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NASA NTRS2010

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗

NASA NTRSDate not supplied

Evaluation of the NASA Artemis Regions of Interest for ISRU Water Mine Potential

The NASA Artemis Campaign has a stated goal to return to the Moon to maintain a sustainable presence; In-Situ Resource Utilization (ISRU) is a key part of sustainability. The regions of interest identified for the Artemis campaign are at Lunar the South Pole where water ice, a valuable resource for ISRU, has been identified. As such, a preliminary evaluation of the ISRU ice mining potential has been performed for of these regions of interest. A set of ground rules for this evaluation were developed to align with current assumptions for customer needs, hardware capabilities, an initially limited infrastructure, and lunar environments/terrain. These ground rules, and the evaluation of six regions of interest, are presented here. The site selections (ISRU and customer assets) and their associated traverses are notional and were intended only to provide a broad preliminary evaluation of the water ISRU potential of the regions. Evaluation of these regions are subject to change as decisions regarding utilization are made. Water ISRU is possible at all regions, though the degree to which each criterion are met is variable. The two regions near Shackleton ranked highest in this evaluation, while the de Gerlache region presented the most difficulties meeting the current criteria. The regions were not explicitly ranked due to the nuances associated with the high number of variables but evaluation summaries of each are presented. It should also be noted that all ISRU ‘mine’ sites in this analysis focused on smaller (few kilometer) size permanently shadowed regions (PSRs). This was necessary to meet proximity requirements between these PSRs and the highly illuminated regions needed for customers and ISRU processing. The areas identified in this study are meant to focus exploration and reconnaissance efforts needed to better evaluate the ISRU potential.

In-situ resource utilization↗

NASA NTRS2017

An ISRU Propellant Production System to Fully Fuel a Mars Ascent Vehicle

ISRU of Mars resources was base lined in 2009 Design Reference Architecture (DRA) 5.0, but only for Oxygen production using atmospheric CO2The Methane (LCH4) needed for ascent propulsion of the Mars Ascent Vehicle (MAV) would need to be brought from Earth. HOWEVER: Extracting water from the Martian Regolith enables the production of both Oxygen and Methane from Mars resources Water resources could also be used for other applications including: Life support, radiation shielding, plant growth, etc. Water extraction was not base lined in DRA5.0 due to perceived difficulties and complexity in processing regolith. The NASA Evolvable Mars Campaign (EMC) requested studies to look at the quantitative benefits and trades of using Mars water ISRU Phase 1: Examined architecture scenarios for regolith water retrieval. Completed October 2015Phase 2: Deep dive of one architecture concept to look at end-to-end system size, mass, power of a LCH4LO2 ISRU production system.Evolvable Mars CampaignPre-deployed Mars ascent vehicle (MAV)4 crew membersPropellants: Oxygen MethaneGenerate a system model to roll up mass power of a full ISRU system and enable parametric trade studies. Leverage models from previous studies and technology development programs Anchor with mass power performance from existing hardware. Whenever possible used reference-able (published) numbers for traceability.Modular approach to allow subsystem trades and parametric studies. Propellant mass needs taken from most recently published MAV study:Polsgrove, T. et al. (2015), AIAA2015-4416MAV engines operate at mixture ratios (oxygen: methane) between 3:1 and 3.5:1, whereas the Sabatier reactor produces at a 4:1 ratio. Therefore:Methane production is the driving requirement-Excess Oxygen will be produced.

Mars surface↗

NASA NTRS2016

Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) Final Report

The Asteroid Redirect Mission (ARM) Formulation Assessment and Support Team (FAST) was a two-month effort, chartered by NASA, to provide timely inputs for mission requirement formulation in support of the Asteroid Redirect Robotic Mission (ARRM) Requirements Closure Technical Interchange Meeting held December 15-16, 2015, to assist in developing an initial list of potential mission investigations, and to provide input on potential hosted payloads and partnerships. The FAST explored several aspects of potential science benefits and knowledge gain from the ARM. Expertise from the science, engineering, and technology communities was represented in exploring lines of inquiry related to key characteristics of the ARRM reference target asteroid (2008 EV5) for engineering design purposes. Specific areas of interest included target origin, spatial distribution and size of boulders, surface geotechnical properties, boulder physical properties, and considerations for boulder handling, crew safety, and containment. In order to increase knowledge gain potential from the mission, opportunities for partnerships and accompanying payloads were also investigated. Potential investigations could be conducted to reduce mission risks and increase knowledge return in the areas of science, planetary defense, asteroid resources and in-situ resource utilization, and capability and technology demonstrations. This report represents the FASTâ€"TM"s final product for the ARM.

Mazanek, Daniel D.↗

NASA NTRSDate not supplied

Evaluation of the NASA Artemis Regions of Interest for ISRU Water Mine Potential

In-situ resource utilization↗

NASA NTRS1986

Stratospheric dust collections: Valuable resources for space and atmospheric scientists

The stratospheric collection at the Johnson Space Center Curatorial Facility offers a unique opportunity to study well-documented, individual particles (or groups of particles) from a wide variety of sources. The nature of the collection and curation process, as well as the timeliness of some sampling periods, ensures that all data obtained from stratospheric particles is a valuable resource for scientists from a wide range of disciplines. A few samples of the uses of these stratospheric dust collections are outlined. An understanding of global parameters at a particular point in time in the stratosphere can be obtained from a study of complete collection surfaces. For example, an accurate assessment of particle concentration over a wide range of sizes was experimentally determined for the stratospheric cloud formed one month after the eruption of El Chichon. Additional studies on the El Chichon cloud over a six-month period showed that volcanic ash settles out of the stratosphere at a rate determined primarily by particle shape and density. Another study during a volcanically quiescent period has shown that total particle number density during the summer of 1981 was approx. 2.7 x 10(-1) cm(-3), for particles 1 micron diameter. However, 95% of these particles were 5 micrometers diameter. With the above classification scheme, an estimate of micrometeorite number density at 20km altitude can also be made. Continuation of these types of studies, for shorter collection periods at regular intervals, can provide important experimental data on the contributions of orbital debris, rocket firings and transient events on the total stratospheric particle budget.

Mackinnon, I. D. R.↗

NASA NTRS2002

Laser Prevention of Earth Impact Disasters

We now believe that while there are about 2000 earth orbit crossing rocks greater than 1 kilometer in diameter, there may be as many as 100,000 or more objects in the 100m size range. Can anything be done about this fundamental existence question facing us? The answer is a resounding yes! We have the technology to prevent collisions. By using an intelligent combination of Earth and space based sensors coupled with an infrastructure of high-energy laser stations and other secondary mitigation options, we can deflect inbound asteroids, meteoroids, and comets and prevent them from striking the Earth. This can be accomplished by irradiating the surface of an inbound rock with sufficiently intense pulses so that ablation occurs. This ablation acts as a small rocket incrementally changing the shape of the rock's orbit around the Sun. One-kilometer size rocks can be moved sufficiently in a month while smaller rocks may be moved in a shorter time span.We recommend that the World's space objectives be immediately reprioritized to start us moving quickly towards a multiple option defense capability. While lasers should be the primary approach, all mitigation options depend on robust early warning, detection, and tracking resources to find objects sufficiently prior to Earth orbit passage in time to allow mitigation. Infrastructure options should include ground, LEO, GEO, Lunar, and libration point laser and sensor stations for providing early warning, tracking, and deflection. Other options should include space interceptors that will carry both laser and nuclear ablators for close range work. Response options must be developed to deal with the consequences of an impact should we move too slowly.

Campbell, J.↗

NASA NTRS2004

K-12 Students as Ground Observers of Contrails in Support of Scientific Research

Scientists are very interested in the formation of contrails, both the type and the coverage. To be detected by a satellite-born instrument, the contrail must be of a certain size, which means that some contrails go undetected. The K-12 education community is assisting with the study of contrails by participating in a network of student observers. To provide a venue for student contrail observations, the GLOBE Contrails protocol was developed as part of the GLOBE Atmospheric Science protocols. The first year of observations has provided a rich resource for researcher.

Chambers, Lin H.↗

NASA NTRSDate not supplied

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley↗

NASA NTRS2024

System Modeling of a Lunar Molten Regolith Electrolysis Plant

In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO 2 , MgO, Al 2 O 3 ) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The S ystem Engineering and Integration ( S E&I) I SRU M odeling and A nalysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant.

In-Situ Resource Utilization↗

NASA NTRS1991

Dehydration kinetics of talc at 1 bar

Experimental results on the dehydration kinetics of talc, which is likely to be a major potential resource for water and hydrogen in carbonaceous chondrites, is presented. The rate of dehydration of an essentially pure Mg-end member natural talc, (Mg(.99)Fe(.01))3Si4O10(OH)2, was studied by measuring in situ weight change under isothermal condition at 1 bar as a function of time in the temperature range 775 to 985 C. The grain size of the starting material was 0.7 to 1 micron. It was found that the data up to 50 to 60 percent dehydration can be fitted by an equation of the form alpha = exp(-Kt(exp n)), where alpha is the weight fraction of talc remaining, K is a rate constant and n is a numerical constant for a given temperature. For any set of isothermal data, there is a major change in the value of n for larger dehydration. For up to approximately 50 percent dehydration, all rate constants can be described by an Arrheniun relation with an activation energy of 432 (+/- 30) kJ/mol; n has a nearly constant value of 0.54 between 775 and 875 C, but increases almost linearly according to n = -10.77 + 0.012T C at T greater than or equal to 875 C.

Ganguly, J.↗

NASA NTRS2007

Space Shuttle Debris Impact Tool Assessment Using the Modern Design of Experiments

Complex computer codes are used to estimate thermal and structural reentry loads on the Shuttle Orbiter induced by ice and foam debris impact during ascent. Such debris can create cavities in the Shuttle Thermal Protection System. The sizes and shapes of these cavities are approximated to accommodate a code limitation that requires simple "shoebox" geometries to describe the cavities -- rectangular areas and planar walls that are at constant angles with respect to vertical. These approximations induce uncertainty in the code results. The Modern Design of Experiments (MDOE) has recently been applied to develop a series of resource-minimal computational experiments designed to generate low-order polynomial graduating functions to approximate the more complex underlying codes. These polynomial functions were then used to propagate cavity geometry errors to estimate the uncertainty they induce in the reentry load calculations performed by the underlying code. This paper describes a methodological study focused on evaluating the application of MDOE to future operational codes in a rapid and low-cost way to assess the effects of cavity geometry uncertainty.

DeLoach, Richard↗

NASA NTRS1976

Radar systems for the water resources mission. Volume 4: Appendices E-I

The use of a scanning antenna beam for a synthetic aperture system was examined. When the resolution required was modest, the radar did not use all the time the beam was passing a given point on the ground to build a synthetic aperture, so time was available to scan the beam to other positions and build several images at different ranges. The scanning synthetic-aperture radar (SCANSAR) could achieve swathwidths of well over 100 km with modest antenna size. Design considerations for a SCANSAR for hydrologic parameter observation are presented. Because of the high sensitivity to soil moisture at angles of incidence near vertical, a 7 to 22 deg swath was considered for that application. For snow and ice monitoring, a 22 to 37 deg scan was used. Frequencies from X-band to L-band were used in the design studies, but the proposed system operated in C-band at 4.75 GHz. It achieved an azimuth resolution of about 50 meters at all angles, with a range resolution varying from 150 meters at 7 deg to 31 meters at 37 deg. The antenna required an aperture of 3 x 4.16 meters, and the average transmitter power was under 2 watts.

Moore, R. K.↗

NASA NTRS2018

Zero Launch Mass Three Dimensional Print Head

NASA's strategic goal is to put humans on Mars in the 2030s. The NASA Human Spaceflight Architecture Team (HAT) and NASA Mars Design Reference Architecture (DRA) 5.0 has determined that in-situ resource utilization (ISRU) is an essential technology to accomplish this mission. Additive construction technology using in-situ materials from planetary surfaces will reduce launch mass, allow structures to be three dimensionally (3D) printed on demand, and will allow building designs to be transmitted digitally from Earth and printed in space. This will ultimately lead to elimination of reliance on structural materials launched from Earth (zero launch mass of construction consumables). The zero launch mass (ZLM) 3D print head project addressed this need by developing a system that 3D prints using a mixture of in-situ regolith and polymer as feedstock, determining the optimum mixture ratio and regolith particle size distribution, developing software to convert g-code into motion instructions for a FANUC robotic arm, printing test samples, performing materials testing, and printing a reduced scale habitable structure concept. This paper will focus on the ZLM 3D Print Head design, materials selection, software development, and lessons learned from operating the system in the NASA KSC Swamp Works Granular Mechanics & Regolith Operations (GMRO) Laboratory.

Regolith↗

NASA NTRS2012

Project 5S: A Safe Stepping Stone into the Solar System

The human exploration program, at least in NASA, has been directed to move beyond the Moon and travel on a flexible path into the solar system. Reaching a Near-Earth Asteroid (NEA) is a major human space flight goal but such missions have tight times and life-support requirements that require huge steps from current capabilities. An objective between the Moon and a NEA is needed. Example interim objectives are the Lagrangian points in either the Sun-Earth or Earth-Moon (EM) system. The nearest of these points beyond the Moon is E-M L2. The Lagrangian points are empty (as far as we know). As objectives for human flight,it has been argued that they suffer from a lack of public interest and of meaningful objectives for astronaut operations. To provide a physical target, a robotic spacecraft could retrieve a small NEA and bring it to a Lagrangian or other nearer-Earth point to be accessed and utilized for human-mission objectives. This paper reports on the results of a recently completed study of an asteroid retrieval mission sponsored by the Keck Institute for Space Studies (KISS) at the California Institute of Technology. The study included an evaluation of potential targets, mission objectives, mission and system design, and potential capture mechanisms. The study concluded that, while challenging, there are no fundamental show stoppers and that such a mission would be possible with technology expected to be available in this decade. The final destination selected (for safety and mission operations) was high lunar orbit. Two options for target selection are considered: (i) retrieving a small (7 meter) NEA with a mass of order 500,000 kg, and (ii) taking a similar size boulder of a large known carbonaceous NEA. Several areas of technology and program requirements were identified, but the most important conclusion was that this approach enables meeting a goal of humans going to a NEA by the mid-2020s. The advantages and benefits for human exploration are considerable as are the advances that would be made in space-resource utilization and science for further exploration and development of the solar system. The combination of the robotic mission to move the asteroid and the human mission to go to its new destination and conduct astronaut operations there would provide a boost and purpose to human space flight.

asteroid retrieval↗

NASA NTRS2002

Development of Metal-impregnated Single Walled Carbon Nanotubes for Toxic Gas Contaminant Control in Advanced Life Support Systems

The success of physico-chemical waste processing and resource recovery technologies for life support application depends partly on the ability of gas clean-up systems to efficiently remove trace contaminants generated during the process with minimal use of expendables. Carbon nanotubes promise superior performance over conventional approaches to gas clean-up due to their ability to direct the selective uptake of gaseous species based on their controlled pore size, high surface area, ordered chemical structure that allows functionalization and their effectiveness also as catalyst support materials for toxic gas conversion. We present results and findings from a preliminary study on the effectiveness of metal impregnated single walled nanotubes as catalyst/catalyst support materials for toxic gas contaminate control. The study included the purification of single walled nanotubes, the catalyst impregnation of the purified nanotubes, the experimental characterization of the surface properties of purified single walled nanotubes and the characterization of physisorption and chemisorption of uptake molecules.

Pisharody, Suresh A.↗

NASA NTRS1981

An optimization model for energy generation and distribution in a dynamic facility

An analytical model is described using linear programming for the optimum generation and distribution of energy demands among competing energy resources and different economic criteria. The model, which will be used as a general engineering tool in the analysis of the Deep Space Network ground facility, considers several essential decisions for better design and operation. The decisions sought for the particular energy application include: the optimum time to build an assembly of elements, inclusion of a storage medium of some type, and the size or capacity of the elements that will minimize the total life-cycle cost over a given number of years. The model, which is structured in multiple time divisions, employ the decomposition principle for large-size matrices, the branch-and-bound method in mixed-integer programming, and the revised simplex technique for efficient and economic computer use.

Lansing, F. L.↗

NASA NTRS2008

On Convergence of Development Costs and Cost Models for Complex Spaceflight Instrument Electronics

Development costs of a few recent spaceflight instrument electrical and electronics subsystems have diverged from respective heritage cost model predictions. The cost models used are Grass Roots, Price-H and Parametric Model. These cost models originated in the military and industry around 1970 and were successfully adopted and patched by NASA on a mission-by-mission basis for years. However, the complexity of new instruments recently changed rapidly by orders of magnitude. This is most obvious in the complexity of representative spaceflight instrument electronics' data system. It is now required to perform intermediate processing of digitized data apart from conventional processing of science phenomenon signals from multiple detectors. This involves on-board instrument formatting of computational operands from row data for example, images), multi-million operations per second on large volumes of data in reconfigurable hardware (in addition to processing on a general purpose imbedded or standalone instrument flight computer), as well as making decisions for on-board system adaptation and resource reconfiguration. The instrument data system is now tasked to perform more functions, such as forming packets and instrument-level data compression of more than one data stream, which are traditionally performed by the spacecraft command and data handling system. It is furthermore required that the electronics box for new complex instruments is developed for one-digit watt power consumption, small size and that it is light-weight, and delivers super-computing capabilities. The conflict between the actual development cost of newer complex instruments and its electronics components' heritage cost model predictions seems to be irreconcilable. This conflict and an approach to its resolution are addressed in this paper by determining the complexity parameters, complexity index, and their use in enhanced cost model.

Kizhner, Semion↗