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NASA NTRS2012

Robotic Manufacturing of 5.5 Meter Cryogenic Fuel Tank Dome Assemblies for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration's (NASA's) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA), the common bulkhead manufacturing development articles (CBMDA) and the thermal protection system demonstration dome (TPS Dome). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminumlithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. An overview of the manufacturing processes will be discussed. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) and the TPS Dome will also be highlighted. Each CBMDA and the TPS Dome consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. The TPS Dome has an additional aluminum alloy 2195 barrel section welded to the y-ring. Manufacturing solutions will be discussed including "fixtureless" welding with self reacting friction stir welding.

Jones, Ronald E.↗

NASA NTRS2012

Manufacturing of 5.5 Meter Diameter Cryogenic Fuel Tank Domes for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration s (NASA s) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA) and the common bulkhead manufacturing development articles (CBMDA). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminum-lithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. Manufacturing solutions will be discussed including the implementation of photogrammetry, an advanced metrology technique, as well as fixtureless welding. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) will also be highlighted. Each CBMDA consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. An overview of CBMDA manufacturing processes and the effect of tooling on weld defect formation will be discussed.

Jones, Ronald E.↗

NASA NTRS2012

An Analysis of Shuttle Crew Scheduling Violations

From the early years of the Space Shuttle program, National Aeronautics and Space Administration (NASA) Shuttle crews have had a timeline of activities to guide them through their time on-orbit. Planners used scheduling constraints to build timelines that ensured the health and safety of the crews. If a constraint could not be met it resulted in a violation. Other agencies of the federal government also have scheduling constraints to ensure the safety of personnel and the public. This project examined the history of Space Shuttle scheduling constraints, constraints from Federal agencies and branches of the military and how these constraints may be used as a guide for future NASA and private spacecraft. This was conducted by reviewing rules and violations with regard to human aerospace scheduling constraints, environmental, political, social and technological factors, operating environment and relevant human factors. This study includes a statistical analysis of Shuttle Extra Vehicular Activity (EVA) related violations to determine if these were a significant producer of constraint violations. It was hypothesized that the number of SCSC violations caused by EVA activities were a significant contributor to the total number of violations for Shuttle/ISS missions. Data was taken from NASA data archives at the Johnson Space Center from Space Shuttle/ISS missions prior to the STS-107 accident. The results of the analysis rejected the null hypothesis and found that EVA violations were a significant contributor to the total number of violations. This analysis could help NASA and commercial space companies understand the main source of constraint violations and allow them to create constraint rules that ensure the safe operation of future human private and exploration missions. Additional studies could be performed to evaluate other variables that could have influenced the scheduling violations that were analyzed.

Bristol, Douglas↗

NASA NTRS2013

Fall 2012 Graduate Engineering Internship Summary

In the fall of 2012, I participated in the National Aeronautics and Space Administration (NASA) Pathways Intern Employment Program at the Kennedy Space Center (KSC) in Florida. This was my second internship opportunity with NASA, a consecutive extension from a summer 2012 internship. During my four-month tenure, I gained valuable knowledge and extensive hands-on experience with payload design and testing as well as composite fabrication for repair design on future space vehicle structures. As a systems engineer, I supported the systems engineering and integration team with the testing of scientific payloads such as the Vegetable Production System (Veggie). Verification and validation (V&V) of the Veggie was carried out prior to qualification testing of the payload, which incorporated a lengthy process of confirming design requirements that were integrated through one or more validatjon methods: inspection, analysis, demonstration, and testing. Additionally, I provided assistance in verifying design requirements outlined in the V&V plan with the requirements outlined by the scientists in the Science Requirements Envelope Document (SRED). The purpose of the SRED was to define experiment requirements intended for the payload to meet and carry out.

Ehrlich, Joshua↗

NASA NTRS2013

Spring 2013 Graduate Engineering Internship Summary

In the spring of 2013, I participated in the National Aeronautics and Space Administration (NASA) Pathways Intern Employment Program at the Kennedy Space Center (KSC) in Florida. This was my final internship opportunity with NASA, a third consecutive extension from a summer 2012 internship. Since the start of my tenure here at KSC, I have gained an invaluable depth of engineering knowledge and extensive hands-on experience. These opportunities have granted me the ability to enhance my systems engineering approach in the field of payload design and testing as well as develop a strong foundation in the area of composite fabrication and testing for repair design on space vehicle structures. As a systems engineer, I supported the systems engineering and integration team with final acceptance testing of the Vegetable Production System, commonly referred to as Veggie. Verification and validation (V and V) of Veggie was carried out prior to qualification testing of the payload, which incorporated the process of confirming the system's design requirements dependent on one or more validation methods: inspection, analysis, demonstration, and testing.

Ehrlich, Joshua↗

NASA NTRS2013

Modeling Longitudinal Data Containing Non-Normal Within Subject Errors

The mission of the National Aeronautics and Space Administration’s (NASA) human research program is to advance safe human spaceflight. This involves conducting experiments, collecting data, and analyzing data. The data are longitudinal and result from a relatively few number of subjects; typically 10 – 20. A longitudinal study refers to an investigation where participant outcomes and possibly treatments are collected at multiple follow-up times. Standard statistical designs such as mean regression with random effects and mixed–effects regression are inadequate for such data because the population is typically not approximately normally distributed. Hence, more advanced data analysis methods are necessary. This research focuses on four such methods for longitudinal data analysis: the recently proposed linear quantile mixed models (lqmm) by Geraci and Bottai (2013), quantile regression, multilevel mixed–effects linear regression, and robust regression. This research also provides computational algorithms for longitudinal data that scientists can directly use for human spaceflight and other longitudinal data applications, then presents statistical evidence that verifies which method is best for specific situations. This advances the study of longitudinal data in a broad range of applications including applications in the sciences, technology, engineering and mathematics fields.

Feiveson, Alan↗

NASA NTRS2014

The ISRU Field Tests 2010 and 2012 at Mauna Kea, Hawaii: Results from the Miniaturised Mossbauer Spectrometers Mimos II and Mimos IIA

The 2010 and 2012 In-Situ Resource Utilization Analogue Test (ISRU) [1] on the Mauna Kea volcano in Hawai'i was coordinated by the Northern Centre for Advanced Technology (NORCAT) in collaboration with the Canadian Space Agency (CSA), the German Aerospace Center (DLR), and the National Aeronautics and Space Administration (NASA), through the PISCES program. Several instruments were tested as reference candidates for future analogue testing at the new field test site at the Mauna Kea volcano in Hawai'i. The fine-grained, volcanic nature of the material is a suitable lunar and martian analogue, and can be used to test excavation, site preparation, and resource utilization techniques. The 2010 location Pu'u Hiwahine, a cinder cone located below the summit of Mauna Kea (19deg45'39.29" N, 155deg28'14.56" W) at an elevation of ~2800 m, provides a large number of slopes, rock avalanches, etc. to perform mobility tests, site preparation or resource prospecting. Besides hardware testing of technologies and systems related to resource identification, also in situ science measurements played a significant role in integration of ISRU and science instruments. For the advanced Mössbauer instrument MIMOS IIA, the new detector technologies and electronic components increase sensitivity and performance significantly. In combination with the high energy resolution of the SDD it is possible to perform Xray fluorescence analysis simultaneously to Mössbauer spectroscopy. In addition to the Fe-mineralogy, information on the sample's elemental composition will be gathered. The 2010 and 2012 field campaigns demonstrated that in-situ Mössbauer spectroscopy is an effective tool for both science and feedstock exploration and process monitoring. Engineering tests showed that a compact nickel metal hydride battery provided sufficient power for over 12 hr of continuous operation for the MIMOS instruments.

Klingelhoefer, G.↗

NASA NTRS2016

The Geostationary Operational Satellite R Series SpaceWire Based Data System

The Geostationary Operational Environmental Satellite R-Series Program (GOES-R, S, T, and U) mission is a joint program between National Oceanic & Atmospheric Administration (NOAA) and National Aeronautics & Space Administration (NASA) Goddard Space Flight Center (GSFC). SpaceWire was selected as the science data bus as well as command and telemetry for the GOES instruments. GOES-R, S, T, and U spacecraft have a mission data loss requirement for all data transfers between the instruments and spacecraft requiring error detection and correction at the packet level. The GOES-R Reliable Data Delivery Protocol (GRDDP) [1] was developed in house to provide a means of reliably delivering data among various on board sources and sinks. The GRDDP was presented to and accepted by the European Cooperation for Space Standardization (ECSS) and is part of the ECSS Protocol Identification Standard [2]. GOES-R development and integration is complete and the observatory is scheduled for launch November 2016. Now that instrument to spacecraft integration is complete, GOES-R Project reviewed lessons learned to determine how the GRDDP could be revised to improve the integration process. Based on knowledge gained during the instrument to spacecraft integration process the following is presented to help potential GRDDP users improve their system designs and implementation.

Networks↗

NASA NTRS2016

Essential SpaceWire Hardware Capabilities for a Robust Network

The Geostationary Operational Environmental Satellite R-Series Program (GOES-R) mission is a joint program between National Oceanic & Atmospheric Administration (NOAA) and National Aeronautics & Space Administration (NASA) Goddard Space Flight Center (GSFC). GOES-R project selected SpaceWire as the best solution to satisfy the desire for simple and flexible instrument to spacecraft command and telemetry communications. GOES-R development and integration is complete and the observatory is scheduled for launch October 2016. The spacecraft design was required to support redundant SpaceWire links for each instrument side, as well as to route the fewest number of connections through a Slip Ring Assembly necessary to support Solar pointing instruments. The final design utilized two different router designs. The SpaceWire standard alone does not ensure the most practical or reliable network. On GOES-R a few key hardware capabilities were identified that merit serious consideration for future designs. Primarily these capabilities address persistent port stalls and the prevention of receive buffer overflows. Workarounds were necessary to overcome shortcomings that could be avoided in future designs if they utilize the capabilities, discussed in this paper, above and beyond the requirements of the SpaceWire standard.

SpaceWire↗

NASA NTRSDate not supplied

Overview of a NASA Centennial Challenges Prize Competition to Address Crew Nutritional Needs for Long-Duration Space Exploration Missions

Historically, competitions and prizes such as those executed by the National Aeronautics and Space Administration (NASA) Centennial Challenges (CC) program have created broader avenues through which to spur innovation from unlikely sources. In 2005, Congress amended the National Aeronautics and Space Act of 1958 to authorize NASA to create challenges through which prizes could be awarded to United States citizens or entities that succeeded in meeting challenge objectives. Over the past 15 years, the CC program has initiated more than 20 challenges in a variety of technology areas, including: propulsion, robotics, communications and navigation, human health, science instrumentation, nanotech, materials/structures and aerodynamics. This paper provides the background, status and ongoing plans by NASA’s CC program in developing a Deep Space Food Challenge (formerly the Lunar Nutrition Challenge) as one approach to fulfilling Space Policy Directive 1 (To the Moon, then Mars”).

Centennial Challenges↗

NASA NTRS2021

NASA KSC Internship Experience & Project Report

As part of the Spring 2021 Engineering Student Trainee rotation with the National Aeronautics and Space Administration (NASA) through the Pathways program at Kennedy Space Center (KSC). I served under KSC’s Engineering directorate as a Pneumatics Engineering Intern for the Environmental and Life support Systems branch (NE-XF). During my Internship, I primarily supported the Exploration Ground Systems (EGS) program under the direct supervision of NE-XF Pneumatics Senior Engineer, Ruben Jaca, and NE-XF matrix supervisor, Stephen M. Anthony. I worked on the completion of a Pressure Vessel and Pressurized System (PVS) certification for a Payload Accommodation Subsystem (PAS) prototype. As part of the Pathways program, I was additionally exposed to various career and skill enhancement activities.

Internship↗

NASA NTRSDate not supplied

The Gateway as a Building Block for Space Exploration and Development

The Gateway, which will be a small, human-tended space station in orbit around the Moon, is an example of the building block approach to space exploration and development. The National Aeronautics and Space Administration (NASA) leads the Gateway Program and serves as the integrator of the spaceflight capabilities and contributions of U.S. commercial partners and international partners. Gateway is a cornerstone of deep space human exploration, one critical element of the strategies and architectures that will enable human exploration of the solar system. This paper will outline: 1) The concept of operations and describe how Gateway is a multipurpose space station, supporting lunar surface missions, cis-lunar research, and as a proving ground for human missions to Mars; 2) Gateway’s international partnerships as an expansion of the partnerships of the “second generation of space programmes,” namely the International Space Station (ISS); and 3) Future commercial, scientific, and technology demonstration opportunities that this infrastructure building block provides. Lastly, the strategies and architectures for future space exploration and development must include thoughtful approaches to the management and business operations of government space programs. This includes planning for limited outyear growth in budgets, partnership and acquisition strategies, pursuing public-private partnerships and the use of firm-fixed price contracts, enabling vendor-to-vendor relationships, the use of multilateral interoperability standards, and incorporating key lessons learned from prior governmental Programs. This paper will discuss the strategies and approaches undertaken when establishing the Gateway Program at the NASA Johnson Space Center in 2019 and the current operational status of this new, lean, and efficient Program.

Gateway↗

NASA NTRSDate not supplied

Development of the Suited Injury Modes and Effects Analysis for Identification of Top Injury Risks in Lunar Missions and Training

A new Exploration Extravehicular Activity Services (xEVAS) suit is being designed to replace the current Extravehicular Mobility Unit (EMU) for the National Aeronautics and Space Administration’s (NASA’s) Artemis program to return astronauts to the lunar surface. This new suit will allow for increased range of motion compared to the current EMU and Apollo era suits and additional features will enhance the health and safety of exploration. With the design of lunar missions and the xEVAS suit progressing, it is important to consider possible injuries and injury mechanisms that could occur in the suit. To address these concerns, the suited Injury Modes and Effects Analysis (IMEA) was developed to outline suited injury scenarios and rank them based on risk score. The IMEA documents possible scenarios and underlying mechanisms of injury. History has shown that more suit injuries occur during training than in flight; therefore, currently planned training events to prepare for lunar missions and tasks during lunar surface EVAs were considered. Each scenario is ranked with likelihood and consequence scorings based on our current understanding of suit and application of Artemis design reference missions. The scoring allowed identification of the high-risk cases that will drive further work in suited injury. Mechanisms of injury, injury outcomes, and mitigation strategies are evaluated within each scenario. The Suited Injury Summit was held on January 5, 2022, to vet the IMEA with external experts. This was an all-day virtual meeting with the suited injury team; ergonomists; suit engineers; safety engineers; the flight operations directorate; flight doctors; astronauts; astronaut strength, conditioning, and rehabilitation specialists (ASCRS); and external subject matter experts (SMEs). External SMEs consisted of surgeons with varying specialties. The intent of this meeting was to walk through the top injury risks identified in the analysis, identify any gaps that were not captured, and discuss mitigations. With participation from all groups, countless lessons-learned came from the Summit meeting. Using these, the top 10 risks have been identified: neutral buoyancy laboratory training, hand/glove injuries, poor suit fit, field training, specific EVA tasks/design of task, boots/ankle injuries, falls from heights, background radiation, repetitive contact, and ambulation/longdistance ambulation. Mitigation steps have also been determined for each of the top risks. The IMEA and documentation of top risks is a living document. Yearly meetings are planned to update the analysis and reevaluate top risks and mitigations. The IMEA is being used to drive work in suited injury, and this work will continue to evolve with IMEA and lunar mission updates.

Teresa Reiber↗

NASA NTRSDate not supplied

The Gateway as a Building Block for Space Exploration and Development

The Gateway, which will be a small, human-tended space station in orbit around the Moon, is an example of the building block approach to space exploration and development. The National Aeronautics and Space Administration (NASA) leads the Gateway Program and serves as the integrator of the spaceflight capabilities and contributions of U.S. commercial partners and international partners. Gateway is a cornerstone of deep space human exploration, one critical element of the strategies and architectures that will enable human exploration of the solar system. This paper will outline: 1) The concept of operations and describe how Gateway is a multi-purpose space station, supporting lunar surface missions, cis-lunar research, and as a proving ground for human missions to Mars; 2) Gateway’s international partnerships as an expansion of the partnerships of the “second generation of space programmes,” namely the International Space Station (ISS); and 3) Future commercial, scientific, and technology demonstration opportunities that this infrastructure building block provides. Lastly, the strategies and architectures for future space exploration and development must include thoughtful approaches to the management and business operations of government space programs. This includes planning for limited outyear growth in budgets, partnership and acquisition strategies, pursuing public-private partnerships and the use of firm-fixed price contracts, enabling vendor-to-vendor relationships, the use of multilateral interoperability standards, and incorporating key lessons learned from prior governmental Programs. This paper will discuss the strategies and approaches undertaken when establishing the Gateway Program at the NASA Johnson Space Center in 2019 and the current operational status of this new, lean, and efficient Program.

Gateway↗

NASA NTRSDate not supplied

Development of the Suited Injury Modes and Effects Analysis for Identification of Top Injury Risks in Lunar Missions and Training

A new Exploration Extravehicular Activity Suit (xEVAS) is being designed to replace the current Extravehicular Mobility Unit (EMU) for the National Aeronautics and Space Administration’s (NASA’s) Artemis program to return astronauts to the lunar surface. This new suit will allow for increased range of motion compared the current EMU and Apollo era suits and will have additional features that will enhance the health and safety of exploration. With the design of lunar missions and the xEVAS progressing, it is important to consider possible injuries and injury mechanisms that could occur in the suit. To address these concerns, the suited Injury Modes and Effects Analysis (IMEA) was developed to outline suited injury scenarios and rank them based on risk score. The IMEA documents possible scenarios and underlying mechanisms of injury while wearing an extravehicular activity (EVA) suit. Tasks during lunar surface EVA as well as training events to prepare for lunar missions were considered as history has shown that more suit injuries occur during training than in flight. Each scenario is ranked with a consequence and likelihood scoring based on our current understanding of the suit and Artemis design reference missions to identify high-risk cases that will drive further work in suited injury. Injuries, mechanisms of injury, and mitigation strategies are evaluated within each scenario. The Suited Injury Summit was held on January 5, 2022, to vet the IMEA with external experts. This was an all-day virtual meeting with the suited injury team, ergonomists, suit engineers, safety engineers, the flight operations directorate, flight doctors, astronauts, astronaut strength, conditioning, and rehabilitation specialists (ASCRS), and external subject matter experts (SMEs). External SMEs consisted of surgeons with varying specialties. The intent of this meeting was to walk through the top injury risks identified in the analysis, identify any gaps that were not captured, and discuss mitigations. With participation from all groups, countless lessons-learned came from the Summit meeting. Using the lessons-learned and discussion from the Summit, the top 10 risks have been identified: neutral buoyancy laboratory training, hand/glove injuries, poor suit fit, field training, specific EVA tasks/design of task, boots/ankle injuries, falls from heights, background radiation, repetitive contact, and ambulation/long-distance ambulation. Mitigation steps have also been determined for each of the top risks. The IMEA and documentation of top risks is a living document. Yearly meetings are planned to update the analysis and reevaluate top risks and mitigations. The IMEA is being used to drive work in suited injury, and this work will continue to evolve with IMEA and lunar mission updates.

Teresa Reiber↗

NASA NTRSDate not supplied

Development of the Suited Injury Modes and Effects Analysis for Identification of Top Injury Risks in Lunar Missions and Training

Tessa Reiber↗

NASA NTRSDate not supplied

Development of Aluminum/Air Battery as High-Capacity Primary Battery Energy Source for SUSAN Electrofan Project

High-capacity, high-performance, and safe battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. These battery technologies, including both secondary (i.e., rechargeable) batteries for hybrid/electric propulsion and primary batteries (i.e. non-rechargeable or single-use) for backup/emergency use in case of turbine engine failure, are important and vital components in SUSAN concept design. This paper is focused on aluminum (Al)-air battery, which is considered to be the most promising candidate to meet the energy goal of primary batteries for SUSAN project. However, there are challenges for Al-air batteries, including aluminum self-corrosion with hydrogen (H2) gassing and sluggish kinetics of oxygen reduction reaction (ORR) in air-cathode. In this paper, the preliminary results on investigation of electrolytes and additives on controlling aluminum self-corrosion/H2 gassing suppression and the study of air-cathode design for ORR improvement are presented and discussed.

James Wu↗

NASA NTRS2024

A Distributed Simulation Framework Applied to Artemis Analysis, Studies, Integration, and Test

The National Aeronautics and Space Administration (NASA) established the Artemis Program, a series of missions to return humans to the Moon and explore further than before. To execute the Artemis missions, NASA is collaborating with commercial and international partners to create the necessary infrastructure and logistics plan that will establish a long term presence on the Moon ahead of exploring Mars. NASA and its partners are developing a collection of space and surface systems to support crewed missions to the lunar surface that will provide the mobility, habitation, logistics, and exploration support necessary for Artemis mission successes which includes robust scientific investigations. This paper details the design, capabilities, and uses of the Artemis Distributed Simulation (ADS) being developed by the NASA Exploration Systems Simulations (NExSyS) Team to support Artemis architecture studies. ADS utilizes international interoperability standards to connect a collection of independent vehicle and service simulations; these include but are not limited to elements such as rovers, landers, and habitation elements along with services like communications, environment, visualization, and data logging. ADS’s distributed nature allows for the complex aggregation of constituent Artemis elements; this includes efficient scenario modification with the addition or removal of individual simulations representing Artemis elements or services. This capability provides support for the rapid performance of various Artemis mission trade studies exploring alternate configurations. Currently, ADS uses NASA developed simulations for development and testing; however, through the use of international simulation interoperability standards, ADS provides an integration framework to incorporate dissimilar authoritative vendor simulations as Artemis systems mature and vendor simulations become available. Vendor simulations will be able to join ADS and interact with other Artemis elements and vehicles while limiting the exposure of proprietary data. This paper describes the expansion of an existing distributed simulation infrastructure to accommodate a collaborative and dynamic framework for the Artemis Program. This work includes updated federation designs, integration into existing NASA facilities, advancements in visualizations, and advancements in human driven inputs. This paper will also outline recently completed and ongoing support and collaboration with NASA studies and testing, namely results from energetics and Human-In-The-Loop (HITL) studies. The paper concludes with a plan for future developments and facility integration to enable enhanced studies in preparation for a return of humans to the lunar surface.

Artemis↗