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NASA NTRS2015

Space-to-Space Power Beaming Enabling High Performance Rapid Geocentric Orbit Transfer

The use of electric propulsion is more prevalent than ever, with industry pursuing all electric orbit transfers. Electric propulsion provides high mass utilization through efficient propellant transfer. However, the transfer times become detrimental as the delta V transitions from near-impulsive to low-thrust. Increasing power and therefore thrust has diminishing returns as the increasing mass of the power system limits the potential acceleration of the spacecraft. By using space-to-space power beaming, the power system can be decoupled from the spacecraft and allow significantly higher spacecraft alpha (W/kg) and therefore enable significantly higher accelerations while maintaining high performance. This project assesses the efficacy of space-to-space power beaming to enable rapid orbit transfer while maintaining high mass utilization. Concept assessment requires integrated techniques for low-thrust orbit transfer steering laws, efficient large-scale rectenna systems, and satellite constellation configuration optimization. This project includes the development of an integrated tool with implementation of IPOPT, Q-Law, and power-beaming models. The results highlight the viability of the concept, limits and paths to infusion, and comparison to state-of-the-art capabilities. The results indicate the viability of power beaming for what may be the only approach for achieving the desired transit times with high specific impulse.

Dankanich, John W.↗

NASA NTRSDate not supplied

Growing the success of Small Satellite missions through community learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED”webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used?What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Moretto Jorgensen, T↗

NASA NTRSDate not supplied

Growing the Success of Small Satellite Missions Through Community Learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED” webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used? What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Small Satellite↗

NASA NTRS2003

Fiber Reinforcement Architectures of PMCs on the Hygrothermal-Mechanical Performance for Aeropropulsion Applications

A rigid lightweight sandwich support structure, for the combustor chamber of a new generation liquid propellant rocket engine, was designed and fabricated using Polymer Matric Composite (PMC) facesheet on a Ti honeycomb or Carbon foam core. The facesheet consisted of high stiffness carbon fiber, M40JB, and high temperature Polyimides, such as PMR-11-50 and HFPE-II. Six different fiber architectures; 4HS woven fabric, uni-fabric, woven-uni hybrid, stitched woven fabric, stitched uni-fabric and tri-axial braided structures have been investigated for optimum stiffness-thickness-weight-performance design criteria for the hygrothermal-mechanical propulsion service exposure conditions including rapid heating up to 200 F/sec, maximum operating temperature of 600 F, internal pressure up to 100 psi. An extensive property and performance database including dry-wet mechanical properties at both 25 F and 600 F in various loading modes, thermal and physical properties including blistering onset condition was developed for fiber architecture down-selection and design guidelines. Various optimized process methods including vacuum bag compression molding, solvent assistant RTM (SaRTM), resin film infusion (RFI) were utilized for PMC panel fabrication depending on the architecture type. In the case of stitched woven fabric architecture, the optimal stitch pattern was chosen in terms of stitch density and yarn size, based on both in-plane mechanical properties and blistering performance. Potential reduction of the in-plane properties transverse to the line of stitching was also evaluated. Attempt to correlate the experimental results with theoretical micro-mechanics predictions will be presented.

Shin, Eugene↗

NASA NTRS2016

Design for Survivability: An Approach to Assured Autonomy

Rapidly expanding unmanned air traffic includes and will continue to include non-cooperative participants. Non-cooperative behavior may be due to technical failure, a lack of appropriate equipment, a careless or malicious operator. Regardless of the cause, the outcome remains: growing density of non-cooperative traffic will increase the risk of collision between unmanned vehicles and aircraft carrying humans. As a result, the degraded safety of airspace may limit access to airspace, with adverse consequences for the traveling public and the economy. Because encounters with small non-cooperative objects, such as birds or wayward drones, can happen too rapidly for an external control system to mitigate them, it is imperative that the aircraft that carry humans survive encounters with non-cooperative vehicles. To-date, design for survivability has been practiced explicitly in the military domain. Survivability against collisions in civil aviation has been limited to tolerances against bird strikes; and these tolerances have proved inadequate on occasion. The growing risk of collision with unmanned vehicles now requires the development of survivability discipline for civilian transport aircraft. The new discipline must be infused into multidisciplinary design methods, on par with traditional disciplines. In this paper, we report on a preliminary study of survivability considerations for the civil aviation domain.

Alexandrov, Natalia M.↗

NASA NTRS2023

The Assembly, Test, and Integration of LOFTID (Low-Earth Orbit Flight Test of an Inflatable Decelera-tor)

R.J. Bodkin Biography Mr. Bodkin worked in industry for a rapid prototype company focusing on UAVs and manned experimental aircraft. Later he served as the Inflation System Lead on IRVE-II and 3 and the Re-Entry Vehicle Lead for LOFTID at NASA Langley Research Center. Introduction: The Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID), developed in partnership with United Launch Alliance (ULA) and flown in conjunction with the National Oceanic and Atmospheric Administration (NOAA) Joint Polar Satellite System-2 (JPSS-2) satellite, demonstrated Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology has progressed and is ready for mission infusion. LOFTID’s success demonstrates that aeroshells are not limited to the internal diame-ter of the launch vehicle payload fairing, allowing larger payloads to be deployed to the surfaces of planetary bodies with atmospheres. The challenges of assembling, integrating, and testing this revolutionary spacecraft will be dis-cussed as well as issues associated with doing this with a fixed launch date the project did not control. Assembly: Because LOFTID flew as a rideshare partner with JPSS-2, it was constrained with addi-tional schedule, milestone, and technical require-ments that were beyond the project’s control. As-sembly of the LOFTID hardware was challenged with the normal mechanical fit issues while also having to navigate the SARS-COVID-II pandemic. Challenges ranged from availability of team per-sonnel required on-site for vehicle assembly to dif-ficulties associated with team collaboration while working remotely and increased costs and lead times of components due to supply chain con-straints. Numerous additional challenges cascaded from the additional time required. Integration: LOFTID flew as a secondary pay-load to JPSS-2 in a mission-unique configuration, directly under JPSS-2 primary payload, inside the Payload Adapter that integrated JPSS-2 to the Atlas V launch vehicle. A mission unique Payload Adapt-er Separation System (PASS) was required to sepa-rate the Payload Adapter from the Launch Vehicle prior to the start of the LOFTID flight demonstra-tion. Development of this system was challenging due to a shortened development schedule resulting from the iterative nature of Payload Adapter devel-opment with the partners at ULA. Preparations to integrate the main segments of the LOFTID vehicle posed unique challenges of having to accommodate issues with a fixed launch date that led to some cre-ative solutions to the integration. The partnership agreement with ULA and JPSS-2 resulted in a mass simulator designed to be installed late in the inte-gration in the event the LOFTID vehicle was not ready in time.. Test: LOFTID testing was carried out in several phases. Some components were tested at the com-ponent level, others at the sub-system levels and then finally the integrated vehicle level. This culmi-nated with the Complete Systems Test (CST) per-formed in a vacuum chamber as one of the final checkouts prior to disassembly for re-packing of the aeroshell. CST challenges will be discussed as well as obstacles encountered post-CST. After CST, the vehicle was disassembled so the HIAD could be repacked, and the vehicle was reassembled for ac-ceptance vibration testing. Testing concluded with the fully assembled vehicle being shipped to the launch site for final testing and integrations with the Payload Adapter to JPSS-2 for launch and opera-tions. Conclusion: The challenges posed by the AI&T for LOFTID could inform the planetary community of some of the opportunities and challenges of de-veloping technologies on a rideshare with a rela-tively small budget.

R.J. Bodkin↗

NASA NTRSDate not supplied

TPSAS-NF1676L-25778-DND

Testing required to design and certify aircraft structures has increased dramatically with the growth in use of composite materials, and the development time and cost have become an issue as industry looks towards the next generation of aircraft. To help address this challenge, NASA has formed an industry-spanning consortium with the goal of cutting by 30% today's 10-year timeline for developing and certifying composite aircraft structures. This goal is to be achieved by infusing leading edge, physics-based tools to improve the prediction of the response and failure of composite aerospace structures. The plan for the public-private partnership of NASA, the FAA, airframe manufacturers, aircraft engine manufacturers, and several universities is to conduct joint research under the five-year Advanced Composites Program (ACP). The emphasis of the ACP project is the development of damage prediction and non-destructive inspection methods capabilities that are sufficiently reliable to enable a reduction in the element and subcomponent testing necessary for design and certification. ACP also is expected to create rapid design tools to speed preliminary design and improve safety and performance. A critical element of this research concerns the residual strength of postbuckled stiffened panels with impact damage. This presentation will discuss different aspects of ongoing research on the prediction of structural collapse due to skin/stiffener separation. In particular, the presentation will examine issues that must be addressed in the analysis, such as R-curve toughening, delamination migration, bridging, as well as some unexpected effects of ply orientation.

Carlos G Davila↗

NASA NTRS2004

Autonomous Multi-Sensor Coordination: The Science Goal Monitor

Many dramatic earth phenomena are dynamic and coupled. In order to fully understand them, we need to obtain timely coordinated multi-sensor observations from widely dispersed instruments. Such a dynamic observing system must include the ability to Schedule flexibly and react autonomously to sciencehser driven events; Understand higher-level goals of a sciencehser defined campaign; Coordinate various space-based and ground-based resources/sensors effectively and efficiently to achieve goals. In order to capture transient events, such a 'sensor web' system must have an automated reactive capability built into its scientific operations. To do this, we must overcome a number of challenges inherent in infusing autonomy. The Science Goal Monitor (SGM) is a prototype software tool being developed to explore the nature of automation necessary to enable dynamic observing. The tools being developed in SGM improve our ability to autonomously monitor multiple independent sensors and coordinate reactions to better observe dynamic phenomena. The SGM system enables users to specify what to look for and how to react in descriptive rather than technical terms. The system monitors streams of data to identify occurrences of the key events previously specified by the scientisther. When an event occurs, the system autonomously coordinates the execution of the users' desired reactions between different sensors. The information can be used to rapidly respond to a variety of fast temporal events. Investigators will no longer have to rely on after-the-fact data analysis to determine what happened. Our paper describes a series of prototype demonstrations that we have developed using SGM and NASA's Earth Observing-1 (EO-1) satellite and Earth Observing Systems' Aqua/Terra spacecrafts' MODIS instrument. Our demonstrations show the promise of coordinating data from different sources, analyzing the data for a relevant event, autonomously updating and rapidly obtaining a follow-on relevant image. SGM was used to investigate forest fires, floods and volcanic eruptions. We are now identifying new Earth science scenarios that will have more complex SGM reasoning. By developing and testing a prototype in an operational environment, we are also establishing and gathering metrics to gauge the success of automating science campaigns.

Koratkar, Anuradha↗

NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗

NASA NTRS2020

Demonstrating Assurance of Model-Based Fault Diagnosis Systems on an Operational Mission

Developers of robotic scientific and commercial spacecraft are trending towards use of onboard autonomous capabilities for responding quickly to dynamic environments and rapidly changing situations. These capabilities need to know the state of the spacecraft’s health. Model-based fault diagnosis (MBFD) is an approach to estimating health by continuously verifying accurate behavior and diagnosing off-nominal behavior. Proper functioning of MBFD depends on 1) the quality of the diagnostic system model that is analyzed and compared to commands and onboard measurements to estimate a system’s health state, and 2) the correct functionality of the diagnosis engine interrogating the model and comparing its analyses to observed system behavior. Our goal is to develop Verification and Validation (V&V) techniques for MBFD to provide future missions sufficient confidence in its functionality and performance to deploy it on the systems they develop. Our work has been focused on infusing the techniques we developed earlier to an operational mission. First, we are constructing diagnostic models of a spacecraft attitude control system and updating our diagnostic engine so they can be demonstrated aboard the Arcsecond Space Telescope Enabling Research in Astrophysics (ASTERIA) mission, an operational spacecraft for which experiments in autonomy are being planned and executed, using the V&V techniques we have previously developed to assure they are both correct and complete. Since it is nearing the end of its life, ASTERIA provides a unique opportunity to demonstrate MBFD since the monitored components are expected to fail. Our demonstration will give system developers additional confidence to make timely, informed MBFD deployment decisions. Second, we will be completing performance assessments of the diagnostic engine/diagnostic model ensemble both on the flight system and ground-based testbeds to gain confidence in MBFD’s ability to run successfully in a spacecraft’s resource-constrained environment without adversely affecting other on-board activities. Finally, we are capturing our experience in preparing this demonstration in a set of checklists and guidance documents. Current practice includes high-level institutional guidance documents and standards, but at a high level of abstraction that does not necessarily address specific MBFD concerns. The purpose of the new checklists is to provide future mission developers clear, unambiguous, procedure-oriented guidance on assuring MBFD. This paper describes our work in these areas. For the first area, we describe the diagnostic models and updated diagnostic engine that will be used for the on-board demonstration. We describe how the V&V techniques we developed earlier are used to assure model and engine correctness and completeness. For the second area, we identify the performance measurement and assessment techniques used to characterize the diagnostic engine and diagnostic models, and discuss the effect of measured performance on overall mission operation. Finally, we present the checklist and guidance documents and describe how they meet the goals of providing system developers with clear, unambiguous, procedure-oriented guidance on MBFD assurance. We show how the techniques we have developed map into those artifacts.

Nikora, Allen↗

NASA NTRS2018

Space Technology Mission Directorate: Game Changing Development Program: Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

Technology Overview: The RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project will develop and advance large scale light-weight multi-metallic freeform manufacturing and composite overwrap techniques and analysis capabilities required to implement them to reduce design and fabrication cycles for regeneratively-cooled liquid rocket engine components; RAMPT will reduce design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and a healthy American supply chain. Four technology areas developed: 1) Freeform Blown Powder Nozzle; 2) Composite overwrap structural jacket; 3) Bimetallic radial deposition for manifolds; 4) Modeling and analysis tools for Additive and Regen design. Exploration & Science Impact: Addresses longest lead, highest cost and heaviest component in engine; Applicable to Lunar Lander Engine, Booster Engines, Upper Stage Engines, and NTP (Nuclear Thermal Propulsion) Technology; Public-private partnerships with specialty industry vendors, government partners, Commercial Crew, and infusion into commercial space companies and manufacturers; SSTIP (NASA's Strategic Space Technology Investment Plan) Core Investment Area - Launch Propulsion Systems (TA01 (NASA Technology Area 01); Lightweight Space Structures and Materials (TA12); Manufacturing (TA12).

RAMPT↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

TPS materials↗

NASA NTRS2001

Evaluation of the National Throughput Benefits of the Civil Tilt Rotor

The air transportation system is a key part of the U.S. and global economic infrastructure. In recent years, this system, by any measure of usage - operations, enplanements, or revenue passenger miles (RPMs) - has grown rapidly. The rapid growth in demand has not been matched; however, by commensurate increases in the ability of airports and the airspace system to handle the additional traffic. As a result, the air transportation system is approaching capacity and airlines will face excessive delays or significant constraints on service unless capacity is expanded. To expand capacity, the air traffic management system must be improved. To improve the air traffic management system, the National Aeronautics and Space Administration (NASA) Aerospace Technology Enterprise developed the strategic goal of tripling air traffic throughput over the next 10 years, in all weather conditions, while at least maintaining current safety standards. As the first step in meeting that goal, the NASA Intercenter Systems Analysis Team (ISAT) is evaluating the contribution of existing programs to meet that goal. A major part of the study is an examination of the ability of the National Airspace System (NAS) to meet the predicted growth in travel demand and the potential benefits of technology infusion to expand NAS capacity. We previously analyzed the effects of the addition of two technology elements - Terminal Area Productivity (TAP) and Advanced Air Transportation Technologies (AATT). The next program we must analyze is not specific to airspace or aircraft technology. The program incorporates a fundamentally different vehicle to improve throughput: the civil tilt rotor (CTR). The CTR has the unique operating characteristic of being able to take off and land like a rotorcraft (vertical take off and landing, or VTOL, capability) but cruises like a traditional fixed-wing aircraft. The CTR also can operate in a short take off and landing (STOL) mode; generally, with a greater payload capacity (i.e., more passengers) than when operating in the VTOL mode. CTR could expand access to major airports without interfering with fixed-wing aircraft operating on congested runways and it could add service to new markets without the infrastructure support needed for fixed-wing aircraft. During FY 1999, we preliminarily assessed the feasibility of operating CTRs at two major U.S. airports as part of the annual review of NASA aerospace goals by the ISAT. This current study expands the analysis and concepts of that study to the complete NAS to quantify the national throughput effects of the CTR.

Johnson, Jesse↗

NASA NTRSDate not supplied

Advancing Dust Tolerant Mechanisms for a Sustained Exploration of the Moon

Introduction: “I think dust is probably one of our greatest inhibitors to a nominal operation on the Moon. I think we can overcome other physio-logical or physical or mechanical problems except dust.”– Gene Cernan, Apollo 17 Technical Debrief The Apollo missions revealed the impact of lu-nar dust on mechanisms. Lunar dust particles are jagged and electrostatically charged, giving them the ability to bind or damage mechanisms and alter thermal properties. Reports documented clogged equipment and jammed mechanisms in every mission, regardless of surface duration, as well as clogged mechanisms in the Extravehicular Mobility Suit (EMS), including zippers, wrist and hose locks, faceplates, and sunshades [1-2]. Several astronauts remarked they could not have sustained surface activity much longer because clogged joints would have frozen up completely [2]. Effective dust mitigation strategies are need-ed to support longer duration stays on the lunar surface [3-4]. State of the Art: Technology for mechanisms able to operate in dusty enviroments is advancing rapidly due to the needs of both Mars rovers and the Artemis program. Vacuum-tight connectors are essential for spacesuits and habitats, and their performance can be dependent on cleaning technologies, which have proven difficult on the lunar surface. Several TRL 3-5 technologies are undergoing tests with the expectation to reach TRL 6 within 1-2 years. Some mechanisms will be infused and tested on the VIPER (Volatiles Inves-tigating Polar Exploration Rover) mission planned for mid-2020s. NASA Funded Efforts: NASA has recognized the need for dust tolerant mechanisms, and has partnered with industry to advance the state-of-the-art. At NASA GRC, KSC, and JSC, the Dust Tolerant Mechanisms Project is working to devel-op advanced actuator seals for rotary joints and rotary bearing technologies for long-term sus-tained operation in lunar dust environments. An-other NASA project at NASA GRC, partnered with GSFC, JPL, and KSC is Motors for Dusty & Ex-treme Cold Environments (MDECE). MDECE is developing an unheated magnetically-geared mo-tor that can operate continuously for a long dura-tion at an ambient temperature of -243 ºC (33 K). NASA GRC has the capability to characterize the effects of dust on seals, mechanisms, and other mating surfaces and components under lunar conditions [5]. Through the SBIR/STTR program, NASA has funded several companies to advance dust toler-ant mechanisms via the Dust Tolerant Mecha-nisms sub-topic with applications in surface mobil-ity, spacesuits, connectors, joints, and more. LSIC and Community Efforts: The Lunar Surface Innovation Consortium (LSIC) Dust Miti-gation focus group has fostered collaborations across NASA, industry, and academia to develop solutions that minimizes the impact of lunar dust on robotic and human systems. Community ef-forts have included topical meetings on dust tol-erant mechanisms, featured technology presenta-tions, and feedback to NASA on potential gaps and needs. Testing: In 2021, NASA released NASA-STD-1008 [6]. This NASA Technical Standard estab-lishes minimum requirements and provides guid-ance for testing systems and hardware to be ex-posed to dust in planetary environments. The standard has specific sections dedicated to Mechanisms Testing (e.g. bearings, gears) as well as Seals and Mating Surfaces Testing (e.g. hatches, docking systems). Gaps and Needs: NASA is tracking dust tol-erant mechanisms as a gap in a cross-directorate analysis of capability areas needed to enable fu-ture human space-flight architectures. Two high-priority gap areas include additional facilities for testing mechanisms in lunar-surface conditions, and a better understanding of vulnerabilities to the smallest, nanometer-scale dust particles. Conclusion: Understanding and mitigating lu-nar dust is critical to successful, sustained opera-tions on the lunar surface – whether autonomous or otherwise. This presentation will discuss both the state-of-the-art and open needs in lunar dust tolerant mechanisms, technology impacts, mitiga-tion approaches, testing, LSIC community efforts, and more. References: [1] Gaier, J. R. (2020). The Im-pact of Dust on Lunar Surface Equipment During Apollo. Lunar Dust 2020. [2] GRC, & Gaier, J. R. (2005). The Effects of Lunar Dust on EVA Sys-tems During the Apollo Missions. [3] Johansen, M. R. (2020). An Update on NASA’s Lunar Dust Mitigation Strategy. Lunar Dust 2020. [4] ASI, CSA, ESA, JAXA, & NASA. (2016). Dust Mitiga-tion Gap Assessment Report. [5] Jimenez, N. et al (2022), LPSC Abstract 2572. [6] NASA-STD-1008, 2021.

J I Nunez↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRS2014

Avionics Architectures for Exploration: Ongoing Efforts in Human Spaceflight

The field of Avionics is advancing far more rapidly in terrestrial applications than in spaceflight applications. Spaceflight Avionics are not keeping pace with expectations set by terrestrial experience, nor are they keeping pace with the need for increasingly complex automation and crew interfaces as we move beyond Low Earth Orbit. NASA must take advantage of the strides being made by both space-related and terrestrial industries to drive our development and sustaining costs down. This paper describes ongoing efforts by the Avionics Architectures for Exploration (AAE) project chartered by NASA's Advanced Exploration Systems (AES) Program to evaluate new avionic architectures and technologies, provide objective comparisons of them, and mature selected technologies for flight and for use by other AES projects. The AAE project team includes members from most NASA centers, and from industry. It is our intent to develop a common core avionic system that has standard capabilities and interfaces, and contains the basic elements and functionality needed for any spacecraft. This common core will be scalable and tailored to specific missions. It will incorporate hardware and software from multiple vendors, and be upgradeable in order to infuse incremental capabilities and new technologies. It will maximize the use of reconfigurable open source software (e.g., Goddard Space Flight Center's (GSFC's) Core Flight Software (CFS)). Our long-term focus is on improving functionality, reliability, and autonomy, while reducing size, weight, and power. Where possible, we will leverage terrestrial commercial capabilities to drive down development and sustaining costs. We will select promising technologies for evaluation, compare them in an objective manner, and mature them to be available for future programs. The remainder of this paper describes our approach, technical areas of emphasis, integrated test experience and results as of mid-2014, and future plans. As a part of the AES Program, we are encouraged to set aggressive goals and fall short if necessary, rather than to set our sights too low. We are also asked to emphasize providing our personnel with hands-on experience in development, integration, and testing. That we have embraced both of these philosophies will be evident in the descriptions below.

Goforth, Montgomery B.↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗