Results for “material obsolescent” — Page 2

NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Water Processor Assembly↗

NASA NTRS2015

Cryoinsulation Material Development to Mitigate Obsolescence Risk for Global Warming Potential Foams

Cryoinsulation foams currently being qualified for the Space Launch System (SLS) core stage are nonozone- depleting substances (ODP) and are compliant with current environmental regulations. However, these materials contain the blowing agent HFC-245fa, a hydrofluorocarbon (HFC), which is a Global Warming Potential (GWP) substance. In August 2014, the Environmental Protection Agency (EPA) proposed a policy change to reduce or eliminate certain HFCs, including HFC-245fa, in end-use categories including foam blowing agents beginning in 2017. The policy proposes a limited exception to allow continued use of HFC and HFC-blend foam blowing agents for military or space- and aeronautics-related applications, including rigid polyurethane spray foams, but only until 2022.

Protz, Alison↗

NASA NTRS2010

Materials Lifecycle and Environmental Consideration at NASA

The aerospace community faces tremendous challenges with continued availability of existing material supply chains during the lifecycle of a program. Many obsolescence drivers affect the availability of materials: environmental safety ahd health regulations, vendor and supply economics, market sector demands,and natural disasters. Materials selection has become increasingly more critical when designing aerospace hardware. NASA and DoD conducted a workshop with subject matter experts to discuss issues and define solutions for materials selections during the lifecycle phases of a product/system/component. The three primary lifecycle phases were: Conceptualization/Design, Production & Sustainment, and End of life / Reclamation. Materials obsolescence and pollution prevention considerations were explored for the aforementioned lifecycle phases. The recommended solutions from the workshop are being presented.

Clark-Ingram, Marceia↗

NASA NTRS2010

Development of the Upgraded DC Brush Gear Motor for Spacebus Platforms

The obsolescence of materials and processes used in the manufacture of traditional DC brush gear motors has necessitated the development of an upgraded DC brush gear motor (UBGM). The current traditional DC brush gear motor (BGM) design was evaluated using Six-Sigma process to identify potential design and production process improvements. The development effort resulted in a qualified UBGM design which improved manufacturability and reduced production costs. Using Six-Sigma processes and incorporating lessons learned during the development process also improved motor performance for UBGM making it a more viable option for future use as a deployment mechanism in space flight applications.

Berning, Robert H.↗

NASA NTRS2017

Technology Evaluation for Environmental Risk Mitigation Compendium

The Technology Evaluation for Environmental Risk Mitigation (TEERM) Principal Center and its predecessor organization the Acquisition Pollution Prevention Program (AP2) supported the National Aeronautics and Space Administration (NASA) in identifying technology solutions to risks and costs to NASA programs driven by environmental regulations and requirements. TEERM researched the commercial and government marketplace to locate viable and available technologies that met NASAs needs. TEERM focused on addressing environmentally-driven risks of direct concern to NASA programs and facilities, including hazardous materials in NASA operations and materials that became obsolescent because of environmental regulations. TEERM projects aimed to reduce cost; ensure the health and safety of people, assets, and the environment; promote efficiency; and minimize duplication. Major TEERM and AP2 projects focused on waste minimization and hazardous waste treatment, recycling, corrosion prevention and control, solvent and ozone depleting substances substitution, and aqueous based cleaners. In 2017, NASA made the decision to terminate the TEERM Principal Center. This Compendium Report documents TEERM and AP2 project successes. The Compendium Report traces the evolution of TEERM based on evolving risks and requirements for NASA and its relationship to the Space Shuttle Program, the United States Department of Defense, the European Space Agency, and other public and private stakeholders. This Compendium Report also documents project details from Project Summaries and Joint Test Plans and describes project stakeholders and collaborative effort results.

material obsolescent↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablators (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

Thermal Protection↗

NASA NTRS2019

Development of Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since 1999. Due to the obsolescence of the input fiber source, new PICA materials were developed using Lyocell, a domestic rayon fiber source. Results are presented from this effort. Manufacturing included fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet testing have been conducted. Initial testing indicates comparable performance with respect to heritage PICA material, and likely "drop-in" replacement for future NASA mission needs.

thermal protection↗

NASA NTRSDate not supplied

Mirror Tech Days (11/02/2021)Next Generation Astronomical X-ray Optics:High Resolution, Light Weight, & Low Cost

We have demonstrated the basic elements of a technology to make high-resolution, light-weight, and low-cost X-ray optics. We continue to advance this technology to meet all requirements of Lynx: performance and programmatic. This technology uses only commercially available equipment and materials. It piggybacks on the semiconductor industry, avoiding obsolescence and ensuring continual advance. This technology can be used for missions of all sizes: sub-orbital, SmallSats, Pioneers, SMEX, MIDEX, Probes, and Flagships(Lynx).

X-Ray↗

NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engines, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over 1 million seconds total accumulated hot-fire time. In addition, there were also 16 flight engines and 2 development engines remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway to improve system affordability and eliminate obsolescence concerns. These key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗

NASA NTRS2000

Non-Asbestos Insulation Testing Using a Plasma Torch

Insulation obsolescence issues are a major concern for the Reusable Solid Rocket Motor (RSRM). As old sources of raw materials disappear, new sources must be found and qualified. No simple, inexpensive test presently exists for predicting the erosion performance of a candidate insulation in the full-scale motor, Large motor tests cost million of dollars and therefore can only be used on a few very select candidates. There is a need for a simple, low cost method of screening insulation performance that can simulate some of the different erosion environments found in the RSRM. This paper describes a series of erosion tests on two different non-asbestos insulation formulations, a KEVLAR(registered) fiber-filled and a carbon fiber-filled insulation containing Ethylene-Propylene-Diene Monomer (EPDM) rubber as the binder. The test instrument was a plasma torch device. The two main variables investigated were heat flux and alumina particle impingement concentration. Statistical analysis revealed that the two different formulations had very different responses to the main variable. The results of this work indicate that there may be fundamental differences in how these insulation formulations perform in the motor operating environment. The plasma torch appears to offer a low-cost means of obtaining a fundamental understanding of insulation response to critical factors in a series of statistically designed experiments.

Morgan, R. E.↗

NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗

NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90's. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗

NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90's. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗

NASA NTRS2017

NASA-STD-6001B Test 7: Impact of Test Methodology and Detection Advancements on the Obsolescence of Historical Offgas Data

NASA-STD-6001B states "all nonmetals tested in accordance with NASA-STD-6001 should be retested every 10 years or as required by the responsible program/project." The retesting of materials helps ensure the most accurate data are used in material selection. Manufacturer formulas and processes can change over time, sometimes without an update to product number and material information. Material performance in certain NASA-STD-6001 tests can be particularly vulnerable to these changes, such as material offgas (Test 7). In addition, Test 7 analysis techniques at NASA White Sands Test Facility were dramatically enhanced in the early 1990s, resulting in improved detection capabilities. Low level formaldehyde identification was improved again in 2004. Understanding the limitations in offgas analysis data prior to 1990 puts into question the validity and current applicability of that data. Case studies on Super Koropon (Registered trademark) and Aeroglaze (Registered trademark) topcoat highlight the importance of material retesting.

Buchanan, Vanessa D.↗

NASA NTRS1993

Knowledge acquisition and interface design for learning on demand systems

The rapid changes in our world precipitated by technology have created new problems and new challenges for education and training. A knowledge 'explosion' is occurring as our society moves toward a service oriented economy that relies on information as the major resource. Complex computer systems are beginning to dominate the workplace, causing alarming growth and change in many fields. The rapidly changing nature of the workplace, especially in fields related to information technology, requires that our knowledge be updated constantly. This characteristic of modern society poses seemingly unsolvable instructional problems involving coverage and obsolescence. The sheer amount of information to be learned is rapidly increasing, while at the same time some information becomes obsolete in light of new information. Education, therefore, must become a lifelong process that features learning of new material and skills as needed in relation to the job to be done. Because of the problems cited above, the current model of learning in advance may no longer be feasible in our high-technology world. In many cases, learning in advance is impossible because there are simply too many things to learn. In addition, learning in advance can be time consuming, and often results in decontextualized knowledge that does not readily transfer to the work environment. The large and growing discrepancy between the amount of potentially relevant knowledge available and the amount a person can know and remember makes learning on demand an important alternative to current instructional practices. Learning on demand takes place whenever an individual must learn something new in order to perform a task or make a decision. Learning on demand is a promising approach for addressing the problems of coverage and obsolescence because learning is contextualized and integrated into the task environment rather than being relegated to a separate phase that precedes work. Learning on demand allows learners to see for themselves the usefulness of new knowledge for actual problem situations, thereby increasing the motivation for learning new information. Finally, learning on demand makes new information relevant to the task at hand, leading to more informed decision making, better quality products, and improved performance.

Nelson, Wayne A.↗

NASA NTRS2015

Hexavalent Chromium IV-Free Primer Development

Primer materials provide corrosion protection for metal parts as well as an increased adhesion between metallic substrates and thermal protection systems (TPSs). Current primers for use in cryogenic applications contain hexavalent chromium. This hexavalent chromium provides excellent corrosion protection even in a cryogenic environment, but it is a carcinogen that requires special equipment and waste control procedures to use. The hazardous nature of hexavalent chromium makes it an obsolescence risk in the future. This study included two phases of evaluation. Thirteen primers were initially identified as candidates and twelve of those primers were tested in phase 1. Four of the best performing candidates from phase 1 continued into phase 2 testing. Phase 1 testing consisted mostly of liquid constituent and physical property testing. Cryoflex and salt fog testing were included in phase 1 because of their importance to the overall success of a candidate material. Phase 2 consisted of physical, thermal, and mechanical properties for nominally processed and fabricated specimens.

Alldredge, Michael J.↗

NASA NTRSDate not supplied

Qualification of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as Mars Science Lab (MSL) and Mars 2020. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues. The challenge involved in finding a replacement fiber source is in processing as well as in the final performance of the ablator. Each replacement necessitates the requalification of the PICA. This has happened at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Due to its flight heritage and proven capability, PICA is baselined as the Thermal Protection System (TPS) for Dragonfly and Mars Sample Return Sample Retrieval Lander mission and is being considered for the backshell of the Mars Sample Return Earth Entry System. All three missions are due to be launched between 2026 and 2028. The challenge this time is to ensure the PICA made with domestic material is a suitable replacement to the heritage PICA used in MSL and Mars 2020 so that the design of the heatshield can be matured without much risk. Results are presented from the recent efforts of 22 PICA-D billets that were Lot Acceptance Tested. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Testing of PICA-Domestic (PICA-D) indicates very comparable performance with respect to “heritage” PICA materials and thus PICA-D is expected to be a sustainable and nearly a “drop-in” replacement solution for future NASA missions.

Matt Gasch↗

NASA NTRSDate not supplied

Qualification of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90’s. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions, from Sample Return missions such as Stardust, OSIRIS-REx to large Mars Lander missions such as Mars Science Lab (MSL) and Mars 2020. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues. The challenge involved in finding a replacement fiber source is in processing as well as in the final performance of the ablator. Each replacement necessitates the requalification of the PICA. This has happened at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Due to its flight heritage and proven capability, PICA is baselined as the Thermal Protection System (TPS) for Dragonfly and Mars Sample Return Sample Retrieval Lander mission and is being considered for the backshell of the Mars Sample Return Earth Entry System. All three missions are due to be launched between 2026 and 2028. The challenge this time is to ensure the PICA made with domestic material is a suitable replacement to the heritage PICA used in MSL and Mars 2020 so that the design of the heatshield can be matured without much risk. Results are presented from the recent efforts of 22 PICA-D billets that were Lot Acceptance Tested. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Testing of PICA-Domestic (PICA-D) indicates very comparable performance with respect to “heritage” PICA materials and thus PICA-D is expected to be a sustainable and nearly a “drop-in” replacement solution for future NASA missions.

PICA↗