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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 NTRS2006

Electron Beam Brazing of Titanium for Construction in Space

An extended presence of humans in space requires an in-situ capability to construct various permanent structures to support scientific research, power generation, communication, radiation shielding and other functions. Electron Beam (EB) vacuum brazing has been identified as one of the best joining processes for in-space joining, particular for making a large quantity of permanent joints as required for construction of the sizeable truss structures. Thin wall titanium tubes are perhaps the best choice because of their high stiffness, excellent strength-to-weight ratio and great metal forming and joining ability. An innovative EB vacuum spot brazing process is being developed at Goddard Space Flight Center to be used for robotic as well as human-assisted construction in space. This paper describes experimental results obtained during the initial effort of EB brazing of titanium tubes with the special emphasis on low temperature aluminum filler metals.

Flom, Yury↗

NASA NTRS2022

Topical. Permanent Low-Earth Orbit Testbed for Welding and Joining: A Path Forward for the Commercialization of Space

NASA, defense, academia, and commercial space companies seek to develop orbital manufacturing to enhance mission capabilities. In-space welding and joining are needed for space-based manufacturing. We propose a permanent low-earth orbital welding and joining testbed for scientific study of relevant physical phenomena and development of welding and joining processes to technical maturity. Such data will enable integrated computational materials engineering(ICME)to elucidate the underlying physical and metallurgical processes needed to achieve critical space welding and joining operations.

In-space manufacturing↗

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 NTRS2005

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The new U.S. National Vision for Space Exploration requires many new enabling technologies to accomplish the goals of space commercialization and returning humans to the moon and extraterrestrial environments. Traditionally, flight elements are complete subsystems requiring humans to complete the integration and assembly. These bulky structures also require the use of heavy launch vehicles to send the units to a desired location. This philosophy necessitates a high degree of safety, numerous space walks at a significant cost. Future space mission costs must be reduced and safety increased to reasonably achieve exploration goals. One proposed concept is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly. Assembly is autonomously performed when two components join after determining that specifications are correct. Local sensors continue monitor joint integrity post assembly, which is critical for safety and structural reliability. Achieving this concept requires a change in space structure design philosophy and the development of innovative technologies to perform autonomous assembly. Assembly of large space structures will require significant numbers of integrity sensors. Thus simple, low-cost sensors are integral to the success of this concept. This paper addresses these issues and proposes a novel concept for assembling space structures autonomously. Core technologies required to achieve in space assembly are presented. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Additionally, these novel technologies can be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

NASA NTRSDate not supplied

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗

NASA NTRS2005

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The fulfillment of the new US. National Vision for Space Exploration requires many new enabling technologies to accomplish the goal of utilizing space for commercial activities and for returning humans to the moon and extraterrestrial environments. Traditionally, flight structures are manufactured as complete systems and require humans to complete the integration and assembly in orbit. These structures are bulky and require the use of heavy launch vehicles to send the units to the desired location, e.g. International Space Station (ISS). This method requires a high degree of safety, numerous space walks and significant cost for the humans to perform the assembly in orbit. For example, for assembly and maintenance of the ISS, 52 Extravehicular Activities (EVA's) have been performed so far with a total EVA time of approximately 322 hours. Sixteen (16) shuttle flights haw been to the ISS to perform these activities with an approximate cost of $450M per mission. For future space missions, costs have to be reduced to reasonably achieve the exploration goals. One concept that has been proposed is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly operations. Assembly is autonomously performed when two components containing onboard electronics join after recognizing that the joint is appropriate and in the precise position and orientation required for assembly. The mechanism only activates when the specifications are correct and m a nominal range. After assembly, local sensors and electronics monitor the integrity of the joint for feedback to a master controller. To achieve this concept will require a shift in the methods for designing space structures. In addition, innovative techniques will be required to perform the assembly autonomously. Monitoring of the assembled joint will be necessary for safety and structural integrity. If a very large structure is to be assembled in orbit, then the number of integrity sensors will be significant. Thus simple, low cost sensors are integral to the success of this concept. This paper will address these issues and will propose a novel concept for assembling space structures autonomously. The paper will present Several autonomous assembly methods. Core technologies required to achieve in space assembly will be discussed and novel techniques for communicating, sensing, docking and assembly will be detailed. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Finally, these technologies can also be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

NASA NTRS2006

The In-Space Soldering Investigation: To Date Analysis of Experiments Conducted on the International Space Station

Soldering is a well established joining and repair process that is of particular importance in the electronics industry. Still, internal solder joint defects such as porosity are prevalent and compromise desired properties such as electrical/thermal conductivity and fatigue strength. Soldering equipment resides aboard the International Space Station (ISS) and will likely accompany Exploration Missions during transit to, as well as on, the moon and Mars. Unfortunately, detrimental porosity appears to be enhanced in lower gravity environments. To this end, the In-Space Soldering Investigation (ISSI) is being conducted in the Microgravity Workbench Area (MWA) aboard the ISS as "Saturday Science" with the goal of promoting our understanding of joining techniques, shape equilibrium, wetting phenomena, and microstructural development in a microgravity environment. The work presented here will focus on direct observation of melting dynamics and shape determination in comparison to ground-based samples, with implications made to processing in other low-gravity environments. Unexpected convection effects, masked on Earth, will also be shown as well as the value of the ISS as a research platform in support of Exploration Missions.

Grugel, Richard N.↗

NASA NTRS2004

The In-Space Soldering Investigation: Research Conducted on the International Space Station in Support of NASA's Exploration Initiative

Soldering is a well established joining and repair process that is of particular importance in the electronics industry. Still. internal solder joint defects such as porosity are prevalent and compromise desired properties such as electrical/thermal conductivity and fatigue strength. Soldering equipment resides aboard the International Space Station (ISS) and will likely accompany Exploration Missions during transit to, as well as on, the moon and Mars. Unfortunately, detrimental porosity appears to be enhanced in lower gravity environments. To this end, the In-Space Soldering Investigation (ISSI) is being conducted in the Microgravity Workbench Area (MWA) aboard the ISS as "Saturday Science" with the goal of promoting our understanding of joining techniques, shape equilibrium, wetting phenomena, and microstructural development in a microgravity environment. The work presented here will focus on direct observation of melting dynamics and shape determination in comparison to ground-based samples, with implications made to processing in other low-gravity environments. Unexpected convection effects, masked on Earth, will also be shown as well as the value of the ISS as a research platform in support of Exploration Missions.

Grugel, R. N.↗

NASA NTRS2006

Mission Benefits of Gridded Ion and Hall Thruster Hybrid Propulsion Systems

The NASA In-Space Propulsion Technology (ISPT) Project Office has been developing the NEXT gridded ion thruster system and is planning to procure a low power Hall system. The new ion propulsion systems will join NSTAR as NASA's primary electric propulsion system options. Studies have been performed to show mission benefits of each of the stand alone systems. A hybrid ion propulsion system (IPS) can have the advantage of reduced cost, decreased flight time and greater science payload delivery over comparable homogeneous systems. This paper explores possible advantages of combining various thruster options for a single mission.

Dankanich, John W.↗

NASA NTRS2013

Multi-Scale CNT-Based Reinforcing Polymer Matrix Composites for Lightweight Structures

Reinforcing critical areas in carbon polymer matrix composites (PMCs), also known as fiber reinforced composites (FRCs), is advantageous for structural durability. Since carbon nanotubes (CNTs) have extremely high tensile strength, they can be used as a functional additive to enhance the mechanical properties of FRCs. However, CNTs are not readily dispersible in the polymer matrix, which leads to lower than theoretically predicted improvement in mechanical, thermal, and electrical properties of CNT composites. The inability to align CNTs in a polymer matrix is also a known issue. The feasibility of incorporating aligned CNTs into an FRC was demonstrated using a novel, yet commercially viable nanofiber approach, termed NRMs (nanofiber-reinforcing mats). The NRM concept of reinforcement allows for a convenient and safe means of incorporating CNTs into FRC structural components specifically where they are needed during the fabrication process. NRMs, fabricated through a novel and scalable process, were incorporated into FRC test panels using layup and vacuum bagging techniques, where alternating layers of the NRM and carbon prepreg were used to form the reinforced FRC structure. Control FRC test panel coupons were also fabricated in the same manner, but comprised of only carbon prepreg. The FRC coupons were machined to size and tested for flexural, tensile, and compression properties. This effort demonstrated that FRC structures can be fabricated using the NRM concept, with an increased average load at break during flexural testing versus that of the control. The NASA applications for the developed technologies are for lightweight structures for in-space and launch vehicles. In addition, the developed technologies would find use in NASA aerospace applications such as rockets, aircraft, aircraft/spacecraft propulsion systems, and supporting facilities. The reinforcing aspect of the technology will allow for more efficient joining of fiber composite parts, thus offering additional weight savings. More robust structures capable of withstanding micrometeoroid and space debris impacts will be possible with the enhanced mechanical properties imparted by the aligned CNTs incorporated into the fiber composite structure, as well as the potential for improved electrical and thermal properties. The materials fabrication approach developed in the present effort is a platform for customer applications where additional reinforcement is required or would be beneficial, especially in FRC structures and component parts. Depending upon the specific customer application, the NRM could be tailored to the specific matrix resin and desired property enhancement.

Eberly, Daniel↗

NASA NTRS2015

Improvements to the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

Devices for manipulating and precisely placing payloads are critical for efficient space operations including berthing of spacecraft, in-space assembly, construction and repair. Key to the success of many NASA space activities has been the availability of long-reach crane-like devices such as the Shuttle Remote Manipulation System (SRMS) and the Space Station Remote Manipulation System (SSRMS). These devices have been used for many operations including berthing visiting spacecraft to the International Space Station, deployment of spacecraft, space station assembly, astronaut positioning, payload transfer, and spacecraft inspection prior to atmospheric re-entry. Retiring the Space Transportation System has led to the removal of the SRMS from consideration for in-space missions, thus creating a capability gap. Recognizing this gap, work was initiated at NASA on a new architecture for long-reach space manipulators. Most current devices are constructed by joining revolute joints with carbon composite tubes, with the joints accounting for the majority of the device mass. For example in the case of the SRMS, the entire device mass is 410 kg (904 lbm); the joint structure, motors, gear train, cabling, etc., accounts for the majority of the system mass because the carbon composite tubes mass is 46 kg (101 lbm). An alternate space manipulator concept, the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) was created to address deficiencies in the current state-of-the-art in long-reach manipulators. The antagonistic tendon actuated joint architecture allows the motors actuating the joint to be removed from the joint axis, which simplifies the joint design while simultaneously providing mechanical advantage for the motors. The improved mechanical advantage, in turn, reduces the size and power requirements for the motor and gear train. This paper will describe recent architectural improvements to the TALISMAN design that: 1) improve the operational robustness of the system by enabling maneuvers not originally possible by varying the TALISMAN geometry; 2) enable efficient active antagonistic control of a joint while sharing cable between antagonistic tension networks; and 3) uses a unique arrangement of differential capstans to reduce motor torque requirements by an order of magnitude. The paper will also summarize recent efforts to enable autonomous deployment of a TALISMAN including the deployment concept of operations and associated hardware system design. The deployment forces are provided by the same motor systems that are used for articulation, thus reducing the mass associated with the deployment system. The deployment approach is being tested on a TALISMAN prototype which is designed to provide the same operational performance as a shuttle-class manipulator. The prototype has been fabricated and is operational in a new facility at NASA Langley Research Center that has a large area (15.2 m by 21.3 m [50 ft by 70 ft]) air-bearing floor.

Doggett, William R.↗

NASA NTRS2009

Development of a Methodology to Gather Seated Anthropometry in a Microgravity Environment

The Constellation Program's Crew Exploration Vehicle (CEV) is required to accommodate the full population range of crewmembers according to the anthropometry requirements stated in the Human-Systems Integration Requirement (HSIR) document (CxP70024). Seated height is one of many critical dimensions of importance to the CEV designers in determining the optimum seat configuration in the vehicle. Changes in seated height may have a large impact to the design, accommodation, and safety of the crewmembers. Seated height can change due to elongation of the spine when crewmembers are exposed to microgravity. Spinal elongation is the straightening of the natural curvature of the spine and the expansion of inter-vertebral disks. This straightening occurs due to fluid shifts in the body and the lack of compressive forces on the spinal vertebrae. Previous studies have shown that as the natural curvature of the spine straightens, an increase in overall height of 3% of stature occurs which has been the basis of the current HSIR requirements. However due to variations in the torso/leg ratio and impact of soft tissue, data is nonexistent as to how spinal elongation specifically affects the measurement of seated height. In order to obtain this data, an experiment was designed to collect spinal elongation data while in a seated posture in microgravity. The purpose of this study was to provide quantitative data that represents the amount of change that occurs in seated height due to spinal elongation in microgravity environments. Given the schedule and budget constraints of ISS and Shuttle missions and the uniqueness of the problem, a methodology had to be developed to ensure that the seated height measurements were accurately collected. Therefore, simulated microgravity evaluations were conducted to test the methodology and procedures of the experiment. This evaluation obtained seat pan pressure and seated height data to a) ensure that the lap restraint provided sufficient restraint to eliminate any gap between the subject s gluteal surface and the seat pan and b) to document any necessary design and procedural changes needed due to the microgravity environment. The methodology and setup used during the simulated microgravity evaluations was replicable to the proposed methodology and setup for in-space missions. A flight-like Shuttle seat, pressure sensors, anthropometer, and existing hardware was used to measure seated height and contact area while experiencing microgravity. The outlying buttock and thigh surface contact areas were collected to determine if the subjects were in contact with the seat pan, while a measurer recorded their seated height with an anthropometer. The Anthropometry and Biomechanics Facility (ABF) completed data collection from three microgravity flights to assess the restraint methods and techniques to be used for the in-flight procedures performed by the crewmembers in orbit. The first flight demonstrated that the restraint system on the seat, used in a nominal configuration, did not sufficiently restrain a person in the seat. The results showed the subjects were not in full contact with the seat pan, resulting in inaccurate sitting height data. Thus, a second flight was conducted to test different restraint system options. The results showed that by 1) changing the restraint system from the nominal 3-points of the 5-point harness, which is used for crewmembers when fully suited with emergency equipment, and 2) rerouting the lap straps around the joint of the backrest, where the backrest and seat pan are joined, resulted in the optimal method to restrain a subject. This rerouting method allowed for the anchor location to change and pull the subjects back into the seat instead of being anchored at the side of the subjects thighs. The results from the third flight validated the final restraint system, which resulted in a verified methodology for collecting seated anthropometry to ultimately determine the amount of spil elongation in a microgravity environment.

Rajulu, Sudhakar↗

NASA NTRS2016

Concept of Operations for a Prospective "Proving Ground" in the Lunar Vicinity

NASA is studying conceptual architectures for a "Proving Ground" near the Moon or in high lunar orbit to conduct human space exploration missions that bridge the gap between today's operations with the International Space Station (ISS) and future human exploration of Mars beginning in the 2030s. This paper describes the framework of a concept of operations ("Conops") for candidate activities in the Proving Ground. The Conops discusses broad goals that the Proving Ground might address, such as participation from commercial entities, support for human landings on the Moon, use of mature technologies, and growth of capability through a steady cadence of increasingly ambitious piloted missions. Additional Proving Ground objectives are outlined in a companion paper. Key elements in the Conops include the Orion spacecraft (with mission kits for docking and other specialized operations) and the Space Launch System (SLS) heavy-lift rocket. Potential additions include a new space suit, commercial launch vehicles and logistics carriers, Solar Electric Propulsion (SEP) stages to move elements between different orbits and eventually take them on excursions to deep space, a core module with multiple docking ports, a habitation block, and robotic and piloted lunar landers. The landers might include reusable ascent modules which could remain docked to in-space elements between lunar sorties. A module providing advanced regenerative life support functions could launch to the ISS, and later move to the Proving Ground. The architecture will include infrastructure for launch preparation, communication, mission control, and range safety. The Conops describes notional missions chosen to guide the design of the architecture and its elements. One such mission might be the delivery of a approximately 10-t Transit Habitat element, comanifested with Orion on a Block 1B SLS launcher, to the Proving Ground. In another mission, the architecture might participate in direct human exploration of an asteroidal boulder brought to high lunar orbit by the Asteroid Redirect Mission. The Proving Ground stack could serve as a staging point and tele-operation center for robotic and piloted Moon landings. With the addition of a SEP stage, the architecture could support months-long excursions within and beyond the Earth's sphere of influence, possibly culminating in a year-long mission to land humans on a near-Earth asteroid. In the last case, after returning to near-lunar space, two of the asteroid explorers could join two crewmembers freshly arrived from Earth for a Moon landing, helping to quantify the risk of landing deconditioned crews on Mars. In a conceptual mission particularly stressing to system design, Proving Ground elements could transit to Mars orbit. Other possible design-driving operations include relocation of the stack with no crew on board, the unpiloted journey of the advanced life support module from ISS to the lunar vicinity, excursions to other destinations in near-Earth space, and additional support for Mars exploration in conjunction with the Evolvable Mars Campaign. The Proving Ground Conops concludes with a discussion of aborts and contingency operations

Love, Stanley G.↗

NASA NTRS2016

Concept of Operations for a Prospective "Proving Ground" in the Lunar Vicinity

NASA is studying a "Proving Ground" near the Moon to conduct human space exploration missions in preparation for future flights to Mars. This paper describes a concept of operations ("conops") for activities in the Proving Ground, focusing on the construction and use of a mobile Cislunar Transit Habitat capable of months-long excursions within and beyond the Earth-Moon system. Key elements in the conops include the Orion spacecraft (with mission kits for docking and other specialized operations) and the Space Launch System heavy-lift rocket. Potential additions include commercial launch vehicles and logistics carriers, solar electric propulsion stages to move elements between different orbits and eventually take them on excursions to deep space, a node module with multiple docking ports, habitation and life support blocks, and international robotic and piloted lunar landers. The landers might include reusable ascent modules which could remain docked to in-space elements between lunar sorties. The architecture will include infrastructure for launch preparation, communication, mission control, and range safety. The conops describes "case studies" of notional missions chosen to guide the design of the architecture and its elements. One such mission is the delivery of a ~10-ton pressurized element, co-manifested with an Orion on a Block 1B Space Launch System rocket, to the Proving Ground. With a large solar electric propulsion stage, the architecture could enable a year-long mission to land humans on a near-Earth asteroid. In the last case, after returning to near-lunar space, two of the asteroid explorers could join two crewmembers freshly arrived from Earth for a Moon landing, helping to safely quantify the risk of landing deconditioned crews on Mars. The conops also discusses aborts and contingency operations. Early return to Earth may be difficult, especially during later Proving Ground missions. While adding risk, limited-abort conditions provide needed practice for Mars, from which early return is likely to be impossible.

Love, Stanley G.↗

NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗

NASA NTRS2019

Setting Sail for the Sun: The NEA Scout & Solar Cruiser Missions

Join HAL5 as we welcome back Les Johnson, who will talk about his work on developing solar sails at Marshall Space Flight Center and its role in propulsion and exploration of the Sun. With the successful flights of NASA's NanoSail-D and the Planetary Society's LightSail, solar sails are making the transition from an interesting idea to be demonstrated to technology ready for use on space missions. Scientists and engineers here in Huntsville are doing just that with the development of the Near Earth Asteroid Scout's 925 square foot solar sail that will fly in 2020. And that's not all, in August, a team led by NASA MSFC was selected as a finalist to develop an 18,000 square foot solar sail for a project called, Solar Cruiser, that may fly as early as 2024. If you would like to learn the fundamentals of solar sailing and get the scoop on these two innovative and exciting missions, then hang on as we "Set Sail for the Sun!"

Heliophysics↗