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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 NTRS2005

Phase Contrast X-ray Imaging of Shuttle Insulating Foam

X-ray radiation has been widely used for imaging applications since Rontgen first discovered X-rays over a century ago. Its large penetration depth makes it ideal for the nondestructive visualization of internal structure of materials or objects unobtainable otherwise. Currently widely used nondestructive evaluation (NDE) tools-X-ray radiography and tomography are absorption-based, and work well in highly absorbing materials where density or composition variations due to internal structure or defects are high enough to be spatially distinguished in terms of absorption contrast. However, in many cases where materials such as insulating foam are light-weight, the conventional absorption-based X-ray methods for NDE become less effective. Indeed, the low-density shuttle insulating foam used for flight mission poses a great challenge to the standard NDE tools in that the absorption contrast arising from internal defects of such a low- density material is either weak or indistinguishable. In this presentation, the latest progress in phase contrast X-ray imaging of internal defects of insulating foam will be presented and discussed, demonstrating new opportunities to solve challenging issues involved in advanced materials development and processing for space exploration.

Hu, Zhengwei↗

NASA NTRS2004

Integrated Modeling Approach for the Terrestrial Planet Finder Mission

Because of the complexity of the Terrestrial Planet Finder (TPF) design concepts, the project will rely heavily on the use of engineering and science simulations to predict on-orbit performance. Furthermore, current understanding of these missions indicates that the 3m to 8m class optical systems need to be as stable as picometers in wavefront and sub-milli arcsec in pointing. These extremely small requirements impose on the models a level of predictive accuracy heretofore never achieved, especially in the area of microgravity effects, material property accuracy, thermal solution convergence, and all other second order modeling effects typically ignored. New modeling tools and analysis paradigms are developed which emphasize computational accuracy and fully integrated analytical simulations. The process is demonstrated on sample problems using the TPF Coronagraph design concept. The TPF project is also planning a suite of testbeds through which various aspects of the models and simulations will be verified.

terrestrial planet finder↗

NASA NTRS2010

Overview of NASA's Thermal Control Technology Development Project

NASA?s Constellation Program included the Orion, Altair, and Lunar Surface Systems project offices. The first two elements, Orion and Altair, were planned to be manned space vehicles while the third element was much broader and included several sub-elements including Rovers and a Lunar Habitat. The planned missions involving these systems and vehicles included several risks and design challenges. Due to the unique thermal operating environment, many of these risks and challenges were associated with the vehicles? thermal control system. NASA?s Exploration Technology Development Program (ETDP) consisted of several technology development projects. The project chartered with mitigating the aforementioned thermal risks and design challenges was the Thermal Control System Development for Exploration Project. These risks and design challenges were being addressed through a rigorous technology development process that was planned to culminate with an integrated thermal control system test. Although these Constellation elements have been cancelled or significantly changed, the thermal technology development process is being continued within a new program entitled Enabling Technology Development and Demonstration (ETDD). The current paper summarizes the development efforts being performed by the technology development project. The development efforts involve heat acquisition and heat rejection hardware including radiators, heat exchangers, and evaporators. The project has also been developing advanced phase change material heat sinks and performing a material compatibility assessment for a promising thermal control system working fluid. The to-date progress and lessons-learned from these development efforts will be discussed throughout the paper.

Stephan, Ryan A.↗

NASA NTRS2015

Feasibility of Supersonic Aircraft Concepts for Low-Boom and Flight Trim Constraints

This paper documents a process for analyzing whether a particular supersonic aircraft configuration layout and a given cruise condition are feasible to achieve a trimmed low-boom design. This process was motivated by the need to know whether a particular configuration at a given cruise condition could be reshaped to satisfy both low-boom and flight trim constraints. Without such a process, much effort could be wasted on shaping a configuration layout at a cruise condition that could never satisfy both low-boom and flight trim constraints simultaneously. The process helps to exclude infeasible configuration layouts with minimum effort and allows a designer to develop trimmed low-boom concepts more effectively. A notional low-boom supersonic demonstrator concept is used to illustrate the analysis/design process.

Li, Wu↗

NASA NTRS2020

Robotics System Process and Concept for On-orbit Assembly for Potential Mars Sample Return

Proposed Mars Sample Return (MSR) missions would require on-orbit assembly of containment vessels to meet backward Planetary Protection requirements and transfer of the sample container through various stations and positions. Some operations would have to be performed autonomously, and others would require ground-in-loop decision-making stages and verification processes. One concept design for an Earth Return Orbiter (ERO) Capture, Contain, and Return System (CCRS) Transfer Mechanism (TM) is a multi-Degree of Freedom (DOF) manipulator that utilizes a passive End Effector (EE) to assist in containment vessel assembly. To converge on a feasible design, a robotic system process has been instantiated. This process is composed of three main phases: robotic problem definition (operating environment, operations/functions, system goals), robotic solution selection (trade studies on the number of degrees of freedom, number of mechanisms, types of mechanisms), robotic solution design, implementation, and verification and validation (kinematic configuration, robotic and kinematic analysis and topology optimization of components). As a final product of this process, a half-scale functional prototype of the TM was developed to demonstrate the end-to-end operation capability.

Strahle, Jackson W↗

NASA NTRSDate not supplied

In Situ Resource Utilization (ISRU) Envisioned Future Priorities

The National Aeronautics and Space Administration (NASA) of the United States of America (US) has initiated the Artemis Moon to Mars program to send astronauts (the first woman and person of color) back to the lunar surface, create a sustainable human lunar exploration program, and lead the first human exploration mission to the Mars surface in the 2030’s. A major objective of this program is to characterize the resources that exist on the Moon and Mars, and learn how to utilize them for sustained and affordable exploration. Commonly known as In Situ Resource Utilization (ISRU), the search for, acquisition, and processing of resources in space has the potential to greatly reduce the dependency on transporting mission consumables and infrastructure from Earth, thereby reducing mission costs, risks, and dependency on Earth. Through the extraction and processing of resources into mission commodities such as rocket propellants, life support consumables, and fuel cell reactants, ISRU enhances and evolves the cis-lunar, lander, and surface transportation systems required for human exploration; expanding and ehancing HOW humans get to, explore, and return from the Moon. Through the extraction and processing of resources into metals, silicon, and other manufacturing and construction feedstock, ISRU enhances and allows for the expansion of critical infrastructure through in situ manufacturing and construction capabilities needed for WHAT humans do on the Moon and in cis-lunar space. Because of this, ISRU supports and enables commercial involvement beyond NASA and governmental agencies by both lowering the cost of sustained transportation to/from/on the Moon as well as supporting the market required for needing these transportation systems. To achieve this vision, NASA’s Space Technology Mission Directorate (STMD) ensures the coordinated development of ISRU and other critical space and surface infrastructure elements such as propulsion, power, manufacturing, construction, and robotics through the Strategic Technology Architecture Roundtable (STAR) process. Through STAR, an integrated framework and process has been created allowing for capabilities and technologies to be linked and assessed, gaps to be identified, specifications and metrics to be established, and provide a means to prioritize and implement technology development and missions. For lunar ISRU, three primary areas of development have been initiated, (1) understanding, mapping, extracting, and processing water and other volatiles found in polar permanently shadowed regions (PSRs), (2) methods, technologies to extract oxygen from regolith, and (3) methods, technologies, and use cases for metals, silicon, and other feedstock commodities extracted and produced from lunar resources. This presentation will briefly discuss the STAR process and elaborate on the current status and future plans for ISRU development, demonstration, and architecture implementation of NASA’s Envisioned Future Priorities plan for ISRU.

In Situ Resource Utilization↗

NASA NTRS2025

Demonstration of Data Processing and Fusion from Distributed Radars for AAM Surveillance

Advanced Air Mobility (AAM) is an active area of development which foresees the integration of autonomous uncrewed aircraft into the civil airspace for air transportation of people and cargo. Safe integration requires significant technological developments and extensive testing phases of sensing and surveillance strategies in dense airspace. Compared to well-assessed manned aviation systems scenarios, surveillance strategies in the AAM and small Uncrewed Aircraft Vehicles (UAVs) context need to detect smaller platforms flying at lower altitude against cluttered backgrounds in dense airspace. Fusion of data provided by a network of distributed sensing nodes is a powerful tool to enable detection and tracking in such complex conditions. This paper contributes to this research direction by proposing a surveillance strategy for the AAM environment based on sensor fusion of data acquired by distributed ground-based radars. Specifically, experimental data collected with three independent radars, observing the flight of two small UAVs, are used. Data fusion at tracking level is based on a leader-helper strategy where the leader radar uses the helper’s measurements to increase the lifespan of its generated tracks. This solution shows promising results with a 10% increase in track coverage with respect to the standalone leader radar tracking solution. The paper also proposes an interference removal processing method which is applied on the data collected by two of the radars.

Federica Vitiello↗

NASA NTRS1975

Weld bonding of titanium with polyimide adhesives

A conductive adhesive primer and a capillary flow adhesive were developed for weld bonding titanium alloy joints. Both formulations contained ingredients considered to be non-carcinogenic. Lap-shear joint test specimens and stringer-stiffened panels were weld bonded using a capillary flow process to apply the adhesive. Static property information was generated for weld bonded joints over the temperature range of 219K (-65 F) to 561K (550 F). The capillary flow process was demonstrated to produce weld bonded joints of equal strength to the weld through weld bonding process developed previously.

Vaughan, R. W.↗

NASA NTRS2008

Processing and Preparation of Advanced Stirling Convertors for Extended Operation

The U.S. Department of Energy (DOE), Lockheed Martin Space Company (LMSC), Sunpower Inc., and NASA Glenn Research Center (GRC) have been developing an Advanced Stirling Radioisotope Generator (ASRG) for use as a power system on space science missions. This generator will make use of the free-piston Stirling convertors to achieve higher conversion efficiency than currently available alternatives. NASA GRC is supporting the development of the ASRG by providing extended operation of several Sunpower Inc. Advanced Stirling Convertors (ASCs). In the past year and a half, eight ASCs have operated in continuous, unattended mode in both air and thermal vacuum environments. Hardware, software, and procedures were developed to prepare each convertor for extended operation with intended durations on the order of tens of thousands of hours. Steps taken to prepare a convertor for long-term operation included geometry measurements, thermocouple instrumentation, evaluation of working fluid purity, evacuation with bakeout, and high purity charge. Actions were also taken to ensure the reliability of support systems, such as data acquisition and automated shutdown checkouts. Once a convertor completed these steps, it underwent short-term testing to gather baseline performance data before initiating extended operation. These tests included insulation thermal loss characterization, low-temperature checkout, and full-temperature and power demonstration. This paper discusses the facilities developed to support continuous, unattended operation, and the processing results of the eight ASCs currently on test.

Oriti, Salvatore M.↗

NASA NTRS2008

Processing and Preparation of Advanced Stirling Convertors for Extended Operation at NASA Glenn Research Center

Oriti, Salvatore M.↗

NASA NTRS2010

Effects of Secondary Task Modality and Processing Code on Automation Trust and Utilization During Simulated Airline Luggage Screening

The purpose of this research was to examine the impact of environmental distractions on human trust and utilization of automation during the process of visual search. Participants performed a computer-simulated airline luggage screening task with the assistance of a 70% reliable automated decision aid (called DETECTOR) both with and without environmental distractions. The distraction was implemented as a secondary task in either a competing modality (visual) or non-competing modality (auditory). The secondary task processing code either competed with the luggage screening task (spatial code) or with the automation's textual directives (verbal code). We measured participants' system trust, perceived reliability of the system (when a target weapon was present and absent), compliance, reliance, and confidence when agreeing and disagreeing with the system under both distracted and undistracted conditions. Results revealed that system trust was lower in the visual-spatial and auditory-verbal conditions than in the visual-verbal and auditory-spatial conditions. Perceived reliability of the system (when the target was present) was significantly higher when the secondary task was visual rather than auditory. Compliance with the aid increased in all conditions except for the auditory-verbal condition, where it decreased. Similar to the pattern for trust, reliance on the automation was lower in the visual-spatial and auditory-verbal conditions than in the visual-verbal and auditory-spatial conditions. Confidence when agreeing with the system decreased with the addition of any kind of distraction; however, confidence when disagreeing increased with the addition of an auditory secondary task but decreased with the addition of a visual task. A model was developed to represent the research findings and demonstrate the relationship between secondary task modality, processing code, and automation use. Results suggest that the nature of environmental distractions influence interaction with automation via significant effects on trust and system utilization. These findings have implications for both automation design and operator training.

Phillips, Rachel↗

NASA NTRSDate not supplied

Undue Conservatisim in Structural Designs

Assuming that dynamic (transient/vibratory) loads are static in the design of structures is a long-standing engineering practice. The assumption is conservative for hardware that will have limited exposure to the specified dynamic environment and fatigue is not a concern. This is the case for most space flight hardware. Once out of the Earth’s atmosphere, significant vibrations are non-existent for most hardware and vibration cycles are limited. Mass is, and has always been, a concern with respect to flight hardware design. How much unnecessary mass due to the subject assumption may be in structural designs was questioned and numerous tests have been performed to qualitatively address that. Tests have been performed on simple aluminum beams, beams with bolted joints and beams with welded joints. Results of those tests are reported in this paper. The objective of these efforts was to demonstrate the order of magnitude of conservatism associated with this engineering process via comparing static to dynamic tests and the longer term endgame is to develop a new or modified quick turnaround structural design process that circumvents assuming dynamic loads are static and results in lighter structural designs. Test results qualitatively demonstrate notable conservatism. Activities to devise the new method are underway.

conservative loads↗

NASA NTRS2003

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Hartley, Paula J.↗

NASA NTRSDate not supplied

Carbothermal Reduction Demonstration (CaRD) Gas Analysis Subsystem Development

The Carbothermal Reduction Demonstration (CaRD) project is currently developing a subscale system to demonstrate the operation and performance of the carbothermal reduction process and quantify the production of molar equivalent oxygen (carbon monoxide (CO) and carbon dioxide (CO2)). Traditionally, gas chromatography (GC) systems are utilized to qualify gases due to their ability to separate the volatile compounds within the gas mixture, followed by quantification of the isolated component of interest. Despite these capabilities, GCs require consumables for their operational mobile phase and consequently are not often considered a flight-forward option. An alternative analytical technique known as mass spectrometry measures the presentence of gas phase molecules based on their mass-to-charge ratio. Residual gas analyzers (RGAs) which utilize mass spectrometry are not traditionally used to quantify analytes, but proper design and calibrations can result in a flight-forward analytical instrument capable of direct quantification of volatile gases of interest. Kennedy Space Center's role for the project is to design a gas analyzer system to detect and quantify the CO and CO2 gas produced during the carbothermal reaction utilizing a commercial version of the Mass Spectrometer Observing Lunar Operations (MSolo) instrument. MSolo is a modified commercial off-the-shelf mass spectrometer which consists of quadrupole mass filter and space rated electronics. MSolo is currently a TRL 6 technology and manifested on the PRIME-1 and VIPER missions. This paper describes leveraging MSolo based instrumentation to develop a gas analysis system for the work outlined in the 2023 International Conference on Environmental Systems (ICES) paper number 313. The design and testing of the brassboard phase of the project will be described along with the current work underway which will cover the design and preliminary test results of the prototype phase.

Ryan Patrick Gott↗

NASA NTRS2013

Lunar Polar In Situ Resource Utilization (ISRU) as a Stepping Stone for Human Exploration

A major emphasis of NASA is to extend and expand human exploration across the solar system. While specific destinations are still being discussed as to what comes first, it is imperative that NASA create new technologies and approaches that make space exploration affordable and sustainable. Critical to achieving affordable and sustainable exploration beyond low Earth orbit (LEO) are the development of technologies and approaches for advanced robotics, power, propulsion, habitats, life support, and especially, space resource utilization systems. Space resources and how to use them, often called In-Situ Resource Utilization (ISRU), can have a tremendous beneficial impact on robotic and human exploration of the Moon, Mars, Phobos, and Near Earth Objects (NEOs), while at the same time helping to solve terrestrial challenges and enabling commercial space activities. The search for lunar resources, demonstration of extraterrestrial mining, and the utilization of resource-derived products, especially from polar volatiles, can be a stepping stone for subsequent human exploration missions to other destinations of interest due to the proximity of the Moon, complimentary environments and resources, and the demonstration of critical technologies, processes, and operations. ISRU and the Moon: There are four main areas of development interest with respect to finding, obtaining, extracting, and using space resources: Prospecting for resources, Production of mission critical consumables like propellants and life support gases, Civil engineering and construction, and Energy production, storage, and transfer. The search for potential resources and the production of mission critical consumables are the primary focus of current NASA technology and system development activities since they provide the greatest initial reduction in mission mass, cost, and risk. Because of the proximity of the Moon, understanding lunar resources and developing, demonstrating, and implementing lunar ISRU provides a near and early opportunity to perform the following that are applicable to other human exploration mission destinations: Identify and characterize resources, how they are distributed, and the material, location and environment in which they are found; Demonstrate concepts, technologies, and hardware that can reduce the cost and risk of human exploration beyond Earth orbit; Use the Moon for operation experience and mission validation for much longer missions that are farther from Earth Develop and evolve ISRU to support sustained, economical human presence beyond Earth's orbit, including promoting space commercialization As Table 1 depicts, the Moon provides environments and resources applicable to Mars and NEOs. Two lunar ISRU resource and product pathways that have notable synergism with NEO, Phobos/Demos, and Mars ISRU are oxygen/metal extraction from regolith, and water/volatile extraction from lunar polar materials. To minimize the risk of developing and incorporating ISRU into human missions, a phased implementation plan is recommended that starts with prospecting and demonstrating critical technologies on robotic and human missions, then performing pilot scale operations (in non-mission critical roles) to enhance exploration mission capabilities, leading to full utilization of space resources in mission critical roles. Which lunar ISRU pathway is followed will depend on the results of early resource prospecting/proof-ofconcept mission(s), and long-term human exploration plans.

Sanders, Gerald B.↗

NASA NTRS1985

Atomization data for spray combustion modeling

Computer models that simulate the energy release processes in spray combustion are highly dependent upon the quality of atomization data utilized. This paper presents results of analyses performed with a state-of-the-art rocket combustion code, demonstrating the important effects of initial droplet sizes and size distributions on combustion losses. Also, the questionable aspects and inapplicability of the generally available atomization data are discussed. One important and misunderstood aspect of the atomization process is the difference between spatial (concentration) and flux (temporal) droplet size distributions. These are addressed, and a computer model developed to assess this difference is described and results presented. Finally, experimental results are shown that demonstrate the often neglected effects of the local gas velocity field on the atomization process.

Ferrenberg, A. J.↗

NASA NTRS2024

Carbothermal Reduction Demonstration (CaRD) Gas Analysis Subsystem Development

The Carbothermal Reduction Demonstration (CaRD) project is currently developing a subscale system to demonstrate the operation and performance of the carbothermal reduction process and quantify the production of molar equivalent oxygen via carbon monoxide (CO) and carbon dioxide (CO2). Traditionally, gas chromatography (GC) systems are utilized to quantify gases due to their ability to separate volatile compounds within the gas mixture, followed by detection of the isolated component of interest. Despite their capabilities, GCs require carrier gas consumables for their operational mobile phase and consequently are not often considered a flight-forward option. An alternative analytical technique known as mass spectrometry measures the presence of gas phase molecules without the need of carrier gas. Residual gas analyzers (RGAs), which are smaller and rugged mass spectrometers, are not traditionally used to quantify analytes as they serve more as a monitoring tool. However, proper application and calibration can result in a flight-forward analytical instrument capable of direct quantification of volatile compounds of interest. Kennedy Space Center's role for the JSC led CaRD project is to design a gas analyzer system to detect and quantify the CO and CO2 gases produced during the carbothermal reaction utilizing a commercial version of the Mass Spectrometer observing lunar operations (MSolo) instrument. MSolo is a modified commercial off-the-shelf RGA, which consists of quadrupole mass filter and space rated electronics. MSolo is currently a TRL 6 technology and manifested on the PRIME-1 and VIPER missions. This paper describes leveraging MSolo based instrumentation to develop a gas analysis system for the work outlined in the 2023 International Conference on Environmental Systems (ICES) paper number 313.

Ryan P Gott↗

NASA NTRS2015

3D Photocatalytic Air Processor for Dramatic Reduction of Life Support Mass and Complexity

To dramatically reduce the cost and risk of CO2 management systems in future extended missions, we have conducted preliminary studies on the materials and device development for advanced "artificial photosynthesis" reaction systems termed the High Tortuosity PhotoElectroChemical (HTPEC) system. Our Phase I studies have demonstrated that HTPEC operates in much the same way a tree would function, namely directly contacting the cabin air with a photocatalyst in the presence of light and water (as humidity) to immediately conduct the process of CO2 reduction to O2 and useful, "tunable" carbon products. This eliminates many of the inefficiencies associated with current ISS CO2 management systems. We have laid the solid foundation for Phase II work to employ novel and efficient reactor geometries, lighting approaches, 3D manufacturing methods and in-house grown novel catalytic materials.The primary objective of the proposed work is to demonstrate the scientific and engineering foundation for light-activated, compact devices capable of converting CO2 to O2 and mission-relevant carbon compounds. The proposed HTPEC CO2 management system will demonstrate a novel pathway with high efficiency and reliability in a compact, lightweight reactor architecture. The proposed HTPEC air processing concept can be developed in multiple architectures, such as centralized processing as well as "artificial leaves" distributed throughout the cabin that utilize pre-existing cabin ventilation (wind). Additionally, HTPEC can be deployed with spectrally tunable collection channels for selectable product generation. HTPEC employs light as its only energy source to remove and convert waste CO2 using a non-toxic composite catalyst.We have demonstrated in the Phase I studies the production, tunability and robustness of the novel composite catalysts following the preliminary work in the Chen laboratory. Additionally, we have designed, fabricated and tested all components of HTPEC device with active materials, including flow modeling to optimize flow mixing and pressure drop as well as the production of ethylene and other larger hydrocarbons. To best determine how this technology could be implemented, we also performed system integration optimization and trade studies. This includes parameters such as mass, volume, power in relation to selected mission configurations, CO2 delivery methods and light source/delivery approaches.

Artificial Photosynthesis↗