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NASA NTRS2011

NASA Technology Demonstrations Missions Program Overview

The National Aeronautics and Space Administration (NASA) Fiscal Year 2010 (FY10) budget introduced a new strategic plan that placed renewed emphasis on advanced missions beyond Earth orbit. This supports NASA s 2011 strategic goal to create innovative new space technologies for our exploration, science, and economic future. As a result of this focus on undertaking many and more complex missions, NASA placed its attention on a greater investment in technology development, and this shift resulted in the establishment of the Technology Demonstrations Missions (TDM) Program. The TDM Program, within the newly formed NASA Office of the Chief Technologist, supports NASA s grand challenges by providing a steady cadence of advanced space technology demonstrations (Figure 1), allowing the infusion of flexible path capabilities for future exploration. The TDM Program's goal is to mature crosscutting capabilities to flight readiness in support of multiple future space missions, including flight test projects where demonstration is needed before the capability can transition to direct mission The TDM Program has several unique criteria that set it apart from other NASA program offices. For instance, the TDM Office matures a small number of technologies that are of benefit to multiple customers to flight technology readiness level (TRL) 6 through relevant environment testing on a 3-year development schedule. These technologies must be crosscutting, which is defined as technology with potential to benefit multiple mission directorates, other government agencies, or the aerospace industry, and they must capture significant public interest and awareness. These projects will rely heavily on industry partner collaboration, and funding is capped for all elements of the flight test demonstration including planning, hardware development, software development, launch costs, ground operations, and post-test assessments. In order to inspire collaboration across government and industry, more than 70% of the TDM funds will be competitively awarded as a result of yearly calls for proposed flight demonstrators and selected based on possible payoff to NASA, technology maturity, customer interest, cost, and technical risk reduction. This paper will give an overview of the TDM Program s mission and organization, as well as its current status in delivering advanced space technologies that will enable more flexible and robust future missions. It also will provide several examples of missions that fit within these parameters and expected outcomes.

Turner, Susan↗

NASA NTRS2016

Systems Analysis of In-Space Manufacturing Applications for the International Space Station and the Evolvable Mars Campaign

Maintenance logistics support is a significant challenge for extended human operations in space, especially for missions beyond Low Earth Orbit (LEO). For missions to Mars (such as NASA's Evolvable Mars Campaign (EMC)), where timely resupply or abort in the event of emergency will not be possible, maintenance logistics mass is directly linked to the Probability of Loss of Crew (P(LoC)), and the cost of driving down risk is an exponential increase in mass requirements. The logistics support strategies that have maintained human operations in LEO will not be effective for these deep space missions. In-Space Manufacturing (ISM) is a promising technological solution that could reduce logistics requirements, mitigate risks, and augment operational capabilities, enabling Earth- independent human spaceflight. This paper reviews maintenance logistics challenges for spaceflight operations in LEO and beyond, and presents a summary of selected results from a systems analysis of potential ISM applications for the ISS and EMC. A quantitative modeling framework and sample assessment of maintenance logistics and risk reduction potential of this new technology is also presented and discussed.

Owens, Andrew C.↗

NASA NTRSDate not supplied

Progress of Aluminum/Air Battery Development for SUSAN Electrofan Project

Safe and high-performance battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. Aluminum (Al)-air battery with very high theoretical specific energy density, is considered as promising battery chemistry which has the potential to meet the targeted specific energy goal of primary battery energy technology for the SUSAN project. In addition to having the exceptional electrochemical properties, aluminum is light weight, rich abundance, low cost, environmentally friendly, and has a good electrical conductivity and recyclability, which is among the key characteristics of SUSAN project on battery energy needs. A non-flammable aqueous electrolyte is used to prevent the fire and thermal runaway hazard for the safety of this battery chemistry. However, there are challenges for Al-air battery in practical application, mainly due to self-corrosion of Al and slow kinetics of oxygen reduction in air-cathode to impact the high-rate performance. Progress on addressing these challenges was made and some of the results were reported in our previous paper. In this paper, the focus is on the investigation of various factors, including electrolyte concentrations, temperature, and air-cathode loadings on ionic transport properties and discharge performance at different current densities. The results are discussed, and the progress is reported.

James J Wu↗

NASA NTRS1999

System Analyses of Pneumatic Technology for High Speed Civil Transport Aircraft

The primary aspiration of this study was to objectively assess the feasibility of the application of a low speed pneumatic technology, in particular Circulation Control (CC) to an HSCT concept. Circulation Control has been chosen as an enabling technology to be applied on a generic High Speed Civil Transport (HSCT). This technology has been proven for various subsonic vehicles including flight tests on a Navy A-6 and computational application on a Boeing 737. Yet, CC has not been widely accepted for general commercial fixed-wing use but its potential has been extensively investigated for decades in wind tunnels across the globe for application to rotorcraft. More recently, an experimental investigation was performed at Georgia Tech Research Institute (GTRI) with application to an HSCT-type configuration. The data from those experiments was to be applied to a full-scale vehicle to assess the impact from a system level point of view. Hence, this study attempted to quantitatively assess the impact of this technology to an HSCT. The study objective was achieved in three primary steps: 1) Defining the need for CC technology; 2) Wind tunnel data reduction; 3) Detailed takeoff/landing performance assessment. Defining the need for the CC technology application to an HSCT encompassed a preliminary system level analysis. This was accomplished through the utilization of recent developments in modern aircraft design theory at Aerospace Systems Design Laboratory (ASDL). These developments include the creation of techniques and methods needed for the identification of technical feasibility show stoppers. These techniques and methods allow the designer to rapidly assess a design space and disciplinary metric enhancements to enlarge or improve the design space. The takeoff and landing field lengths were identified as the concept "show-stoppers". Once the need for CC was established, the actual application of data and trends was assessed. This assessment entailed a reduction of the wind tunnel data from the experiments performed by Mr. Bob Englar at the GTRI. Relevant data was identified and manipulated based on the required format of the analysis tools utilized. Propulsive, aerodynamic, duct sizing, and vehicle sizing investigations were performed and information supplied to a detailed takeoff and landing tool, From the assessments, CC was shown to improve the low speed performance metrics, which were previously not satisfied. An HSCT with CC augmentation does show potential for full-scale application. Yet, an economic assessment of an HSCT with and without CC showed that a moderate penalty was incurred from the increased RDT&E costs associated with developing the CC technology and slight increases in empty weight.

Mavris, Dimitri N.↗

NASA NTRS2017

Oxygen Extraction from Minerals

Oxygen, whether used as part of rocket bipropellant or for astronaut life support, is a key consumable for space exploration and commercialization. In Situ Resource Utilization (ISRU) has been proposed many times as a method for making space exploration more cost effective and sustainable. On planetary and asteroid surfaces the presence of minerals in the regolith that contain oxygen is very common, making them a potential oxygen resource. The majority of research and development for oxygen extraction from minerals has been for lunar regolith although this work would generally be applicable to regolith at other locations in space. This presentation will briefly survey the major methods investigated for oxygen extraction from regolith with a focus on the current status of those methods and possible future development pathways. The major oxygen production methods are (1) extraction from lunar ilmenite (FeTiO3) with either hydrogen or carbon monoxide, (2) carbothermal reduction of iron oxides and silicates with methane, and (3) molten regolith electrolysis (MRE) of silicates. Methods (1) and (2) have also been investigated in a two-step process using CO reduction and carbon deposition followed by carbothermal reduction. All three processes have byproducts that could also be used as resources. Hydrogen or carbon monoxide reduction produce iron metal in small amounts that could potentially be used as construction material. Carbothermal reduction also makes iron metal along with silicon metal and a glass with possible applications. MRE produces iron, silicon, aluminum, titanium, and glass, with higher silicon yields than carbothermal reduction. On Mars and possibly on some moons and asteroids, water is present in the form of mineral hydrates, hydroxyl (-OH) groups on minerals, andor water adsorbed on mineral surfaces. Heating of the minerals can liberate the water which can be electrolyzed to provide a source of oxygen as well. The chemistry of these processes, some key development and demonstration projects, the challenges remaining to be overcome, and possible future directions will be discussed with a goal of increased understanding of these important ISRU technologies and their potential applications to space exploration and settlement.

propellant production↗

NASA NTRS1981

An industrial perspective of the LANDSAT opportunity

The feasibility of enhancing LANDSAT products to provide the greatest usability low cost data possible can be determined through government sponsorship and finance of one or more task forces composed of a critical number of experts in multiple disciplines from many industries and academia. The synergism of multiple minds addressing singular problems without the creation of permanent or perpetual structures must yield output in the form of implementable specifications, even if presented as alternatives. Changes are needed within the spacecraft in order to account for Sun angle changes. The use of pointing accuracy to make geometric corrections (and possible radiometric corrections, is needed more than onboard data reduction and information extraction, which assume a proper knowledge of application and reduce potential utilization. Multilinear arrays need to be investigated and methods for sensor calibration and for determining the effects of atmospheric inversion, as well as the best way to back out the modulation transfer function must be determined.

Williams, B. F.↗

NASA NTRSDate not supplied

Integrated Waste Trade Study: Lunar Surface to Deep Space

The Logistics Reduction Project is one of NASA's technology development projects that is preparing humanity for deep space missions. Reducing the mass and volume of logistical supplies that must be carried from Earth to support the missions and their crews is the primary goal of the project. Effective ways to achieve this goal include reducing, reusing, or recycling wastes generated throughout the mission. Due to the goal of the project, waste processing technologies were analyzed for Lunar surface missions at various lengths and an 850-day Mars transit mission to evaluate the potential benefits of waste processing pertaining to each mission. The technologies assessed include trash compaction, trash-to-gas and human metabolic waste processing technologies, integrated with the baseline architectures of each mission’s habitat. The fully integrated systems were analyzed using an equivalent system mass, which is a metric that encompasses the mass, volume, power and cooling of a system, resulting in an estimate of launch mass and serving as a proxy for cost. Each system’s equivalent system mass was compared to that of the baseline waste processing system of the respective habitat, hand compaction with storage for Lunar surface missions and hand compaction with jettisoning for Mars transit, to evaluate whether the traded waste processing technology was beneficial. This analysis identifies a general trend that more sophisticated waste processing can be beneficial depending on the mission duration. For Lunar surface missions, the water recovery from waste processing can pay off over consecutive missions, due to offsetting the losses from the system via extravehicular activities. In contrast for Mars transit, the primary objective is mass removal from the spacecraft, so technologies like trash-to-gas are competitive with the baseline. Furthermore, the technologies which can recover resources from waste, such as water, may present additional advantages to an ever-changing Mars mission architecture.

Waste processing↗

NASA NTRS1995

Lead-Lag Control for Helicopter Vibration and Noise Reduction

As a helicopter transitions from hover to forward flight, the main rotor blades experience an asymmetry in flow field around the azimuth, with the blade section tangential velocities increasing on the advancing side and decreasing on the retreating side. To compensate for the reduced dynamic pressure on the retreating side, the blade pitch angles over this part of the rotor disk are increased. Eventually, a high enough forward speed is attained to produce compressibility effects on the advancing side of the rotor disk and stall on the retreating side. The onset of these two phenomena drastically increases the rotor vibratory loads and power requirements, thereby effectively establishing a limit on the maximum achievable forward speed. The alleviation of compressibility and stall (and the associated decrease in vibratory loads and power) would potentially result in an increased maximum forward speed. In the past, several methods have been examined and implemented to reduce the vibratory hub loads. Some of these methods are aimed specifically at alleviating vibration at very high flight speeds and increasing the maximum flight speed, while others focus on vibration reduction within the conventional flight envelope. Among the later are several types passive as well as active schemes. Passive schemes include a variety of vibration absorbers such as mechanical springs, pendulums, and bifilar absorbers. These mechanism are easy to design and maintain, but incur significant weight and drag penalties. Among the popular active control schemes in consideration are Higher Harmonic Control (HHC) and Individual Blade Control (IBC). HHC uses a conventional swash plate to generate a multi-cyclic pitch input to the blade. This requires actuators capable of sufficiently high power and bandwidth, increasing the cost and weight of the aircraft. IBC places actuators in the rotating reference frame, requiring the use of slip rings capable of transferring enough power to the actuators. Both schemes cause an increase in pitch link loads. Trailing Edge Flap (TEF) deployment can also used to generate unsteady aerodynamic forces and moments that counter the original vibratory loads, and thereby reduce rotor vibrations. While the vibrations absorbers, HHC, IBC, and TEF concepts discussed above attempt to reduce the vibratory loads, they do not specifically address the phenomena causing the vibrations at high advance ratios. One passive method that attempts to directly alleviate compressibility and stall, instead of reducing the ensuing vibrations, is the use of advanced tip designs. Taper, sweep, anhedral, and the manipulation of other geometric properties of the blade tips can reduce the severity of stall and compressibility effects , as well as reduce rotor power. A completely different approach to solve these problems is the tiltrotor configuration. As the forward velocity of the aircraft increases, the rotors, in this case, are tilted forward until they are perpendicular to the flow and act as propellers. This eliminates the edgewise flow encountered by conventional rotors and circumvents all the problems associated with flow asymmetry. However, the success involves a tremendous increase in cost and complexity of the aircraft. Another possible approach that has been proposed for the alleviation of vibratory loads at high forward flight speeds involves the use of controlled lead-lag motions to reduce the asymmetry in flow. A correctly phased 1/rev controlled lag motion could be introduced such that it produces a backward velocity on the advancing side and a forward velocity on the retreating side, to delay compressibility effects and stall to a higher advance ratio. Using a large enough lead-lag amplitude, the tip velocities could be reduced to levels encountered in hover. This concept was examined by two groups in the 1950's and early 1960's. In the United States, the Research Labs Division of United Aircraft developed a large lead-lag motion rotor, meant to achieve lag motion amplitudes up to 45 degrees. In order to reduce the required actuation force, the blade hinges were moved to 40% of the blade radius to increase the rotating lag frequency to approximately 1/rev. The blade hinges were redesigned to produce a flap-lag coupling so the large flapwise aerodynamic loads could be exploited to actuate the blades in the lag direction. A wind tunnel test of this rotor concept revealed actuation and blade motion scheduling problems. The project was eventually discontinued due to these problems and high blade stresses. Around the same time, at Boelkow in Germany, a similar lead-lag rotor program was conducted under the leadership of Hans Derschmidt. Here, too, the blade hinges were moved outboard to 34% radius to reduce the actuation loads. The main difference between this and the United Aircraft program was the use of a mechanical actuation scheme with maximum lead-lag motions of 400. This program was also discontinued for unclear reasons. The present study is directed toward conducting a comprehensive analytical examination to evaluate the effectiveness of controlled lead-lag motions in reducing vibratory hub loads and increasing maximum flight speed. Since both previous studies on this subject were purely experimental, only a limited data set and physical understanding of the problem was obtained. With the currently available analytical models and computational resources, the present effort is geared toward developing an in-depth physical understanding of the precise underlying mechanisms by which vibration reduction may be achieved. Additionally, in recognition of the fact that large amplitude lead-lag motions would - (i) be difficult to implement, and (ii) produce very large blade stresses; the present study examines the potential of only moderate-to-small lead-lag motions for reduction of vibratory hub loads. Using such an approach, the emphasis is not on eliminating the periodic variations in tangential velocity at the blade tip, but at best reducing these variations slightly so that compressibility and stall are delayed to slightly higher advance ratios. This study was conducted in two steps. In the first step, a hingeless helicopter rotor was modeled using rigid blades undergoing flap-lag-torsion rotations about spring restrained hinges and bearings. This model was then modified by separating the lead-lag degree of freedom into two components, a free and a prescribed motion. Using this model, a parametric study of the effect of phase and amplitude of a prescribed lead-lag motion on hub vibration was conducted. The data gathered was analyzed to obtain an understanding of the basic physics of the problem and show the capability of this method to reduce vibration and expand the flight envelope. In the second half of the study, the similar analysis was conducted using an elastic blade model to confirm the effects predicted by the simpler model.

Gandhi, Farhan↗

NASA NTRS2009

COTSAT Small Spacecraft Cost Optimization for Government and Commercial Use

Cost Optimized Test of Spacecraft Avionics and Technologies (COTSAT-1) is an ongoing spacecraft research and development project at NASA Ames Research Center (ARC). The prototype spacecraft, also known as CheapSat, is the first of what could potentially be a series of rapidly produced low-cost spacecraft. The COTSAT-1 team is committed to realizing the challenging goal of building a fully functional spacecraft for $500K parts and $2.0M labor. The project's efforts have resulted in significant accomplishments within the scope of a limited budget and schedule. Completion and delivery of the flight hardware to the Engineering Directorate at NASA Ames occurred in February 2009 and a cost effective qualification program is currently under study. The COTSAT-1 spacecraft is now located at NASA Ames Research Center and is awaiting a cost effective launch opportunity. This paper highlights the advancements of the COTSAT-1 spacecraft cost reduction techniques.

Swank, Aaron J.↗

NASA NTRS1984

Economic impact of fuel properties on turbine powered business aircraft

The principal objective was to estimate the economic impact on the turbine-powered business aviation fleet of potential changes in the composition and properties of aviation fuel. Secondary objectives include estimation of the sensitivity of costs to specific fuel properties, and an assessment of the directions in which further research should be directed. The study was based on the published characteristics of typical and specific modern aircraft in three classes; heavy jet, light jet, and turboprop. Missions of these aircraft were simulated by computer methods for each aircraft for several range and payload combinations, and assumed atmospheric temperatures ranging from nominal to extremely cold. Five fuels were selected for comparison with the reference fuel, nominal Jet A. An overview of the data, the mathematic models, the data reduction and analysis procedure, and the results of the study are given. The direct operating costs of the study fuels are compared with that of the reference fuel in the 1990 time-frame, and the anticipated fleet costs and fuel break-even costs are estimated.

Powell, F. D.↗

NASA NTRS1992

A compilation of lunar and Mars exploration strategies utilizing indigenous propellants

The use of propellants manufactured from indigenous space materials has the potential to significantly reduce the amount of mass required to be launched from the Earth's surface. The extent of the leverage, however, along with the cost for developing the infrastructure necessary to support such a process, is unclear. Many mission analyses have been performed that have attempted to quantify the potential benefits of in situ propellant utilization. Because the planning of future space missions includes many unknowns, the presentation of any single study on the use of in situ propellants is often met with critics' claims of the inaccuracy of assumptions or omission of infrastructure requirements. The results of many such mission analyses are presented in one format. Each summarized mission analysis used different assumptions and baseline mission scenarios. The conclusion from the studies is that the use of in situ produced propellants will provide significant reductions in Earth launch requirements. This result is consistent among all of the analyses regardless of the assumptions used to obtain the quantitative results. The determination of the best propellant combination and the amount of savings will become clearer and more apparent as the technology work progresses.

Linne, Diane L.↗

NASA NTRS2000

ISRU Technologies for Mars Life Support

The primary objectives of the Mars Exploration program are to collect data for planetary science in a quest to answer questions related to Origins, to search for evidence of extinct and extant life, and to expand the human presence in the solar system. The public and political engagement that is critical for support of a Mars exploration program is based on all of these objectives. In order to retain and to build public and political support, it is important for NASA to have an integrated Mars exploration plan, not separate robotic and human plans that exist in parallel or in sequence. The resolution stemming from the current architectural review and prioritization of payloads may be pivotal in determining whether NASA will have such a unified plan and retain public support. There are several potential scientific and technological links between the robotic-only missions that have been flown and planned to date, and the robotic + human missions that will come in the future. Taking advantage of and leveraging those links are central to the idea of a unified Mars exploration plan. One such link is in situ resource utilization (ISRU) as an enabling technology to provide consumables such as fuels, oxygen, sweep and utility gases from the Mars atmosphere. ISRU for propellant production and for generation of life support consumables is a key element of human exploration mission plans because of the tremendous savings that can be realized in terms of launch costs and reduction in overall risk to the mission. The Human Exploration and Development of Space (HEDS) Enterprise has supported ISRU technology development for several years, and is funding the MIP and PROMISE payloads that will serve as the first demonstrations of ISRU technology for Mars. In our discussion and presentation at the workshop, we will highlight how the PROMISE ISRU experiment that has been selected by HEDS for a future Mars flight opportunity can extend and enhance the science experiments on board.

Finn, John E.↗

NASA NTRS2017

Software Defined Radios - Architectures, Systems and Functions

Software Defined Radio (SDR) technology has been proven in the commercial sector since the early 90's. Today's rapid advancement in mobile telephone reliability and power management capabilities exemplifies the effectiveness of the SDR technology for the modern communications market. SDR technology offers potential to revolutionize satellite transponder technology by increasing science data through-put capability by at least an order of magnitude. While the SDR is adaptive in nature and is "One-size-fits-all" by design, conventional transponders are built to a specific platform and must be redesigned for every new bus. The SDR uses a minimum amount of analog/Radio Frequency (RF) components to up/down-convert the RF signal to/from a digital format. Once analog data is digitized, all processing is performed using hardware logic. Typical SDR processes include; filtering, modulation, up/down converting and demodulation. These innovations have reduced the cost of transceivers, a decrease in power requirements and a commensurate reduction in volume. An additional pay-off is the increased flexibility of the SDR: allowing the same hardware to implement multiple transponder types by altering hardware logic -no change of analog hardware is required -all of which can be ultimately accomplished in orbit.

Sims, Herb↗

NASA NTRS2014

Musculoskeletal-induced Nucleation in Altitude Decompression Sickness

Musculoskeletal activity has the potential to both improve and compromise decompression safety. Exercise enhances inert gas elimination during oxygen breathing prior to decompression (prebreathe), but it may also promote bubble nuclei formation (nucleation), which can lead to gas phase separation and bubble growth and increase the risk of decompression sickness (DCS). The timing, pattern and intensity of musculoskeletal activity and the level of tissue supersaturation may be critical to the net effect. There are limited data available to evaluate cost-benefit relationships. Understanding the relationship is important to improve our understanding of the underlying mechanisms of nucleation in exercise prebreathe protocols and to quantify risk in gravity and microgravity environments. Data gathered during NASA's Prebreathe Reduction Program (PRP) studies combined oxygen prebreathe and exercise followed by low pressure (4.3 psi; altitude equivalent of 30,300 ft [9,235 m]) microgravity simulation to produce two protocols used by astronauts preparing for extravehicular activity. Both the Phase II/CEVIS (cycle ergometer vibration isolation system) and ISLE (in-suit light exercise) trials eliminated ambulation to more closely simulate the microgravity environment. The CEVIS results (35 male, 10 female) serve as control data for this NASA/Duke study to investigate the influence of ambulation exercise on bubble formation and the subsequent risk of DCS.

Pollock, N. W.↗

NASA NTRS2005

A Survey of Intelligent Control and Health Management Technologies for Aircraft Propulsion Systems

Intelligent Control and Health Management technology for aircraft propulsion systems is much more developed in the laboratory than in practice. With a renewed emphasis on reducing engine life cycle costs, improving fuel efficiency, increasing durability and life, etc., driven by various government programs, there is a strong push to move these technologies out of the laboratory and onto the engine. This paper describes the existing state of engine control and on-board health management, and surveys some specific technologies under development that will enable an aircraft propulsion system to operate in an intelligent way--defined as self-diagnostic, self-prognostic, self-optimizing, and mission adaptable. These technologies offer the potential for creating extremely safe, highly reliable systems. The technologies will help to enable a level of performance that far exceeds that of today s propulsion systems in terms of reduction of harmful emissions, maximization of fuel efficiency, and minimization of noise, while improving system affordability and safety. Technologies that are discussed include various aspects of propulsion control, diagnostics, prognostics, and their integration. The paper focuses on the improvements that can be achieved through innovative software and algorithms. It concentrates on those areas that do not require significant advances in sensors and actuators to make them achievable, while acknowledging the additional benefit that can be realized when those technologies become available. The paper also discusses issues associated with the introduction of some of the technologies.

Litt, Jonathan S.↗

NASA NTRS1995

Advanced solar panel designs

This paper describes solar cell panel designs that utilize new hgih efficiency solar cells along with lightweight rigid panel technology. The resulting designs push the W/kg and W/sq m parameters to new high levels. These new designs are well suited to meet the demand for higher performance small satellites. This paper reports on progress made on two SBIR Phase 1 contracts. One panel design involved the use of large area (5.5 cm x 6.5 cm) GaAs/Ge solar cells of 19% efficiency combined with a lightweight rigid graphite fiber epoxy isogrid substrate configuration. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power level of 60 W/kg with a potential of reaching 80 W/kg. The second panel design involved the use of newly developed high efficiency (22%) dual junction GaInP2/GaAs/Ge solar cells combined with an advanced lightweight rigid substrate using aluminum honeycomb core with high strength graphite fiber mesh facesheets. A coupon (38 cm x 38 cm) was fabricated and tested which demonstrated an array specific power of 105 W/kg and 230 W/sq m. This paper will address the construction details of the panels and an a analysis of the component weights. A strawman array design suitable for a typical small-sat mission is described for each of the two panel design technologies being studied. Benefits in respect to weight reduction, area reduction, and system cost reduction are analyzed and compared to conventional arrays.

Ralph, E. L.↗

NASA NTRS1996

Near-Net Forging Technology Demonstration Program

Significant advantages in specific mechanical properties, when compared to conventional aluminum (Al) alloys, make aluminum-lithium (Al-Li) alloys attractive candidate materials for use in cryogenic propellant tanks and dry bay structures. However, the cost of Al-Li alloys is typically five times that of 2219 aluminum. If conventional fabrication processes are employed to fabricate launch vehicle structure, the material costs will restrict their utilization. In order to fully exploit the potential cost and performance benefits of Al-Li alloys, it is necessary that near-net manufacturing methods be developed to off-set or reduce raw material costs. Near-net forging is an advanced manufacturing method that uses elevated temperature metal movement (forging) to fabricate a single piece, near-net shape, structure. This process is termed 'near-net' because only a minimal amount of post-forge machining is required. The near-net forging process was developed to reduce the material scrap rate (buy-to-fly ratio) and fabrication costs associated with conventional manufacturing methods. The goal for the near-net forging process, when mature, is to achieve an overall cost reduction of approximately 50 percent compared with conventional manufacturing options for producing structures fabricated from Al-Li alloys. This NASA Marshall Space Flight Center (MSFC) sponsored program has been a part of a unique government / industry partnership, coordinated to develop and demonstrate near-net forging technology. The objective of this program was to demonstrate scale-up of the near-net forging process. This objective was successfully achieved by fabricating four integrally stiffened, 170- inch diameter by 20-inch tall, Al-Li alloy 2195, Y-ring adapters. Initially, two 2195 Al-Li ingots were converted and back extruded to produce four cylindrical blockers. Conventional ring rolling of the blockers was performed to produce ring preforms, which were then contour ring rolled to produce 'contour preforms'. All of the contour preforms on this first-of-a-kind effort were imperfect, and the ingot used to fabricate two of the preforms was of an earlier vintage. As lessons were learned throughout the program, the tooling and procedures evolved, and hence the preform quality. Two of the best contour preforms were near- net forged to produce a process pathfinder Y-ring adapter and a 'mechanical properties pathfinder' Y-ring adapter. At this point, Lockheed Martin Astronautics elected to procure additional 2195 aluminum-lithium ingot of the latest vintage, produce two additional preforms, and substitute them for older vintage material non-perfectly filled preforms already produced on this contract. The existing preforms could have been used to fulfill the requirements of the contract.

Hall, I. Keith↗

NASA NTRS2009

First Stage of a Highly Reliable Reusable Launch System

Electromagnetic launch assist has the potential to provide a highly reliable reusable first stage to a space access system infrastructure at a lower overall cost. This paper explores the benefits of a smaller system that adds the advantages of a high specific impulse air-breathing stage and supersonic launch speeds. The method of virtual specific impulse is introduced as a tool to emphasize the gains afforded by launch assist. Analysis shows launch assist can provide a 278-s virtual specific impulse for a first-stage solid rocket. Additional trajectory analysis demonstrates that a system composed of a launch-assisted first-stage ramjet plus a bipropellant second stage can provide a 48-percent gross lift-off weight reduction versus an all-rocket system. The combination of high-speed linear induction motors and ramjets is identified, as the enabling technologies and benchtop prototypes are investigated. The high-speed response of a standard 60 Hz linear induction motor was tested with a pulse width modulated variable frequency drive to 150 Hz using a 10-lb load, achieving 150 mph. A 300-Hz stator-compensated linear induction motor was constructed and static-tested to 1900 lbf average. A matching ramjet design was developed for use on the 300-Hz linear induction motor.

Kloesel, Kurt J.↗