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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

The NASA Langley building solar project and the supporting Lewis solar technology program

The use of solar energy to heat and cool a new office building that is now under construction is reported. Planned for completion in December 1975, the 53,000 square foot, single story building will utilize 15,000 square feet of various types of solar collectors in a test bed to provide nearly all of the heating demand and over half of the air conditioning demand. Drawing on its space-program-developed skills and resources in heat transfer, materials, and systems studies, NASA-Lewis will provide technology support for the Langley building project. A solar energy technology program underway at Lewis includes solar collector testing in an indoor solar simulator facility and in an outdoor test facility, property measurements of solar panel coatings, and operation of a laboratory-scale solar model system test facility. Based on results obtained in this program, NASA-Lewis will select and procure the solar collectors for the Langley test bed.

Ragsdale, R. G.↗
NASA NTRS2024

An Integrated Architecture Study for Autonomous Lunar Construction

Lunar construction is an expanding field within NASA’s Moon to Mars objectives that presents many challenges and requires innovative and reliable forms of autonomous operations on the surface of the Moon to further the technologies needed for human space exploration. Marshal Space Flight Center’s (MSFC) Advanced Concepts Office (ACO) addressed Lunar Infrastructure Objective LI-4 l by developing a Pre-Phase A, integrated architecture to inform a demonstration for lunar construction operations. The ACO study traded three architectures that would survey and prepare a construction area to build a landing pad out of lunar regolith using MMPACT (Moon-to-Mars Planetary Autonomous Construction Technology) platforms, rovers, and navigation outposts. The main trades examined navigation for the system/architecture, options for rover navigation, battery vs continuous tether power for the MMPACT robotic arm, and assigning site prep functionality to the rovers vs the platforms. Results of the study determined that the best options for the scenario provided would be local navigation (more accurate and continuous), a combination of Light Detection and Ranging (LiDAR) for initial site mapping with subsequent Smart Video Guidance Sensors (SVGS) to save power for construction, and using tethered power to decrease mission duration. The team also concluded that assigning site prep functionality to either the rovers or the platforms has benefits and challenges; future studies could explore having that functionality on both the rovers and platforms. Lastly, the team provided a Concept of Operations (ConOps) timeline that can be used in real-time ground demonstrations to explore the mission timeline, construction processes, autonomous operations, and communication systems that can be tested using MSFC’s lunar regolith field and Lunar Utilization Control Area (LUCA).

Sarah Triana↗
NASA NTRS2013

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗
NASA NTRS2003

3-Dimensional Topographic Models for the Classroom

We have recently undertaken a program to develop educational tools using 3-dimensional solid models of digital elevation data acquired by the Mars Orbital Laser Altimeter (MOLA) for Mars as well as a variety of sources for elevation data of the Earth. This work is made possible by the use of rapid prototyping technology to construct solid 3-Dimensional models of science data. We recently acquired rapid prototyping machine that builds 3-dimensional models in extruded plastic. While the machine was acquired to assist in the design and development of scientific instruments and hardware, it is also fully capable of producing models of spacecraft remote sensing data. We have demonstrated this by using Mars Orbiter Laser Altimeter (MOLA) topographic data and Earth based topographic data to produce extruded plastic topographic models which are visually appealing and instantly engage those who handle them.

Keller, J. W.↗
NASA NTRS2017

NASA Centennial Challenge: Three Dimensional (3D) Printed Habitat, Phase 2

The NASA Centennial Challenges: 3D-Printed Habitat Challenge seeks to develop the fundamental technologies necessary to manufacture an off-world habitat using mission recycled materials and/or local indigenous materials. The vision is that autonomous habitat manufacturing machines will someday be deployed to the Moon or Mars to construct shelters for human habitation. NASA and Bradley University, are holding a new US$ 2.5 million competition to design and build a 3-D printed habitat for deep space exploration, including the agency's journey to Mars. The multi-phase 3-D Printed Habitat Challenge, part of NASA's Centennial Challenges program, is designed to advance the additive construction technology needed to create sustainable housing solutions for Earth and beyond. The first phase of the competition ran through Sept. 27, 2015. This phase, a design competition, called on participants to develop state-of-the-art architectural concepts that take advantage of the unique capabilities 3-D printing offers. The top 3 prizes with a prize purse of $40,000 were awarded at the 2015 World Maker Faire in New York. The second phase of the competition is called the Structural Member Competition and it is divided into three levels happening in the spring and summer of 2017. The Compression Test Competition (Level 1) focuses on the fabrication technologies needed to manufacture structural components from a combination of indigenous materials and recyclables, or indigenous materials alone. For Level 1, teams will develop 3D printable materials, build a 3D printing machine, and print two specimens: a truncated cone and a cylinder. The Level 2 Beam Member Competition is the second of three sub-competitions within the overall Structural Member Competition. For Level 2, teams will print a beam that will be tested. The Level 3 Head to Head Competition is the third of three sub-competitions within the overall Structural Member Competition. For Level 3, teams will develop 3D printable materials, use a 3D printing machine, and print three compression specimens of the elected material, three flexural specimens of the elected material, and one dome structure. Tests conducted on the specimens and the dome structure will determine Level 3 scores and awards. On Earth these same habitat manufacturing capabilities could be used to produce housing wherever affordable housing is needed and access to conventional building materials and skills is limited. Terrestrially, it is envisioned that local indigenous materials (dirt, clay, sand, etc.) could be combined with readily available recyclable materials and used to construct semi-permanent shelters against environmental elements for human habitation. The goal of the 3D-Printed Habitat Challenge is to foster the development of new technologies necessary to additively manufacture a habitat using local indigenous materials with, or without, recyclable materials. This paper will summarize the Level 2 results of this NASA Centennial Challenge competition and it will discuss related technology advancement.

3D printing↗
NASA NTRSDate not supplied

Lunar Mega Project: Processes, Work Flow and Terminology of the Terrestrial Construction Industry versus the Space Industry

Recent developments around the world show an increased interest and international activity toward developing a lunar surface human and robotic presence with a long term, sustainable vision. In Europe, the construction of a "Moon Village" has been proposed, and China has stated its intention to build a research station with a crew at the lunar South Pole. Russia stated it will land cosmonauts on the Moon in the 2030's. India has sent an orbiter, a robotic lander, and rover to the Moon. The USA intends to land the first woman and a man on the Moon by 2024 to initiate a sustained human lunar presence.A lunar research station with associated commercial activities will require infrastructure to become a permanent capability. Landing and launch pads, propellant storage and distribution farms, spacecraft access and handling structures, cranes, blast protection berms or walls, roads, graded areas, dust stabilized areas, foundations, parking lots, radiation shelters, micro-meteorite protection hangars, habitats and other human shelters, greenhouse farms, utility trenches, power plants, industrial water and oxygen extraction plants, communications antenna towers, thermal protection, mining zones, crater access and sub-surface access will be required to create a safe and sustainable lunar operations capability. This infrastructure will require significant construction activities in an extreme environment, with risky and expensive operations. On Earth, there are similar large and expensive projects (>$1 Billion) in difficult locations that attract a lot of public attention. These are known as "Mega Projects" and examples include bridges, tunnels, highways, railways, airports, seaports, power plants, dams, wastewater projects, Special Economic Zones (SEZ), oil and natural gas extraction projects, public buildings, information technology systems, aerospace projects, and weapons systems. Large consortiums consisting of public and private entities typically implement these infrastructure Mega-Projects.This paper will compare the typical design process, project management process, and work flow in the terrestrial construction industry to the space industry in order to create a better understanding between the terrestrial construction industry and the space industry, to further enable collaboration on a lunar Mega Project to build infrastructure on the Moon. In addition, a glossary of respective industry terminology with annotated linkages and definitions has been compiled. This information will enable contracts and business practices to be formulated for generating requests for proposals (RFP) by governments to consortiums consisting of construction and space industry companies that will bid on Lunar Infrastructure Projects that could lead to contracts to build the permanent capabilities.

Robert P Mueller↗
NASA NTRSDate not supplied

Lunar Base Construction Planning

Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews(NASA Apollo program).Now, the next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and theEuropean Union of nations, have all expressed interest in either collaborating or competing with NASA on theMoon. This next phase has an overarching goal of achieving a permanent human presence on theMoon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment.Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity(EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. Radiation shielding via the use of regolith can also mitigate radiation dangers.The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve.In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give ahistorical review and current status of lunar construction planning and a high level introduction to the required infrastructure and construction equipment that will be required to robotically build a lunar base using in-situ resources.It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.

Lunar↗
NASA NTRS2018

Zero Launch Mass Three Dimensional Print Head

NASA's strategic goal is to put humans on Mars in the 2030's. 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.

3D print↗
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 NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed – A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed: A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRS1991

Optical fiber sensor for temperature measurement from 600 to 1900 C in gas turbine engines

A temperature sensor system has been fabricated specifically for the harsh environment encountered in temperature measurement on gas turbine engines. Four components comprised the system: a thermally emissive source, a high temperature lightguide, a flexible optical cable and an electro-optic signal processor. The emissive source was located inside a sapphire rod so that the sapphire serves as both a lightguide and as a protective shroud. As the probe was heated, the thermal radiation from the emissive source increased with increasing temperature. The flexible optical cable was constructed with 200 micron core fiber and ruggedized for turbine engine applications. The electro-optic signal processor used the ratio of intensity in two wavelength intervals to determine a digital value of the temperature. The probe tip was operated above 1900 C in a low velocity propane flame and above 1500 C at Mach .37. Probe housings, optical cables, and signal processors were constructed and environmentally tested for the temperature and vibration experienced by turbine engine sensors. This technology was used to build an optical exhaust gas sensor for a General Electric Aircraft Engines F404 turbine. The four optical probes and optical cable were a functional replacement for four thermocouple probes. The system was ground tested for 50 hours with an excess of 1000 thermal cycles. This optical temperature sensor system measured gas temperature up to the operational limit of the turbine engine.

Tregay, G. W.↗
NASA NTRSDate not supplied

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status

NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) projectwas initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.

lunar infrastructure↗
NASA NTRSDate not supplied

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status

NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) project was initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.

Additive construction, regolith processing, lunar ↗
NASA NTRS1974

Flat plate collector performance determined experimentally with a solar simulator

The NASA is constructing a new office building at Langley Research Center that will utilize solar energy for heating and cooling. A collector technology program being conducted at Lewis will provide the basis for selecting collectors for use at Langley. The technology program includes testing collectors in an indoor facility under simulated solar radiation. Tests have been conducted on five collectors to date and performance data are presented herein.

Vernon, R. W.↗
NASA NTRS1974

Flat-plate collector performance determined experimentally with a solar simulator

The NASA is constructing a new office building at Langley Research Center that will utilize solar energy for heating and cooling. A collector technology program is described which includes testing collectors in an indoor facility under simulated solar radiation. Tests have been conducted on five collectors to date and performance data are presented. The collector performance obtained with the solar simulator will be correlated with data obtained by conducting tests outdoors at Lewis.

Vernon, R. W.↗