replenishment (STICCR) study

The Space Infrared Telescope Facility (SIRTF) is a long-life cryogenically cooled space-based telescope for infrared astronomy from 2 micrometer to 700 miocrometers currently under study by NASA-ARC, and planned for launch in approximately the mid 90's. SIRTF will operate as a multi-user facility, initially carrying 3 instruments at the focal plane. It will be cooled to below 2 K by superfluid liquid helium to achieve radiometric sensitivity limited only by the statistical fluctuations in the natural infrared background radiation over most of its spectral range. The lifetime of the mission will be limited by the lifetime of the liquid helium supply, and is currently baselined to be 2 years. The telescope changes required to allow in-space replenishment of the 2,000 liter superfluid helium tank are investigated. A preliminary design for the space services equipment is also developed. The impacts of basing the equipment and servicing on the space station are investigated. Space replenishment and changeout of instruments requires changes to the telescope design and preliminary concepts are presented.

Mord, A. J.↗

NASA NTRS1988

Cryogenic Fluid Management Technology Workshop. Volume 2: Roundtable Discussion of Technology Requirements

The Cryogenic Fluid Management Technology Workshop was held April 28 to 30, 1987, at the NASA Lewis Research Center in Cleveland, Ohio. The major objective of the workshop was to identify future NASA needs for technology concerning the management of subcritical cryogenic fluids in the low-gravity space environment. In addition, workshop participants were asked to identify those technologies which will require in-space experimentation and thus are candidates for inclusion in the flight experiment being defined at Lewis. The principal application for advanced fluid management technology is the Space-Based Orbit Transfer Vehicle (SBOTV) and its servicing facility, the On-Orbit Cryogenic Fuel Depot (OOCFD). Other potential applications include the replenishment of cryogenic coolants (with the exception of superfluid helium), reactants, and propellants on board a variety of spacecraft including the space station and space-based weapon systems. The last day was devoted to a roundtable discussion of cryogenic fluid management technology requirements by 30 representatives from NASA, industry, and academia. This volume contains a transcript of the discussion of the eight major technology categories.

Source record↗

NASA NTRS1988

In-space research, technology and engineering experiments and Space Station

The NASA Space Station will serve as a technology research laboratory, a payload-servicing facility, and a large structure fabrication and assembly facility. Space structures research will encompass advanced structural concepts and their dynamics, advanced control concepts, sensors, and actuators. Experiments dealing with fluid management will gather data on such fundamentals as multiphase flow phenomena. As requirements for power systems and thermal management grow, experiments quantifying the performance of energy systems and thermal management concepts will be undertaken, together with expanded efforts in the fields of information systems, automation, and robotics.

Tyson, Richard↗

NASA NTRS1985

SIRTF Telescope Instrument Changeout and Cryogen Replenishment (STICCR) Study

The Space Infrared Telescope Facility (SIRTF) is a long-life cryogenically cooled space-based telescope for infrared astronomy from 2 to 700 micrometers. SIRTF is currently under study by NASA-ARC (Reference AP) and planned for launch in approximately the mid 1990s. SIRTF will operate as a multiuser facility, initially carrying three instruments at the focal plane. It will be cooled to below 2 K by superfluid liquid helium to achieve radiometric sensitivity limited only by the statistical fluctuations in the natural infrared background radiation over most of its spectral range. The lifetime of the mission will be limited by the lifetime of the liquid helium supply, and baseline is currently to be 2 years. The telescope changes required to allow in-space replenishment of the 4,000-L superfluid helium tank was investigated. A preliminary design for the space services equipment was also developed. The impacts of basing the equipment and servicing on the space station were investigated. Space replenishment and changeout of instruments required changes to the telescope design. Preliminary concepts are presented.

Nast, T. C.↗