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NASA NTRS2016

Advanced Technologies to Improve Closure of Life Support Systems

As NASA looks beyond the International Space Station toward long-duration, deep space missions away from Earth, the current practice of supplying consumables and spares will not be practical nor affordable. New approaches are sought for life support and habitation systems that will reduce dependency on Earth and increase mission sustainability. To reduce launch mass, further closure of Environmental Control and Life Support Systems (ECLSS) beyond the current capability of the ISS will be required. Areas of particular interest include achieving higher degrees of recycling within Atmosphere Revitalization, Water Recovery and Waste Management Systems. NASA is currently investigating advanced carbon dioxide reduction processes that surpass the level of oxygen recovery available from the Sabatier Carbon Dioxide Reduction Assembly (CRA) on the ISS. Candidate technologies will potentially improve the recovery of oxygen from about 50% (for the CRA) to as much as 100% for technologies who's end product is solid carbon. Improving the efficiency of water recycling and recovery can be achieved by the addition of advanced technologies to recover water from brines and solid wastes. Bioregenerative technologies may be utilized for water reclaimation and also for the production of food. Use of higher plants will simultaneously benefit atmosphere revitalization and water recovery through photosynthesis and transpiration. The level at which bioregenerative technologies are utilized will depend on their comparative requirements for spacecraft resources including mass, power, volume, heat rejection, crew time and reliability. Planetary protection requirements will need to be considered for missions to other solar system bodies.

Barta, Daniel J.↗

NASA NTRS2016

Methane Post-Processing for Oxygen Loop Closure

State-of-the-art United States Atmospheric Revitalization carbon dioxide (CO2) reduction is based on the Sabatier reaction process, which recovers approximately 50% of the oxygen (O2) from crew metabolic CO2. Oxygen recovery from carbon dioxide is constrained by the limited availability of reactant hydrogen. Post-processing of methane to recover hydrogen with the Umpqua Research Company Plasma Pyrolysis Assembly (PPA) has the potential to further close the Atmospheric Revitalization oxygen loop. The PPA decomposes methane into hydrogen and hydrocarbons, predominantly acetylene, and a small amount of solid carbon. The hydrogen must then be purified before it can be recycled for additional oxygen recovery. Long duration testing and evaluation of a four crew-member sized PPA and a discussion of hydrogen recycling system architectures are presented.

Greenwood, Zachary W.↗

NASA NTRS2016

3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing, and Future Work

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS), an orbiting laboratory 200 miles above the earth, provides a unique and incredible opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In particularly, additive manufacturing (or 3D printing) techniques can potentially be deployed in the space environment to enhance crew safety (by providing an on-demand part replacement capability) and decrease launch mass by reducing the number of spare components that must be launched for missions where cargo resupply is not a near-term option. In September 2014, NASA launched the 3D Printing in Zero G technology demonstration mission to the ISS to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on-orbit. The printer for this mission was designed and operated by the company Made In Space under a NASA SBIR (Small Business Innovation Research) phase III contract. The overarching objectives of the 3D print mission were to use ISS as a testbed to further maturation of enhancing technologies needed for long duration human exploration missions, introduce new materials and methods to fabricate structure in space, enable cost-effective manufacturing for structures and mechanisms made in low-unit production, and enable physical components to be manufactured in space on long duration missions if necessary. The 3D print unit for fused deposition modeling (FDM) of acrylonitrile butadiene styrene (ABS) was integrated into the ISS Microgravity Science Glovebox (MSG) in November 2014 and phase I printing operations took place from November through December of that year. Phase I flight operations yielded 14 unique parts (21 total specimens) that could be directly compared against ground-based prints of identical geometry manufactured using the printer prior to its launch to ISS. The 3DP unit functioned safely and produced specimens necessary to advance the understanding of the critical design and operational parameters for the FDM process as affected by the microgravity environment. From the standpoint of operations, 3DP demonstrated the ability to remove parts from the build-tray on-orbit, teleoperate the printer from the ground, perform critical maintenance functions within defined human factors limits, produce a functional tool that could be evaluated for form/fit/function, and uplink a new part file from the ground and produce it on the printer. The flight parts arrived at NASA Marshall Space Flight Center in Huntsville, Alabama in April 2015, where they underwent months of testing in the materials and processes laboratory. Ground and flight prints completed the following phases of testing: photographic/visual inspection, mass and density evaluation, structured light scanning, XRay and CT, mechanical testing, optical microscopy, scanning electron microscopy, and chemical analysis. This presentation will discuss the results of this testing as well as phase II operations for the printer, which took place in June and July of 2016. Lessons learned from the tech demo and their impacts on the design and development of the second generation 3D printer for ISS, the Additive Manufacturing Facility (AMF) by Made In Space will also be presented. In addition, progress in other elements of NASA's In Space Manufacturing (ISM) initiative such as the on-demand ISM utilization catalog, in-space Recycler ISS Technology Demonstration development, launch packaging recycling, in-space printable electronics, development of higher strength polymeric materials for 3D printing and Additive Construction by Mobile Emplacement (ACME) will also be addressed.

Prater, Tracie↗

NASA NTRS2017

Axiomatic Design of Space Life Support Systems

Systems engineering is an organized way to design and develop systems, but the initial system design concepts are usually seen as the products of unexplained but highly creative intuition. Axiomatic design is a mathematical approach to produce and compare system architectures. The two axioms are:- Maintain the independence of the functional requirements.- Minimize the information content (or complexity) of the design. The first axiom generates good system design structures and the second axiom ranks them. The closed system human life support architecture now implemented in the International Space Station has been essentially unchanged for fifty years. In contrast, brief missions such as Apollo and Shuttle have used open loop life support. As mission length increases, greater system closure and increased recycling become more cost-effective.Closure can be gradually increased, first recycling humidity condensate, then hygiene wastewater, urine, carbon dioxide, and water recovery brine. A long term space station or planetary base could implement nearly full closure, including food production. Dynamic systems theory supports the axioms by showing that fewer requirements, fewer subsystems, and fewer interconnections all increase system stability. If systems are too complex and interconnected, reliability is reduced and operations and maintenance become more difficult. Using axiomatic design shows how the mission duration and other requirements determine the best life support system design including the degree of closure.

Axiomatic design↗

NASA NTRS2017

NASA's In-Space Manufacturing Project: A Roadmap for a Multimaterial Fabrication Laboratory in Space

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities (2014-2017), and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The presentation provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. In 2017, the in-space manufacturing project issued a broad agency announcement for this capability. Requirements of the Fabrication Laboratory as stated in the solicitation will be discussed. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into future exploration capabilities. Key data from ISM projects to date will also be summarized.

Prater, Tracie↗

NASA NTRS2011

Performance of the Three-Stage ADR that Provides Cooling of the Soft X-Ray Spectrometer Aboard Astro-H

The requirements levied upon the cooling system for the soft X-ray spectrometer (SXS) aboard the Astro-H satellite are demanding: Provide an operating temperature of 0.050 degrees Kelvin for a minimum of 24 hours, recycle in less than 2 hours (less than 1 hour in some cases), produce a dipole moment of less than 10 amperes per square meter at the detector location, and do all this with a mass less than 15 kilograms. This is further complicated by the availability of both a 1.3 degrees Kelvin helium bath and a 4.5 degrees Kelvin JT (Joule-Thomson) cooler to recycle the refrigerator. Here we detail the performance of the adiabatic demagnetization refrigerator (ADR) built specifically for SXS that is capable of meeting, and often significantly exceeding, the requirements placed upon it.

Kimball, Mark 0.↗

NASA NTRS2018

A Discussion of Integrated Life Support and In Situ Resource Utilization Architectures for Mars Surface Missions

Life support on the International Space Station is made possible by a combination of technologies to ensure the availability of clean water and air for the crew. Resources, including water and oxygen, are partially recovered and recycled; the balance is lost as waste either to space or incinerated during reentry into Earth's atmosphere. Frequent resupply cargo is provided to ISS to replace these lost resources. For missions beyond Low Earth Orbit, resupply becomes increasingly challenging both economically and logistically. To limit the need for these resupply missions, three options are available: increase the recovery and recycling of necessary materials, leverage in situ resources available for a given mission, or a combination of both. Here we discuss several basic life support and in situ resource utilization (ISRU) architectures, identify common technologies, propose possible integrated architectures, identify benefits of and challenges to varying levels of life support and ISRU integration, and discuss several considerations for technology commonality, dis-similar redundancy, and developmental overlap.

Abney, Morgan B.↗

NASA NTRS2018

Sabatier System Design Study for a Mars ISRU Propellant Production Plant

As NASA looks towards human missions to Mars, an effort has started to advance the technology of a Mars in situ resource utilization (ISRU) Propellant Production Plant to a flight demonstration. This paper will present a design study of the Sabatier subsystem. The Sabatier subsystem receives carbon dioxide, CO2, and hydrogen, H2, and converts them to methane, CH4, and water, H2O. The subsystem includes the Sabatier reactor, condenser, thermal management, and a recycling system (if required). This design study will look at how the choice of reactor thermal management, number of reactors, and recycling system affect the performance of the overall Sabatier system. Different schemes from the literature involving single or cascading reactors will be investigated to see if any provide distinct advantages for a Mars propellant production plant.

Hintze, Paul E.↗

NASA NTRS2018

Aiding in the Efforts of Bioregenerative Life Support for the Future Residents of Mars and Long-Duration Space Flights Plant Growth in Amended Martian Regolith Simulant

Currently, the goal of plant growth research at KSC (Kennedy Space Center) is to provide a sustainable source of healthy food on long-duration space flights so astronauts and future residents of Mars can get the nutrition they need and produce food, recycle the atmosphere, and aid in recycling water. The sustainable production of food will aid in the efforts of closed life support. Plants have a vital application for bioregenerative life support as demands for food and oxygen can be provided through photosynthesis, while the carbon dioxide from human respiration is removed. In order for a growing medium to provide for plant growth, it needs to provide support, oxygen, ions, and liquid to the plant. This summer research determines how amended Martian regolith simulant acts as a growing medium for plants through looking at the structural properties of each amendment. Mars is covered with regolith which is crushed volcanic rock that is composed of a high amount of perchlorate salts. The composition of Martian soil is such that it is roughly basaltic and consists of sulfur, nitrates, and oxychlorine species. Martian regolith simulants have been generated to further analyze plant growth and aim to replicate features of the reference sample. The JSC (Johnson Space Center) Mars-1A regolith simulant resembles Martian regolith at the Viking I landing site. The objectives of the research this summer at Kennedy Space Center are to devise a plant growth in amended JSC Mars-1A Martian regolith simulant and perform crop studies to assess the performance of full duration crop growth in amended Martian regolith simulant. This research will provide a deeper understanding of how the combination of soil amendments to Martian regolith has a synergistic effect on improving crop production The plant growth experiment will be completed with three treatments each containing inorganic and organic soil amendments.

Onsay, Daphne↗

NASA NTRS2018

NASA's In-Space Manufacturing Project: Toward a Multimaterial Fabrication Laboratory for the International Space Station

uman space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities, and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The paper provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into FabLab exploration capabilities as well.

Prater, Tracie↗

NASA NTRS2019

Cost-Effective High Reliability for Space Life Support Requires Using Storage

Cost-effective high reliability can be achieved in future space life support systems through careful systems analysis and design. This paper outlines a comprehensive approach. Potential future human space missions are described. The mission parameter impacts on life support system design and reliability requirements are discussed. Not all human space missions require high reliability life support. The potential reliability and cost of storage and of recycling life support systems are investigated. Simple storage systems can provide cost-effective high reliability life support where it is needed. More complex recycling systems with lower reliability and higher cost can be used when suitable.

Jones, Harry W.↗

NASA NTRSDate not supplied

In-Space Manufacturing and Planetary Surface Construction: A "Make It, Don't Take It" Approach to Long Duration Human Exploration

This presentation will focus on technology development efforts at NASA Marshall Space Flight Center (MSFC) related to the long term sustainability of human spaceflight operations. NASA’s in-space manufacturing (ISM) project is developing approaches for on-demand manufacturing of metals, printed electronics, and recycling. These technologies will be demonstrated onboard the International Space Station (ISS) before transitioning to more logistically remote platforms such as Gateway or a foundational lunar surface habitat. Based on quantitative analyses, the operations and logistics approach used for ISS (which relies on storage of a large volume of spares and frequent cargo resupply), will not be transferrable to long duration, long endurance missions beyond low earth orbit. The deployment of manufacturing and recycling technologies on crewed platforms will enable on-demand manufacturing of spares at the point of use and conversion of nuisance materials to manufacturing feedstock, reducing both launch mass and waste material. This talk will also include information on NASA’s 3D Printed Habitat Centennial Challenge, which concluded in 2019 and served to advance the state of the art for large scale 3D printing with indigenous materials similar to those which would be available on a planetary surface. MSFC also recently began work on the Moon-to-Mars Planetary Autonomous Construction Technologies (MMPACT) project, which seeks to demonstrate capabilities for the creation of infrastructure on the lunar surface via construction of landing pads and habitats with lunar regolith based materials.

materials↗

NASA NTRS2020

Aquatic Invertebrate Protein Sources for Long-Duration Space Travel

During the summer of 2020, NASA returned to launching astronauts to the International Space Station (ISS) from American soil. By 2024, NASA’s mission is to return to the Moon, and by 2028 create a sustainable presence. Long duration missions come with obstacles, especially when trying to create a sustainable environment in a location where “living off the land” is impossible. Some resources on the Moon can be recovered or resupplied; however, many resources such as those needed for sustaining life must be recycled or grown to support humans. To achieve sustainability, food and water must be grown and recycled using elements found within the habitat. NASA’s current work focuses on food resupply and growing plants as supplemental nutrient content. This paper examines the possibility for using aquaculture systems to purify water while growing nutrient-rich species as food sources, which aquatic food sources would be ideal for a habitat environment, and which species might provide an ideal test case for future studies aboard ISS. The aquatic species should be rapidly grown with high protein content and low launch mass requirements. Although there are numerous challenges and unknown technology gaps for maintaining aquaculture systems in reduced gravity environments, the benefit of employing such systems would be of great advantage towards creating a sustainable presence beyond Earth’s orbit for sustainable aquaculture.

Aquaculture↗

NASA NTRSDate not supplied

Metrics in Space Life Support Technology Selection

Engineering metrics are useful in space life support technology selection, but they must be carefully used. Metrics are only part of a complete system trade-off. Metrics do harm if they cause neglect of other important technical, organizational, or intuitive decision factors. Two metrics have damaged space life support, closure and Equivalent Systems Mass (ESM). Closure measures the fraction of the required system inputs that are produced by recycling system outputs. Increasing closure produces diminishing returns and becomes increasingly expensive. Increasing closure does not directly contribute to providing better life support. ESM measures the total launch mass required to provide life support. ESM includes the mass of the system hardware and of its power, cooling, pressurized volume, spares, and logistics. ESM predicts launch costs, but recently launch costs have been reduced by a factor of 20 or more. System development cost for space hardware is often much greater than launch cost. The past nearly exclusive use of ESM has led to the neglect of Life Cycle Cost (LCC), reliability, cost, and the other engineering factors. Closure and ESM have misguided space life support technology selection for more than twenty years and have adversely affected the expenditure of 100’s of millions of dollars. Metrics can be effectively used three ways in space life support technology selection: 1. A small set of key engineering metrics for preliminary screening. 2. A full set of engineering to guide technical selection. 3. Combining engineering metrics with organizational, political, and intuitive decision factors to understand technology selection. The past emphasis on closure and ESM served to support recycling life support over resupply and built on the intuitive appeal of a human ecosystem in space.

Harry W Jones↗

NASA NTRSDate not supplied

Managing spacecraft waste

Waste is a universal problem, on Earth, in spacecraft, and for any closed ecological system. Waste must be processed and is often recycled to recover resources. Many different approaches and technologies are used. Spacecraft waste is derived from the spacecraft logistics supplies, the materials provided for use by the crew. The composition of spacecraft logistics and the resulting waste depend on the mission and its duration and use of recycling. Spacecraft waste is a more serious problem on long duration missions because of the large logistics supplies consumed and the difficulty of storing or disposing of waste. The quantity and composition of waste can vary and may require flexible management. Most missions will produce about two kilograms per crewmember per day of trash, consisting of food waste, plastic, paper, packaging, hygiene wipes and many other supplies used and discarded by the crew. The waste is bulky, messy and difficult to store since the wet waste can decompose and produce odors and an accumulation of pathogenic bacteria. Many different methods have been proposed for managing spacecraft waste.

Harry W Jones↗

NASA NTRSDate not supplied

Impact of Powder Supply Variation on Mechanical Properties for Additive Manufacture of Alloy 718

The Additive Manufacturing Structural Integrity Initiative (AMSII) examined how a number of different Alloy 718 powder lots can create variation in microstructure and mechanical properties in parts fabricated using Laser Powder Bed Fusion. Being a common alloy, Alloy 718 powder can be found in a variety of compositions, fabrication techniques, and powder size distribution. Sixteen virgin powders, and three recycled powders were used to build samples for microstructure analysis, fatigue and tensile testing. The major impacts of the different powders manifested in variations in the microstructure, such as minor phases and grain size variation. There were corresponding variations in mechanical properties. A down-selection of powders were chosen for additional analysis, and a powder recyclability study was completed to look at the effect of reused powder.

Alloy 718↗

NASA NTRSDate not supplied

The Effective Use of Metrics in Space Life Support System Trade-Offs

Harry W. Jones↗

NASA NTRS2020

Gravitational-Wave Constraints on the Equatorial Ellipticity of Millisecond Pulsars

We present a search for continuous gravitational waves from five radio pulsars, comprising three recycled pulsars (PSR J0437−4715, PSR J0711−6830, and PSR J0737−3039A) and two young pulsars: the Crab pulsar (J0534+2200) and the Vela pulsar (J0835−4510). We use data from the third observing run of Advanced LIGO and Virgo combined with data from their first and second observing runs. For the first time, we are able to match (for PSR J0437−4715) or surpass (for PSR J0711−6830) the indirect limits on gravitational-wave emission from recycled pulsars inferred from their observed spin-downs, and constrain their equatorial ellipticities to be less than 10−8. For each of the five pulsars, we perform targeted searches that assume a tight coupling between the gravitational-wave and electromagnetic signal phase evolution. We also present constraints on PSR J0711−6830, the Crab pulsar, and the Vela pulsar from a search that relaxes this assumption, allowing the gravitational-wave signal to vary from the electromagnetic expectation within a narrow band of frequencies and frequency derivatives.

R Abbott↗