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Structures and materials technology issues for reusable launch vehicles

Projected space missions for both civil and defense needs require significant improvements in structures and materials technology for reusable launch vehicles: reductions in structural weight compared to the Space Shuttle Orbiter of up to 25% or more, a possible factor of 5 or more increase in mission life, increases in maximum use temperature of the external surface, reusable containment of cryogenic hydrogen and oxygen, significant reductions in operational costs, and possibly less lead time between technology readiness and initial operational capability. In addition, there is increasing interest in hypersonic airbreathing propulsion for launch and transmospheric vehicles, and such systems require regeneratively cooled structure. The technology issues are addressed, giving brief assessments of the state-of-the-art and proposed activities to meet the technology requirements in a timely manner.

Dixon, S. C.↗

Structures and materials technology issues for reusable launch vehicles

Projected space missions for both civil and defense needs require significant improvements in structures and materials technology for reusable launch vehicles: reductions in structural weight compared to the Space Shuttle Orbiter of up to 25 percent or more, a possible factor of 5 or more increase in mission life, increases in maximum use temperature of the external surface, reusable containment of cryogenic hydrogen and oxygen, significant reductions in operational costs, and possibly less lead time between technology readiness and initial operational capability. In addition, there is increasing interest in hypersonic airbreathing propulsion for launch and transmospheric vehicles, and such systems require regeneratively cooled structure. The technology issues are addressed, giving brief assessments of the state-of-the-art and proposed activities to meet the technology requirements in a timely manner.

Dixon, S. C.↗

Comments on the MIT Assessment of the Mars One Plan

The MIT assessment of the Mars One mission plan reveals design assumptions that would cause significant difficulties. Growing crops in the crew chamber produces excessive oxygen levels. The assumed in-situ resource utilization (ISRU) equipment has too low a Technology Readiness Level (TRL). The required spare parts cause a large and increasing launch mass logistics burden. The assumed International Space Station (ISS) Environmental Control and Life Support (ECLS) technologies were developed for microgravity and therefore are not suitable for Mars gravity. Growing food requires more mass than sending food from Earth. The large number of spares is due to the relatively low reliability of ECLS and the low TRL of ISRU. The Mars One habitat design is similar to past concepts but does not incorporate current knowledge. The MIT architecture analysis tool for long-term settlements on the Martian surface includes an ECLS system simulation, an ISRU sizing model, and an analysis of required spares. The MIT tool showed the need for separate crop and crew chambers, the large spare parts logistics, that crops require more mass than Earth food, and that more spares are needed if reliability is lower. That ISRU has low TRL and ISS ECLS was designed for microgravity are well known. Interestingly, the results produced by the architecture analysis tool - separate crop chamber, large spares mass, large crop chamber mass, and low reliability requiring more spares - were also well known. A common approach to ECLS architecture analysis is to build a complex model that is intended to be all-inclusive and is hoped will help solve all design problems. Such models can struggle to replicate obvious and well-known results and are often unable to answer unanticipated new questions. A better approach would be to survey the literature for background knowledge and then directly analyze the important problems.

Mars mission↗

Characterization and Measurement of Spacecraft Airborne Particulate Matter

The International Space Station (ISS) gives a 6-member astronaut crew the ability to live and work in low Earth orbit. It is a unique indoor environment, which has served as both home and workplace to over 230 people since the year 2000. In this low gravity environment, smoke does not rise and cookie crumbs do not settle the way they do on Earth, causing airborne particulate matter, or aerosols, to behave differently and pose unique hazards for crew members. In its existence, virtually the same volume of ISS air has been continuously conditioned and ‘revitalized,’ including the removal of particles by filtration. While gaseous constituents of ISS air are monitored meticulously, sparse data exists on the indoor aerosols. The quantity and types of ISS airborne debris have been investigated in NASA’s Aerosol Sampling Experiment. Both active and passive samplers successfully collected airborne particulate matter in U.S. segments of the ISS, which were returned to Earth for characterization by microscopy and other techniques. The resulting data has informed the design of candidate particle instruments for spacecraft. In 2020, a reference-quality aerosol instrument will be flown to ISS, and will provide real-time data of particle concentrations in various modules. Smaller, more compact instruments will be necessary in future space missions, for example, in smaller vehicles, in habitats on lunar and planetary surfaces with ubiquitous dust, and also for use as wearable technology throughout missions. Miniaturized aerosol sensors, though lower fidelity than reference-quality instruments, can monitor the environment well when calibrated appropriately. Indoor air quality in spacecraft is fundamentally important to human health and comfort, and several particulate monitoring technologies will be at sufficient technology readiness levels for operational use within the next two years. Results of the Aerosol Sampling Experiment will be presented, along with the status of NASA’s aerosol instrument technology demonstrations on ISS.

Meyer, Marit E.↗

"ATLAS" Advanced Technology Life-cycle Analysis System

Making good decisions concerning research and development portfolios-and concerning the best systems concepts to pursue - as early as possible in the life cycle of advanced technologies is a key goal of R&D management This goal depends upon the effective integration of information from a wide variety of sources as well as focused, high-level analyses intended to inform such decisions Life-cycle Analysis System (ATLAS) methodology and tool kit. ATLAS encompasses a wide range of methods and tools. A key foundation for ATLAS is the NASA-created Technology Readiness. The toolkit is largely spreadsheet based (as of August 2003). This product is being funded by the Human and Robotics The presentation provides a summary of the Advanced Technology Level (TRL) systems Technology Program Office, Office of Exploration Systems, NASA Headquarters, Washington D.C. and is being integrated by Dan O Neil of the Advanced Projects Office, NASA/MSFC, Huntsville, AL

Lollar, Louis F.↗

Segmented X-Ray Optics for Future Space Telescopes

Lightweight and high resolution mirrors are needed for future space-based X-ray telescopes to achieve advances in high-energy astrophysics. The slumped glass mirror technology in development at NASA GSFC aims to build X-ray mirror modules with an area to mass ratio of approx.17 sq cm/kg at 1 keV and a resolution of 10 arc-sec Half Power Diameter (HPD) or better at an affordable cost. As the technology nears the performance requirements, additional engineering effort is needed to ensure the modules are compatible with space-flight. This paper describes Flight Mirror Assembly (FMA) designs for several X-ray astrophysics missions studied by NASA and defines generic driving requirements and subsequent verification tests necessary to advance technology readiness for mission implementation. The requirement to perform X-ray testing in a horizontal beam, based on the orientation of existing facilities, is particularly burdensome on the mirror technology, necessitating mechanical over-constraint of the mirror segments and stiffening of the modules in order to prevent self-weight deformation errors from dominating the measured performance. This requirement, in turn, drives the mass and complexity of the system while limiting the testable angular resolution. Design options for a vertical X-ray test facility alleviating these issues are explored. An alternate mirror and module design using kinematic constraint of the mirror segments, enabled by a vertical test facility, is proposed. The kinematic mounting concept has significant advantages including potential for higher angular resolution, simplified mirror integration, and relaxed thermal requirements. However, it presents new challenges including low vibration modes and imperfections in kinematic constraint. Implementation concepts overcoming these challenges are described along with preliminary test and analysis results demonstrating the feasibility of kinematically mounting slumped glass mirror segments.

McClelland, Ryan S.↗

NASA Environmental Control and Life Support Technology Development for Exploration: 2021 to 2022 Overview

Over the past year, significant progress has occurred in technology development, ground testing, and ISS technology demonstrations within the NASA Environmental Control and Life Support (ECLSS) community. This paper provides a technology development update in the following capability areas: life support, environmental monitoring, fire safety, and logistics. Technologies for exploration missions must be reliable in their operation which support crewed mission phases. However, they also need to be put into a reduced use or dormant states to support uncrewed mission phases and then successfully and reliably returned to a nominal state to support crew. Multi-year demonstration of systems operation across this range of conditions are essential to mission success. Project overviews will include how the current activity supports the goal of multi-year demonstrations, planned follow-on activities, and what type of exploration mission elements are targeted for infusion. Technologies must be demonstrated and validated early enough to inform early exploration element milestone reviews (mission concept reviews, systems requirement reviews and no later than preliminary design reviews) so that supporting vehicle systems can also be matured. Consequently, for low technology readiness activities, it is important to also identify which mission elements they might infuse into and how they may offer potential operational, dormancy, or mass benefits. While low TRL technology timelines may not support initial mission needs, early infusion is still reasonable with sufficient testing to validate performance and reliability.

Life Support↗

Airframe Technology Development for Next Generation Launch Vehicles

The Airframe subproject within NASA's Next Generation Launch Technology (NGLT) program has the responsibility to develop airframe technology for both rocket and airbreathing vehicles for access to space. The Airframe sub-project pushes the state-of-the-art in airframe technology for low-cost, reliable, and safe space transportation. Both low and medium technology readiness level (TRL) activities are being pursued. The key technical areas being addressed include design and integration, hot and integrated structures, cryogenic tanks, and thermal protection systems. Each of the technologies in these areas are discussed in this paper.

Glass, David E.↗

Using System Mass (SM), Equivalent Mass (EM), Equivalent System Mass (ESM) or Life Cycle Mass (LCM) in Advanced Life Support (ALS) Reporting

The Advanced Life Support (ALS) has used a single number, Equivalent System Mass (ESM), for both reporting progress and technology selection. ESM is the launch mass required to provide a space system. ESM indicates launch cost. ESM alone is inadequate for technology selection, which should include other metrics such as Technology Readiness Level (TRL) and Life Cycle Cost (LCC) and also consider perfom.arxe 2nd risk. ESM has proven difficult to implement as a reporting metric, partly because it includes non-mass technology selection factors. Since it will not be used exclusively for technology selection, a new reporting metric can be made easier to compute and explain. Systems design trades-off performance, cost, and risk, but a risk weighted cost/benefit metric would be too complex to report. Since life support has fixed requirements, different systems usually have roughly equal performance. Risk is important since failure can harm the crew, but it is difficult to treat simply. Cost is not easy to estimate, but preliminary space system cost estimates are usually based on mass, which is better estimated than cost. Amass-based cost estimate, similar to ESM, would be a good single reporting metric. The paper defines and compares four mass-based cost estimates, Equivalent Mass (EM), Equivalent System Mass (ESM), Life Cycle Mass (LCM), and System Mass (SM). EM is traditional in life support and includes mass, volume, power, cooling and logistics. ESM is the specifically defined ALS metric, which adds crew time and possibly other cost factors to EM. LCM is a new metric, a mass-based estimate of LCC measured in mass units. SM includes only the factors of EM that are originally measured in mass, the hardware and logistics mass. All four mass-based metrics usually give similar comparisons. SM is by far the simplest to compute and easiest to explain.

Jones, Harry↗

NASA's UAS NAS Access Project

The vision of the Unmanned Aircraft System (UAS) Integration in the National Airspace System (NAS) Project is "A global transportation system which allows routine access for all classes of UAS." The goal of the UAS Integration in the NAS Project is to "contribute capabilities that reduce technical barriers related to the safety and operational challenges associated with enabling routine UAS access to the NAS." This goal will be accomplished through a two-phased approach based on development of system-level integration of key concepts, technologies and/or procedures, and demonstrations of integrated capabilities in an operationally relevant environment. Phase 1 will take place the first two years of the Project and Phase 2 will take place the following three years. The Phase 1 and 2 technical objectives are: Phase 1: Developing a gap analysis between current state of the art and the Next Generation Air Transportation System (NextGen) UAS Concept of Operations . Validating the key technical areas identified by this Project . Conducting initial modeling, simulation, and flight testing activities . Completing Sub-project Phase 1 deliverables (spectrum requirements, comparative analysis of certification methodologies, etc.) and continue Phase 2 preparation (infrastructure, tools, etc.) Phase 2: Providing regulators with a methodology for developing airworthiness requirements for UAS, and data to support development of certifications standards and regulatory guidance . Providing systems-level, integrated testing of concepts and/or capabilities that address barriers to routine access to the NAS. Through simulation and flight testing, address issues including separation assurance, communications requirements, and human systems integration in operationally relevant environments. The UAS in the NAS Project will demonstrate solutions in specific technology areas, which will address operational/safety issues related to UAS access to the NAS. Since the resource allocation for this Project is limited ($150M over the five years), the focus is on reducing the technical barriers where NASA has unique capabilities. As a result, technical areas, such as Sense and Avoid (SAA) and beyond line of sight command and control will not be addressed. While these are critical barriers to UAS access, currently, there is a great deal of global effort being exercised to address these challenge areas. Instead, specific technology development in areas where there is certainty that NASA can advance the research to high technology readiness levels will be the Project's focus. Specific sub-projects include Separation Assurance, Human Systems Integration, Communications, Certification, and Integrated Test and Evaluation. Each sub-project will transfer technologies to relevant key stakeholders and decision makers through research transition teams, technology forums, or through other analogous means.

Johnson, Charles W.↗

NASA electric propulsion program

Major portions of the NASA electric propulsion technology program have attained the level of maturity required to achieve near-term technology readiness for flight missions for primary and auxiliary propulsion application. Advanced electric propulsion program elements addressing less immediate requirements are in more exploratory stages. This paper will discuss the NASA electric propulsion technology program including - planetary and earth orbit raising applications, attitude control and stationkeeping of geosynchronous satellites, and the research support program. Objectives, requirements, and hardware status are presented for each program.

Hudson, W. R.↗

Readiness levels for spacecraft information technologies

Presented in this paper is a modified interpretation of the traditional TRLs aimed solely at information technology. The intent of this new set of definitions is twofold: First, to enable a definitive measurement of progress among developing information technologies for spacecraft; and second, to clarify particular challenges and requirements that must be met as these technologies are validated in increasingly realistic environments.

technology readiness levels spacecraft information↗

Solar Sail Model Validation from Echo Trajectories

The NASA In-Space Propulsion program has been engaged in a project to increase the technology readiness of solar sails. Recently, these efforts came to fruition in the form of several software tools to model solar sail guidance, navigation and control. Furthermore, solar sails are one of five technologies competing for the New Millennium Program Space Technology 9 flight demonstration mission. The historic Echo 1 and Echo 2 balloons were comprised of aluminized Mylar, which is the near-term material of choice for solar sails. Both spacecraft, but particularly Echo 2, were in low Earth orbits with characteristics similar to the proposed Space Technology 9 orbit. Therefore, the Echo balloons are excellent test cases for solar sail model validation. We present the results of studies of Echo trajectories that validate solar sail models of optics, solar radiation pressure, shape and low-thrust orbital dynamics.

Heaton, Andrew F.↗

Design of an Excavation Robot: Regolith Advanced Surface Systems Operations Robot (RASSOR) 2.0

To continue on a sustainable and flexible path, NASA needs to address the challenge of collecting and moving large amounts of regolith at the destination. Acquiring the water resources on Mars will require mining significant quantities of regolith and this is not possible with the state-of-the-art low mass excavation systems. Low gravity environments (Mars = 3/8 G) and launch mass restrictions limit the traction and the resulting reaction force of the vehicle, making current terrestrial techniques impractical. This project addressed this challenge by developing a completely new technology that can mine large quantities of regolith on Mars. Recent measurements by the “Curiosity” rover on Mars have found that the regolith contains ~ 2% water by weight globally, ~4% in Jezero Crater (Human Architecture Team’s reference landing site), and much more at the poles(Leshin et al, 2013). RASSOR 2.0 is a planetary excavator, which has a mass of 66 kg, with a 0.38 kg vehicle mass per kilogram, per hour of excavation rate and power usage of 4 W per kg of regolith excavation rate. A single RASSOR 2.0 can excavate a minimum of 2.7 metric tons of regolith per day.This is accomplished by using counteracting excavation forces on two opposing digging implements called bucket drums and an autonomous mining control system. This work has addressed several major research areas outlined in the NASA Technology Area (TA) 04 Robotics & Autonomous Systems and TA 07 Human Destination Systems roadmaps. This project started at Technology Readiness Level (TRL) 4 as a low fidelity “proof of concept” prototype which has successfully demonstrated basic regolith simulant excavation functionality in a lab-scale gravity off load test. The foundational technology described here was awarded US patent number: US 9027265 for a “Zero horizontal reaction force excavator” on May 12, 2015.

RASSOR↗

Brief state-of-the-art review on optical communications for the NASA ISES workshop

The current state of the art of optical communications is briefly reviewed. This review covers NASA programs, DOD and other government agency programs, commercial aerospace programs, and foreign programs. Included is a brief summary of a recent NASA workshop on optical communications. The basic conclusions from all the program reviews is that optical communications is a technology ready to be accepted but needed to be demonstrated. Probably the most advanced and sophisticated optical communications system is the Laser Intersatellite Transmission Experiment (LITE) system developed for flight on the Advanced Communications Technology Satellite (ACTS). Optical communications technology is available for the applications of data communications at data rates in the under 300 MBits/sec for nearly all applications under 2 times GEO distances. Applications for low-earth orbiter (LEO) to ground will allow data rates in the multi-GBits/sec range. Higher data rates are limited by currently available laser power. Phased array lasers offer technology which should eliminate this problem. The major problem of cloud coverage can probably be eliminated by look ahead pointing, multiple ground stations, and knowledge of weather conditions to control the pointing. Most certainly, optical communications offer a new spectral region to relieve the RF bands and very high data communications rates that will be required in less than 10 years to solve the communications problems on Earth.

Hendricks, Herbert D.↗

Mars Sample Return: Grand Challenge for EDL

A year ago, I gave a talk in anticipation of a Mars Sample Return effort at the 9th Ablation Workshop. Since then a lot has happened. "April of this year, after a year of study phase, NASA and ESA (European Space Agency) signed a Statement of Intent (SOI) to jointly develop a Mars Sample Return plan to be submitted to their respective authorities by the end of 2019. This signing is historic, as it signals the desire, the readiness, and the willingness to work together to execute this inspiring mission, we all have the opportunity to tackle this grand challenge. We have the scientific and engineering maturity to identify the critical technologies ready to be applied, and with discipline this campaign can be executed affordably," Jim Watzin, Mars Program Executive, NASA. NASA Centers with JPL (Jet Propulsion Laboratory) leading the charge is in the midst of a pre-formulation phase for executing a Mars Sample Return before the end of next decade. The proposed talk builds on the previous year talk. In light of the agreement between NASA and ESA, NASA has assumed the responsibilities for developing the earth entry vehicle (EEV) that will fly along with a European Spacecraft and return with the sample from Mars. EEV will be deployed for entry into earth. The EEV design, development, testing and certification have to result in a highly reliable sample return system. The entire architecture has to be demonstrated to meet the planetary protection requirement. NASA is considering two distinctly different earth entry vehicle architectures and with each choice, many different ablative TPS (Thermal Protective Shield) candidates. As a result of the NASA-ESA ongoing studies, some of the key entry conditions and design requirements are better understood today and more are being scoped out. The heat-shield ablative TPS choice need to be done with a good understanding as it plays a very significant role in determining the robustness of the EEV. Knowledge about how materials and system perform, and how the features could become flaws and how flaws lead to failure, etc. need to be clearly understood and the knowledge then need to be used to down select the TPS. This proposed talk will provide greater insight into the progress being made and the challenges that need to be tackled.

Mars Sample Return: Grand Challenge for EDL↗

A Decade of NASA Strategic Astrophysics Technology Investments: Technology Maturation, Infusion, and Other Benefits

NASA’s Astrophysics Division (APD) funds development of cutting-edge technology to enable its missions to achieve ambitious and groundbreaking science goals. These technology development efforts are managed by the Physics of the Cosmos (PCOS), Cosmic Origins (COR), and Exoplanet Exploration (ExE) Programs. The NASA Strategic Astrophysics Technology (SAT) Program was established in 2009 as a new technology maturation program to fill the gap in the Technology Readiness Level (TRL) range from 3 to 6. Since program inception, 100 SAT grants have been openly competed and awarded, along with dozens of direct-funded projects, leading to a host of technologies advancing their TRLs and/or being infused into space and suborbital missions and ground-based projects. We present the portfolio distribution in terms of specific technology areas addressed, including optics, detectors, coatings, coronagraphs, starshades, lasers, electronics, cooling systems, and micro-thruster subsystems. We show an analysis of the rate of TRL advances, infusion success stories, and other benefits such as training the future astrophysics workforce, including students and postdoctoral fellows hired by projects. Finally, we present APD’s current strategic technology maturation priorities for investment, enabling a range of future strategic astrophysics missions

NASA, astrophysics, technology development, optics↗

Considerations For Waste-to-Base Future Research Paths

Developing innovative technologies to reprocess low value waste into high value base products will enable a new “Waste-to-Base” (WtB) capability leading to innovative approaches to space mission design. Systems engineers and mission architects will work together under a new paradigm in logistics planning. Equipment, components, packaging, storage, and structures will be understood not only by functional requirements, but also in terms of useful lifetimes and materials of construction. The advent of a new technical discipline - reprocess engineering - will grow from the intersection between chemical, mechanical, and systems engineering, mission design, and logistics planning. A crowdsourcing approach was employed to gather low Technology Readiness Level (TRL) concepts into workable solutions for issues in trash management, CO2 processing, foam reprocessing, and fecal processing. The results of the crowdsourcing activities are summarized along with a discussion for future technology development work.

Logistics reduction↗