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NASA NTRS2012

A Novel Technique for Running the NASA Legacy Code LAPIN Synchronously With Simulations Developed Using Simulink

This report presents a method for running a dynamic legacy inlet simulation in concert with another dynamic simulation that uses a graphical interface. The legacy code, NASA's LArge Perturbation INlet (LAPIN) model, was coded using the FORTRAN 77 (The Portland Group, Lake Oswego, OR) programming language to run in a command shell similar to other applications that used the Microsoft Disk Operating System (MS-DOS) (Microsoft Corporation, Redmond, WA). Simulink (MathWorks, Natick, MA) is a dynamic simulation that runs on a modern graphical operating system. The product of this work has both simulations, LAPIN and Simulink, running synchronously on the same computer with periodic data exchanges. Implementing the method described in this paper avoided extensive changes to the legacy code and preserved its basic operating procedure. This paper presents a novel method that promotes inter-task data communication between the synchronously running processes.

Vrnak, Daniel R.↗

NASA NTRS2012

Post-Flight EDL Entry Guidance Performance of the 2011 Mars Science Laboratory Mission

The 2011 Mars Science Laboratory was the first successful Mars mission to attempt a guided entry which safely delivered the rover to a final position approximately 2 km from its target within a touchdown ellipse of 19.1 km x 6.9 km. The Entry Terminal Point Controller guidance algorithm is derived from the final phase Apollo Command Module guidance and, like Apollo, modulates the bank angle to control the range flown. For application to Mars landers which must make use of the tenuous Martian atmosphere, it is critical to balance the lift of the vehicle to minimize the range error while still ensuring a safe deploy altitude. An overview of the process to generate optimized guidance settings is presented, discussing improvements made over the last nine years. Key dispersions driving deploy ellipse and altitude performance are identified. Performance sensitivities including attitude initialization error and the velocity of transition from range control to heading alignment are presented. Just prior to the entry and landing of MSL in August 2012, the EDL team examined minute tuning of the reference trajectory for the selected landing site, analyzed whether adjustment of bank reversal deadbands were necessary, the heading alignment velocity trigger was in union with other parameters to balance the EDL risks, and the vertical L/D command limits. This paper details a preliminary postflight assessment of the telemetry and trajectory reconstruction that is being performed, and updates the information presented in the former paper Entry Guidance for the 2011 Mars Science Laboratory Mission (AIAA Atmospheric Flight Mechanics Conference; 8-11 Aug. 2011; Portland, OR; United States)

Mendeck, Gavin F.↗

NASA NTRS2015

CapiBRIC- Capillary-Based Brine Residual In-Containment for Secondary Water Recovery

One of the goals of the AES Life Support Systems Project is to achieve 98% water loop closure for long-duration human exploration missions. Brine water recovery is the primary technology gap that must be bridged to realize this goal. In response to an Agency call for technologies to compete in an October down-select, Capi-BRIC was chosen through a JSC down-select as the strongest candidate to go forward. This resulted in a period of intense development to increase its TRL in preparation for the Agency down-select. This was achieved through rapid prototype design, fabrication, and test at JSC and in a zero-g drop tower at Portland State University. INNOVATION CapiBRIC takes a novel approach of optimizing the containment geometry to support capillary flow and static phase separation to enable evaporation in a microgravity environment. OUTCOME TRL was advanced from 3 to 4, and was selected for continued funding through the AES program. CapiBRIC is poised for development into an ISS technology demonstration, proving its viability as an enabling technology for exploration.

Sargusingh, Miriam↗

NASA NTRS2016

Design Status of the Capillary Brine Residual in Containment Water Recovery System

One of the goals of the AES Life Support System (LSS) Project is to achieve 98% water loop closure for long duration human exploration missions beyond low Earth orbit. To meet this objective, the AES LSS Project is developing technologies to recover water from wastewater brine; highly concentrated waste products generated from a primary water recovery system. The state of the art system used aboard the International Space Station (ISS) has the potential to recover up to 85% water from unine wastewater, leaving a significant amounts of water in the waste brine, the recovery of which is critical technology gap that must be filled in order to enable long duration human exploration. Recovering water from the urine wastewater brine is complicated by the concentration of solids as water is removed from the brine, and the concentration of the corrosive, toxic chemicals used to stabilize the urine which fouls and degrades water processing hardware, and poses a hazard to operators and crew. Brine Residual in Containment (BRIC) is focused on solids management through a process of "in-place" drying - the drying of brines within the container used for final disposal. Application of in-place drying has the potential to improve the safety and reliability of the system by reducing the exposure to curew and hardware to the problematic brine residual. Through a collaboration between the NASA Johnson Space Center and Portland Status University, a novel water recovery system was developed that utilizes containment geometry to support passive capillary flow and static phase separation allowing free surface evaporation to take place in a microgravity environment. A notional design for an ISS demonstration system was developed. This paper describes the testing performed to characterize the performance of the system as well as the status of the system level design.

Sargusingh, Miriam J.↗

NASA NTRS2015

Report About the NASA-MSU Professional Enhancement Awards in 2015

With support from NASA and Michigan State University (MSU), 17 "NASA-MSU Professional Enhancement Award" recipients were able to attend the 2015 World Congress of Landscape Ecology. This year's conference was held in Portland (Oregon) during July 5-10, 2015 (http://www.ialeworldcongress.org/). On May 6, a dinner gathering was organized for the new NASA-MSU Award recipients. At the gathering, the participants first made a brief self-introduction regarding their background and research interests. Then they formed five groups to work on manuscripts. Furthermore, each new awardee was recognized with a certificate at the conference luncheon on July 6. In addition, the awardees attended a "Student/Mentor Lunch" on July 8 when the awardees (and other students) met with leading scientists. The awardees also attended a workshop on telecoupling on July 5. The awardees had a great time and were very productive at the conference, and many are continuing to collaborate on preparing manuscripts after the conference and preparing presentations for next year's meeting of US-IALE.

Liu, Jianguo (Jack)↗

NASA NTRS2016

Design Status of the Capillary Brine Residual in Containment Water Recovery System

One of the goals of the AES Life Support System (LSS) Project is to achieve 98% water loop closure for long duration human exploration missions beyond low Earth orbit. To meet this objective, the AES LSS Project is developing technologies to recover water from wastewater brine; highly concentrated waste products generated from a primary water recovery system. The state of the art system used aboard the International Space Station (ISS) has the potential to recover up to 85% water from unine wastewater, leaving a significant amounts of water in the waste brine, the recovery of which is a critical technology gap that must be filled in order to enable long duration human exploration. Recovering water from the urine wastewater brine is complicated by the concentration of solids as water is removed from the brine, and the concentration of the corrosive, toxic chemicals used to stabilize the urine which fouls and degrades water processing hardware, and poses a hazard to operators and crew. Brine Residual in Containment (BRIC) is focused on solids management through a process of "in-place" drying - the drying of brines within the container used for final disposal. Application of in-place drying has the potential to improve the safety and reliability of the system by reducing the exposure to crew and hardware to the problematic brine residual. Through a collaboration between the NASA Johnson Space Center and Portland Status University, a novel water recovery system was developed that utilizes containment geometry to support passive capillary flow and static phase separation allowing free surface evaporation to take place in a microgravity environment. A notional design for an ISS demonstration system was developed. This paper describes the concept for the system level design.

Callahan, Michael R.↗

NASA NTRS2016

Low Temperature Regolith Bricks for In-Situ Structural Material

Current technology for producing in-situ structural materials on future missions to Mars or the moon relies heavily on energy-intensive sintering processes to produce solid bricks from regolith. This process requires heating the material up to temperatures in excess of 1000 C and results in solid regolith pieces with compressive strengths in the range of 14000 to 28000 psi, but are heavily dependent on the porosity of the final material and are brittle. This method is currently preferred over a low temperature cementation process to prevent consumption of precious water and other non-renewable materials. A high strength structural material with low energy requirements is still needed for future colonization of other planets. To fulfill these requirements, a nano-functionalization process has been developed to produce structural bricks from regolith simulant and shows promising mechanical strength results. Functionalization of granular silicate particles into alkoxides using a simple low temperature chemical process produces a high surface area zeolite particles that are held together via inter-particle oxygen bonding. Addition of water in the resulting zeolite particles produces a sol-gel reaction called "inorganic polymerization" which gives a strong solid material after a curing process at 60 C. The aqueous solution by-product of the reaction is currently being investigated for its reusability; an essential component of any ISRU technology. For this study, two batches of regolith bricks are synthesized from JSC-1A; the first batch from fresh solvents and chemicals, the second batch made from the water solution by-product of the first batch. This is done to determine the feasibility of recycling necessary components of the synthesis process, mainly water. Characterization including BET surface area, SEM, and EDS has been done on the regolith bricks as well as the constituent particles,. The specific surface area of 17.53 sq m/g (average) of the granular regolith material was obtained from nitrogen adsorption isotherm measurement. The size, shape and textures of regolith from SEM shows that the particles are 25-50 micrometers in size and mostly irregular in shape (Figure 1a). The elemental composition of regolith was identified from EDS analysis showed the presence of Si, Al, Fe, Na, Mg, Ca, Ti, O and C (see figure 1b). Each set of cylindrical brick samples were prepared by low energy process, and cured for 21 and 28 days, respectively to compare their compressive strength. Figure 1c, and d shows the JSC-1A brick and the compressive strength measurements. The results from the 21 day cured bricks (2 bricks) have been done and yielded an aver-age strength of 3050 psi, considerably higher than Portland cement mortars (Type IV and V). This promising technology provides the benefits of construction material similar to concrete, with a low complexity, low energy synthesis process and the likelihood of complete reusability of precious resources. Compressive strength using this method can be improved by increasing the surface area of the particles, using bi-modal particle size distribution, and adding certain additives to increase inter-particle forces.

ISRU↗

NASA NTRS2017

Hypervelocity Impact Testing of Materials for Additive Construction: Applications on Earth, the Moon, and Mars

Additive Construction is the process of building infrastructure such as habitats, garages, roads, berms, etcetera layer by layer (3D printing). The National Aeronautics and Space Administration (NASA) and the United States Army Corps of Engineers (USACE) are pursuing additive construction to build structures using resources available in-situ. Using materials available in-situ reduces the cost of planetary missions and operations in theater. The NASA team is investigating multiple binders that can be produced on planetary surfaces, including the magnesium oxide-based Sorel cement; the components required to make Ordinary Portland Cement (OPC), the common cement used on Earth, have been found on Mars. The availability of OPC-based concrete on Earth drove the USACE to pursue additive construction for base housing and barriers for military operations. Planetary and military base structures must be capable of resisting micrometeoroid impacts with velocities ranging from 11 to 72km/s for particle sizes 200 micrometers or more (depending on protection requirements) as well as bullets and shrapnel with a velocity of 1.036km/s with projectiles 5.66mm diameter and 57.40mm in length, respectively.

Hypervelocity Impact↗

NASA NTRS2016

Student Design Challenges in Capillary Flow

For some grade 8-12 students, capillary flow has bridged the gap between the classroom and research facility, from normal gravity to microgravity. In the past four years, NASA and the Portland State University (PSU) have jointly challenged students to design test cells, using Computer-Aided Design (CAD), to study capillary action in microgravity as PSU has done on the International Space Station (ISS). Using the student-submitted CAD drawings, the test cells were manufactured by PSU and tested in their 2.1-second drop tower. The microgravity results were made available online for student analysis and reporting. Over 100 such experiments have been conducted, where there has been participation from 15 states plus a German school for the children of U.S. military personnel. In 2016, a related NASA challenge was held in partnership with the ASGSR, again, based on the research conducted by PSU. In this challenge, grade 9-12 students designed and built devices using capillary action to launch droplets as far as possible in NASAs 2.2 Second Drop Tower. Example results will be presented by students at this conference. The challenges engage students in ISS science and technology and can inspire them to pursue technical careers.

capillary flow↗

NASA NTRS2018

Additive Construction with Mobile Emplacement (ACME) / Automated Construction of Expeditionary Structures (ACES) Materials Delivery System (MDS)

The purpose of the Automated Construction of Expeditionary Structures, Phase 3 (ACES 3) project is to incorporate the Liquid Goods Delivery System (LGDS) into the Dry Goods Delivery System (DGDS) structure to create an integrated and automated Materials Delivery System (MDS) for 3D printing structures with ordinary Portland cement (OPC) concrete. ACES 3 is a prototype for 3-D printing barracks for soldiers in forward bases, here on Earth. The LGDS supports ACES 3 by storing liquid materials, mixing recipe batches of liquid materials, and working with the Dry Goods Feed System (DGFS) previously developed for ACES 2, combining the materials that are eventually extruded out of the print nozzle. Automated Construction of Expeditionary Structures, Phase 3 (ACES 3) is a project led by the US Army Corps of Engineers (USACE) and supported by NASA. The equivalent 3D printing system for construction in space is designated Additive Construction with Mobile Emplacement (ACME) by NASA.

Mueller, R. P.↗

NASA NTRS2018

The Disruptive Technology That is Additive Construction: System Development Lessons Learned for Terrestrial and Planetary Applications

Disruptive technologies are unique in that they spawn other new technologies and applications as they grow. These activities are usually preceded by the question, "What If?" For example, "What if we could use an emerging technology and in-situ materials to promote exploration on the Moon or Mars, and then use that same technology to keep our troops out of harm's way and/or help the worlds' homeless?" This question allows us to flip the mindset of "how can people create more valuable innovation?" to "how can innovation create more valuable people?." This approach allows us to view augmented human labor as an inclusive opportunity, not a threat. The discipline of Additive Construction is growing rapidly due to the flexibility, speed, safety and logistics benefits offered as compared to standard construction techniques. Additive construction is a disruptive technology in that it employs the principles of additive manufacturing on a human habitat structure scale. Developed initially for emergency management and disaster relief applications, additive construction has now grown into military infrastructure and planetary (Moon and Mars) surface infrastructure applications as well. Additive Construction with Mobile Emplacement (ACME) is a NASA technology development project that seeks to demonstrate the feasibility of constructing shelters for human crews, and other surface infrastructure, on the Moon or Mars for a future human presence. The ACME project will allow, for the first time, the 3-dimensional printing of surface structures on planetary bodies using local materials for construction, thereby tremendously reducing launch and transportation mass and logistics. Some examples of infrastructure that could be constructed using robotic additive construction methods are landing pads, rocket engine blast protection berms, roads, dust free zones, equipment shelters, habitats and radiation shelters. Terrestrial applications include the development of surface structures using Earth-based materials for emergency response, disaster relief, general construction, and housing at all economic levels. This paper will describe the progress made by the NASA ACME project with a focus on prototypes and full scale additive construction demonstrations using both Portland cement concrete and other indigenous material mixtures. Rationale for the use of additive construction for both terrestrial and planetary applications will be explored and a thorough state-of-the-art of additive construction techniques will be presented. An evolutionary history of NASA's additive construction development efforts, dating back to 2004, will be included. The paper will then step through a series of trade studies performed to inform key processing and design decisions in the development of the full-scale ACES-3 system developed by NASA and the Jacobs Space Exploration Group for the U.S. Army Corps of Engineers (USACE) Construction Engineers Research Laboratory (CERL) in Champaign, IL. The selection of aggregate and binders, based on in-situ materials, will also be presented and discussed

Space Processing↗

NASA NTRSDate not supplied

Toward an IMU-based Space Suit Motion Capture System

Spacesuits are complex engineering systems that sustain human health and enable performance outside of Earth-like environments. These systems must support human mobility and physical workload demands while minimizing injury risk during extravehicular activity (EVA). Future EVA on the lunar surface during the Artemis program is expected to be more frequent and require higher physical workloads than previous EVAs during the ISS, Shuttle, or Apollo programs. Hence it is important to optimize future as well as current spacesuits to be efficient and comfortable for the success of space and planetary missions. To enable this, an efficient method is needed to test these spacesuits on the ground.When testing spacesuits in ground environments, it is often necessary to understand the kinematics of the suit to validate the design against relevant requirements or characterize the physical workload necessary to operate the suit. This is a challenging task for traditional optical motion capture (OMC) approaches: suit-mounted OMC markers are easily occluded by the subject or environment and may become detached during testing. Controlling lighting and reflectivity of objects in the motion capture volume is also difficult. Fixed-position OMC cameras also constrain testing to a small and contrived laboratory environment, disallowing kinematics capture in field environments.One promising alternative is the use of suit-mounted inertial measurement units (IMUs). These sensors are small, unobtrusive, and portable, but come at the cost of increased sensor noise and complexity of the software and mathematics to analyze the collected data. To this end, engineers at NASA are developing the Augmented Suit Inverse Kinematics (ASIK) system, a complete motion capture methodand inverse kinematics solver which relies solely on a network of wireless IMUs attached to the major kinematic segments of the spacesuit. The ASIK modeling language allows for the simple inclusion of probabilistic priors such as suit size and shape or IMU positions and rotations. Furthermore, to increase accuracy and reduce operational overhead to use this motion capture approach, the developed inverse kinematics solver exploits so-called self-calibratingalgorithmic techniques, which reduce the need for precise alignment of the sensors on the segments or scripted functional calibration procedures. The ASIK system was tested in a 7-subject pilot study. Each subject donned NASA’s new prototype exploration spacesuit in the Active Response Gravity Offload System (ARGOS) facility at the NASA Johnson Space Center. The subjects were outfitted with a set of 14 APDM (Portland, OR, USA) Opal IMUs, 12 of which were used in the ASIK model to estimate lower body and trunk kinematics. The subjects were also outfitted with a set of reflective OMC markers and traditional OMC data was collected and processed. Presented results will include characterization of ASIK-derived suit joint angles accuracy against an optical motion capture datum. Discussion of these results, as well as discussion of system calibration and nuances of mathematical observability, will be included.If successful, IMU-based motion capture will enable testing and validation of spacesuits more frequently, with less overhead, in more extreme environments. Future work will apply these techniques to common spacesuit testing tasks, such as gait, mobility, and balance assessment, physical workload characterization, and ergonomics evaluations.

Timothy Mcgrath↗

NASA NTRSDate not supplied

Functional Task Tests in Partial Gravity During Parabolic Flight

BACKGROUND Understanding how critical mission tasks are performed in partial gravity such as on the moon or Mars is necessary to define effective and comprehensive countermeasure strategies for preserving crew performance during exploration missions. We studied the performance of tasks such as standing, walking, and jumping during the partial gravity phases of parabolic flight. We hypothesized that the acute effects of partial gravity on vestibular, proprioceptive, and sensorimotor functions would negatively impact performance. METHODS Twelve subjects were tested over three flights of 30 parabolas each, including 10 parabolas at 0.25g, 10 parabolas at 0.5g, and 10 parabolas at 0.75g. Subjects also performed tests in 1g between parabolas. During the sit-to-stand with obstacle walk task, subjects rose from a seated position and walked as quickly as possible straight ahead towards a cone (4 m distance), walked around the cone making a 180° left turn, returned, and sat in the chair. On the way to and from the cone, subjects stepped over a 30 cm high obstacle. For the recovery from fall task, subjects lay prone for the pull-up phase and initial 10 sec of the parabola. Then they were asked to rise as quickly as possible and maintain a quiet stance for 10 sec. The tandem rail balance task involved standing with both feet on a 4.5 cm wide rail. The time ended when subjects either stepped off the rail or grabbed on to support straps. The jump down task started with the subjects standing on a 30 cm high platform, then the subjects were instructed to step off the platform, land with both feet simultaneously, and settle in a quiet stance. The cone of stability task involved subjects leaning about the ankles as far as they could in the anterior, posterior, and lateral directions without unfolding their arms or taking a step. The center of pressure distance between endpoints was calculated. Data were collected using inertial measurement units (Opal V2, APDM, Portland, OR) worn on the head and trunk, heart rate monitors (RS800CX, Polar, Kempele, Finland), and a force plate (Bertec, Columbus, OH). RESULTS Gravity level had a significant effect on performance, with the greatest changes from 1g tending to be at the 0.25g level (Table 1). Lower gravity levels were associated with increased times to complete the sit-to-stand obstacle walk task and the recovery from fall task, decreased change in heart rate during the recovery from fall task, decreased rail balance times, and increased cone of stability distance in the anterior-posterior direction. Table 1. Functional task performance at different gravity levels during parabolic flight. Measure0.25g0.5g0.75g1gp-valueSit-to-stand with obstacle walk time (sec)9.8 ±1.4*7.2 ±0.76.9 ±0.8*7.4 ±0.9<0.001Recovery from fall time to settle (sec)5.3 ± 0.9*4.6 ± 0.84.2 ± 0.64.3 ± 0.70.002Recovery from fall change in heart rate (bpm)6.0 ± 7.3*11.2 ± 6.5*14.9 ± 4.915.9 ± 6.5<0.001Rail balance with eyes open time (sec)2.7 ±0.8*4.8 ±2.16.6 ±4.78.4 ±6.70.031Rail balance with eyes closed time (sec)1.6 ±0.4*2.1 ±0.42.4 ±0.62.6 ±0.8<0.001Jump down time to settle (sec)2.1 ± 0.41.9 ± 0.42.0 ± 0.31.8 ± 0.30.328Cone of stability –anterior-posterior (cm)20.8 ±2.7*18.8 ±2.218.6 ±1.717.9 ±2.00.039Cone of stability –lateral (cm)26.8 ±6.624.4 ±2.123.0 ±2.123.8 ±2.30.215p-value: one-way repeated measures analysis of variance; *Significant pairwise difference from 1g (p<0.05). DISCUSSION These data suggest that there is a dose-response relationship between gravity level and functional task performance. The largest changes in performance were expected at the lowest gravity level (0.25g) because subjects would no longer be able to use the gravitational reference for the perception of upright. Understanding the extent of performance deficits informs the risks and design of countermeasures for exploration spaceflight missions. ACKNOWLEDGEMENT This work is supported by NASA’s Human Research Program Human Health Countermeasures Element.

T R Macaulay↗

NASA NTRSDate not supplied

Durability of Geopolymer Lunar Concrete From Exposure in Low Earth Orbit

Constructing infrastructure autonomously with concrete materials through additive manufacturing techniques on the lunar surface is a feasible option. The environmental and exposure conditions that the lunar concrete material will undergo are more extreme than on Earth and studying the durability aspect is important to scaling up the implementation of such materials. Conditions that the material will be exposed to include a hard vacuum, extreme temperatures, and ultraviolet radiation. To that end, geopolymer lunar concrete and ordinary portland cement paste samples were placed outside the International Space Station (ISS) for an approximate six-month exposure period. The samples were part of the 15th Materials International Space Station Experiment (MISSE-15) mission and were mounted in the zenith direction. After the exposure time, results for the samples exhibited discoloration, microstructural cracking, and an overall reduction in volume compared to data collected beforehand. The intent of this work was to characterize geopolymer lunar concrete durability in terms of the lunar environmental conditions in LEO and potential exposure scenarios from a simulated subscale rocket engine plume. To understand the durability of samples in space environment conditions, samples were placed outside the International Space Station (ISS) for a six-month period on the MISSE-FF. Additionally, to test the material's durability if implemented for use in a landing pad, samples were created for an experiment that mimics the exposure of the material to a rocket engine associated with the human lander system. This work is essential to progressing and scaling up geopolymer lunar concrete for implementation as the material's durability is assessed.

Peter J Collins↗

NASA NTRS2024

Life Cycle Assessment and Design of LignoBlock: A Lignin Bound Block on the Path Towards a Green Transition of the Construction Industry

Lignin-based biopolymer-bound soil composites (BSCs) are a new class of sustainable construction materials that utilize a bio-based biopolymer — lignin — as a binder. Prior use of lignin suggests that lignin is a promising candidate for the development of bio-based construction materials. Inspired by these applications, lignin-based BSCs were developed using lignoboost lignin, lignoforce lignin, alkali lignin, and hydrolysis lignin. Uni-axial compressive testing of lignin-based BSC shows that the compressive strength for these BSCs range from 1.6–8.1 MPa, which makes them appropriate for low compressive strength construction applications. We performed a life cycle assessment (LCA) of lignin-based BSC, with the functional unit being a CMU-sized block ( V =6423 cm -3 ). The major advantage of BSC lies in the elimination of ordinary portland cement, which is common to many construction materials, including many forms of concrete. Furthermore, the use of lignin in lignin-based BSC results in carbon sequestration (lignin ≈ 60 wt% carbon), potentially making construction materials made from lignin-based BSC carbon negative. Additionally, a design guide for estimating the life cycle carbon footprint of lignin-based BSC for a required compressive strength was developed. By utilizing the results from material tests and the LCA, designers are now able to use lignin effectively in construction applications, as they can now design lignin-based BSC for a target compressive strength with a full understanding of the life cycle carbon footprint implications.

Lignin↗

NASA NTRS2025

Functional Task Tests in Partial Gravity During Parabolic Flight

T R Macaulay↗

NASA NTRSDate not supplied

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗