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Welding program produces premium quality, multipass welds in heavy tube sections of Hastelloy-X. It develops semiautomatic tungsten/inert gas procedures, weld wire procurement specifications material weld properties, welder-operator training, and nondestructive testing inspection techniques and procedures.
NASA Glenn Research Center is interested in developing Solid Oxide Fuel Cell for use in aerospace applications. Solid oxide fuel cell requires hydrogen rich feed stream by converting commercial aviation jet fuel in a fuel processing process. The grantee's primary research activities center on designing and constructing a test facility for evaluating injector concepts to provide optimum feeds to fuel processor; collecting and analyzing literature information on fuel processing and desulfurization technologies; establishing industry and academic contacts in related areas; providing technical support to in-house SOFC-based system studies. Fuel processing is a chemical reaction process that requires efficient delivery of reactants to reactor beds for optimum performance, i.e., high conversion efficiency and maximum hydrogen production, and reliable continuous operation. Feed delivery and vaporization quality can be improved by applying NASA's expertise in combustor injector design. A 10 KWe injector rig has been designed, procured, and constructed to provide a tool to employ laser diagnostic capability to evaluate various injector concepts for fuel processing reactor feed delivery application. This injector rig facility is now undergoing mechanical and system check-out with an anticipated actual operation in July 2004. Multiple injector concepts including impinging jet, venturi mixing, discrete jet, will be tested and evaluated with actual fuel mixture compatible with reforming catalyst requirement. Research activities from September 2002 to the closing of this collaborative agreement have been in the following areas: compiling literature information on jet fuel reforming; conducting autothermal reforming catalyst screening; establishing contacts with other government agencies for collaborative research in jet fuel reforming and desulfurization; providing process design basis for the build-up of injector rig facility and individual injector design.
As Lunar exploration continues to become more commonplace, reliable methods of precise Terrain Relative Navigation (TRN) are needed. While there are many TRN techniques available, one that has received increased interest in the past few years is that of crater based navigation. Crater based navigation has numerous benefits, including being a human recognizable feature (important for crewed missions), as well as the fact that craters are often possible hazards that need to be detected and avoided. The use of crater based navigation has been limited however. This has been due to the difficulty of running such algorithms on board a spacecraft, as well as the difficulty in procuring large amounts of the required training data. This paper presents a new rendering tool for generating large amounts of high quality training data. It then looks at two recently developed machine learning techniques for crater detection and crater identification in real-time on near-future space hardware.
Guidelines are presented for a quality assurance system to be implemented by the manufacturer in support of designing, developing, fabricating, assembling, inspecting, testing, handling, and delivery of equipment being procured for use in public urban mass transit systems. The guidelines apply to this equipment when being procured for: (1) use in revenue service; (2) demonstration of systems that will be revenue producing or used by the public; (3) use as a prototype for follow-on operational/revenue producing equipment procurements; and (4) qualification tests.
The life support systems on the International Space Station (ISS) are the culmination of an extensive effort encompassing development, design, and test to provide the highest possible confidence in their operation on ISS. Many years of development testing are initially performed to identify the optimum technology and the optimum operational approach. The success of this development program depends on the accuracy of the system interfaces. The critical interfaces include the specific operational environment, the composition of the waste stream to be processed and the quality of the product. Once the development program is complete, a detailed system schematic is built based on the specific design requirements, followed by component procurement, assembly, and acceptance testing. A successful acceptance test again depends on accurately simulating the anticipated environment on ISS. The ISS Water Recovery System (WRS) provides an excellent example of where this process worked, as well as lessons learned that can be applied to the success of future missions. More importantly, ISS has provided a test bed to identify these design issues. Mechanical design issues have included an unreliable harmonic drive train in the Urine Processor's fluids pump, and seals in the Water Processor's Catalytic Reactor with insufficient life at the operational temperature. Systems issues have included elevated calcium in crew urine (due to microgravity effect) that resulted in precipitation at the desired water recovery rate, and the presence of an organosilicon compound (dimethylsilanediol) in the condensate that is not well removed by the water treatment process. Modifications to the WRS to address these issues are either complete (and now being evaluated on ISS) or are currently in work to insure the WRS has the required reliability before embarking on a mission to Mars.
The life support systems on the International Space Station (ISS) are the culmination of an extensive effort encompassing development, design, and test to provide the highest possible confidence in their operation on ISS. Many years of development testing are initially performed to identify the optimum technology and the optimum operational approach. The success of this development program depends on the accuracy of the system interfaces. The critical interfaces include the specific operational environment, the composition of the waste stream to be processed and the quality of the product. Once the development program is complete, a detailed system schematic is built based on the specific design requirements, followed by component procurement, assembly, and acceptance testing. A successful acceptance test again depends on accurately simulating the anticipated environment on ISS. The ISS Water Recovery System (WRS) provides an excellent example of where this process worked, as well as lessons learned that can be applied to the success of future missions. More importantly, ISS has provided a test bed to identify these design issues. Mechanical design issues have included an unreliable harmonic drive train in the Urine Processor's fluids pump, and seals in the Water Processor's Catalytic Reactor with insufficient life at the operational temperature. Systems issues have included elevated calcium in crew urine (due to microgravity effect) that resulted in precipitation at the desired water recovery rate, and the presence of an organosilicon compound (dimethylsilanediol) in the condensate that is not well removed by the water treatment process. Modifications to the WRS to address these issues are either complete (and now being evaluated on ISS) or are currently in work to insure the WRS has the required reliability before embarking on a mission to Mars.
The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.
Standards and controls are established for the procurement of wide channel bandwidth one inch video magnetic recording tapes for Very Long Base Interferometer (VLBI) system applications. The Magnetic Tape Certification Facility (MTCF) currently maintains three specifications for the Quality Products List (QPL) and acceptance testing of magnetic tapes. NASA-TM-79724 is used for the QPL and acceptance testing of new analog tapes; NASA-TM-80599 is used for QPL and acceptance testing of new digital tapes; and NASA-TM-100702 is used for the QPL and acceptance testing of new IBM/IBM compatible 3480 magnetic tape cartridges. This specification will be used for the QPL and acceptance testing of new wide channel bandwidth one inch video magnetic recording tapes. The one inch video tapes used by the Jet Propulsion Lab., the Deep Space Network and the Haystack Observatory will be covered by this specification. These NASA stations will use the video tapes for their VLBI system applications. The VLBI system is used for the tracking of quasars and the support of interplanetary exploration.
Landsat 10 will be the upcoming mission in the 50+ year Landsat series of Earth observation platforms. The centerpiece of the observatory will be a super-spectral imager known as the Landsat Instrument Suite (LandIS). The sensor will feature 26 spectral channels from the visible through near-, short-wave, and thermal infrared wavelengths with spatial resolutions of 10, 20, and 60 meters on the ground, depending on the band. These enhancements over the legacy Landsat instruments will ensure data continuity with the existing archive and will expand upon the core Landsat capabilities to enable new applications in Earth science. After a competitive procurement, NASA selected the design submitted by the Raytheon Company for the LandIS instrument. The innovative Raytheon instrument concept utilizes an advanced whiskbroom architecture to fulfill the strict radiometric, spatial, and geometric image quality requirements demanded by the Landsat 10 mission and fits within restrictive mass, volume, and power constraints. The instrument will continue the Landsat directive to image all daylit land and near-shore water areas, along with select nighttime imaging. On-board calibration source data will ensure high radiometric and geometric accuracy and stability consistent with previous missions to enable continuity in data products available to users. This paper discusses the driving requirements for LandIS and provides a description of the chosen design and operations concept of the instrument.
The reliability and quality assurance system and procedures used in developing test equipment for the Lunar Experiment projects are described. The subjects discussed include the following: (1) documentation control, (2) design review, (3) parts and materials selection, (4) material procurement, (5) inspection procedures, (6) qualification and special testing, and failure modes and effects analysis.
Welding at NASA's Marshall Space Flight Center (MSFC), Huntsville, Alabama, has taken a new direction through the last 10 years. Fusion welding processes, namely variable polarity plasma arc (VPPA) and tungsten inert gas (TIG) were once the corner stone of welding development in the Space Flight Center's welding laboratories, located in the part of MSFC know as National Center for Advanced Manufacturing (NCM). Developed specifically to support the Shuttle Program's External Tank and later International Space Station manufacturing programs, was viewed as the paragon of welding processes for joining aluminum alloys. Much has changed since 1994, however, when NASA's Jeff Ding brought the FSW process to the NASA agency. Although, at that time, FSW was little more than a "lab curiosity", NASA researchers started investigating where the FSW process would best fit NASA manufacturing programs. A laboratory FSW system was procured and the first welds were made in fall of 1995. The small initial investment NASA made into the first FSW system has certainly paid off for the NASA agency in terms of cost savings, hardware quality and notoriety. FSW is now a part of Shuttle External Tank (ET) production and the preferred weld process for the manufacturing of components for the new Crew Launch Vehicle (CLV) and Heavy Lift Launch Vehicle (HLLV) that will take this country back to the moon. It is one of the solid state welding processes being considered for on-orbit space welding and repair, and is of considerable interest for Department of Defense @OD) manufacturing programs. MSFC involvement in these and other programs makes NASA a driving force in this country's development of FSW and other solid state welding technologies. Now, a decade later, almost the entire on-going welding R&D at MSFC now focuses on FSW and other more advanced solid state welding processes.
Significant advantages in specific mechanical properties, when compared to conventional aluminum (Al) alloys, make aluminum-lithium (Al-Li) alloys attractive candidate materials for use in cryogenic propellant tanks and dry bay structures. However, the cost of Al-Li alloys is typically five times that of 2219 aluminum. If conventional fabrication processes are employed to fabricate launch vehicle structure, the material costs will restrict their utilization. In order to fully exploit the potential cost and performance benefits of Al-Li alloys, it is necessary that near-net manufacturing methods be developed to off-set or reduce raw material costs. Near-net forging is an advanced manufacturing method that uses elevated temperature metal movement (forging) to fabricate a single piece, near-net shape, structure. This process is termed 'near-net' because only a minimal amount of post-forge machining is required. The near-net forging process was developed to reduce the material scrap rate (buy-to-fly ratio) and fabrication costs associated with conventional manufacturing methods. The goal for the near-net forging process, when mature, is to achieve an overall cost reduction of approximately 50 percent compared with conventional manufacturing options for producing structures fabricated from Al-Li alloys. This NASA Marshall Space Flight Center (MSFC) sponsored program has been a part of a unique government / industry partnership, coordinated to develop and demonstrate near-net forging technology. The objective of this program was to demonstrate scale-up of the near-net forging process. This objective was successfully achieved by fabricating four integrally stiffened, 170- inch diameter by 20-inch tall, Al-Li alloy 2195, Y-ring adapters. Initially, two 2195 Al-Li ingots were converted and back extruded to produce four cylindrical blockers. Conventional ring rolling of the blockers was performed to produce ring preforms, which were then contour ring rolled to produce 'contour preforms'. All of the contour preforms on this first-of-a-kind effort were imperfect, and the ingot used to fabricate two of the preforms was of an earlier vintage. As lessons were learned throughout the program, the tooling and procedures evolved, and hence the preform quality. Two of the best contour preforms were near- net forged to produce a process pathfinder Y-ring adapter and a 'mechanical properties pathfinder' Y-ring adapter. At this point, Lockheed Martin Astronautics elected to procure additional 2195 aluminum-lithium ingot of the latest vintage, produce two additional preforms, and substitute them for older vintage material non-perfectly filled preforms already produced on this contract. The existing preforms could have been used to fulfill the requirements of the contract.
ARCO Solar's experiences as a participant in an industry-utility-government environmental qualification team examining photovoltaic devices are discussed. Included is an assessment of the applicability, completeness and appropriateness of the testing procedures and of the acceptance criteria for megawatt-sized procurements for utilities. Like the stand-alone users, the utility industry is interested in obtaining low costs, but additional concerns exist related to reliability and durability, safety, grounding and overall system criteria including performance prediction (related to output power acceptance testing), power quality and dispatchability. For purposes of this first major purchase of photovoltaic modules and panels by the utility industry, there was a carry-over of the JPL specifications. The need exists for futher development, assessement, and selection of qualification and testing standards and evaluation criteria specifically addressing these additional concerns for utility-connected PV power-plant applications.
Our team developed a motion-based simulation system for lunar terrain vehicles which resides at Johnson Space Center’s Systems Engineering Simulator (SES) facility. This activity integrates existing fixed base simulation capabilities with a newly procured motion base platform for the design, development, evaluation, and training associated with lunar terrain vehicles. This incorporates a South Pole Lunar virtual reality simulation, combined with a pair of VR headsets, integrated within a rover cockpit on a motion platform for evaluating human performance and vehicle handling qualities for concept roving vehicle designs for surface mobility operations.
— Motion and visual cue influences are critical in any simulator system, as they impact multiple aspects of the human’s neurovestibular and visual systems. Cues of real motion proceeds to the brain before cues of visual change. It is important therefore for simulator motion cues to exist and to match those realistically with those of the real vehicle to provide transferable training of the activity for operations. The United Kingdom’s Royal Air Force Institute of Aviation Medicine (1989)[1] stated that motion platforms are the only simulation devices capable of fully stimulating the body motion sensors. They confirmed that motion platforms can impart accelerations to the whole body and therefore exercise the automatic motion feedback-loop that operators are used to. With both visual and motion cues handling the vehicle becomes more realistic. Strachan (2019)[1] confirms motion cueing from a well set-up motion platform has been found to be important especially in conditions such as night or reduced visibility where motion cues may be more relied upon. As of this writing, the only lunar rover motion simulator is housed at the General Motors (GM) Milford Proving Ground, which only simulates the motions of a traditional car. A NASA Test Team proposed to complete a motion-based simulation system for NASA’s Lunar Terrain Vehicle (LTV) which resides at Johnson Space Center’s Systems Engineering Simulator facility. This activity integrated existing fixed base simulation capabilities with a newly procured six-degree of freedom motion base platform for the design, development, evaluation, and training associated with the LTV project. This would incorporate a South Pole Lunar virtual reality simulation using Lunar Reconnaissance Orbiter 5m/pixel high-resolution imagery and Unreal 5.2 Virtual Shadow Maps, combined with a virtual reality (VR) headset, integrated within a rover cockpit on a Mikrolar Motion Platform for evaluating human performance and vehicle handling qualities for concept roving vehicle designs. The motion-based system received its Human Rating Certification on March 2023. To begin testing the new facility, a preliminary handling qualities study was conducted. The objectives were to determine if there is a correlation amongst three handling quality methods of performance for a lunar vehicle and to understand the effects of a simulated 1/6-g loads and visuals with a motion platform on the operator while in a 1-g physical environment. The capability this system provides directly benefits the NASA’s Extravehicular Activity and Human Surface Mobility Program and NASA’s Flight Operations Directorate in evaluating the driving qualities of vehicle concepts, human performance related to the operating of a lunar surface vehicle, and assessment of suit related driving impacts. It would also provide direct operational benefit by providing a first-in class and unique simulation platform for the lunar astronaut training curriculum. The empirical knowledge of rover and human performance on this scale is paramount as there is currently no other lunar surface simulator with these capabilities. The result of this study ensures a broadly applicable method of testing for shirtsleeve, unpressurized and pressurized suited rover handling qualities.
This document establishes electrical, electronic, and electromechanical (EEE) parts management and control requirements for contractors providing and maintaining space flight and mission-essential or critical ground support equipment for NASA space flight programs. Although the text is worded 'the contractor shall,' the requirements are also to be used by NASA Headquarters and field installations for developing program/project parts management and control requirements for in-house and contracted efforts. This document places increased emphasis on parts programs to ensure that reliability and quality are considered through adequate consideration of the selection, control, and application of parts. It is the intent of this document to identify disciplines that can be implemented to obtain reliable parts which meet mission needs. The parts management and control requirements described in this document are to be selectively applied, based on equipment class and mission needs. Individual equipment needs should be evaluated to determine the extent to which each requirement should be implemented on a procurement. Utilization of this document does not preclude the usage of other documents. The entire process of developing and implementing requirements is referred to as 'tailoring' the program for a specific project. Some factors that should be considered in this tailoring process include program phase, equipment category and criticality, equipment complexity, and mission requirements. Parts management and control requirements advocated by this document directly support the concept of 'reliability by design' and are an integral part of system reliability and maintainability. Achieving the required availability and mission success objectives during operation depends on the attention given reliability and maintainability in the design phase. Consequently, it is intended that the requirements described in this document are consistent with those of NASA publications, 'Reliability Program Requirements for Aeronautical and Space System Contractors,' NHB 5300.4(1A-l); 'Maintainability Program Requirements for Space Systems,' NHB 5300.4(1E); and 'Quality Program Provisions for Aeronautical and Space System Contractors,' NHB 5300.4(1B).
The contracted activities for the procurement of 'Investigate Zero-Stress Replicated Optics' to support the AXAF-S x-ray spectrometer mirrors has been completed. To date four large Wolter I grazing incidence x-ray optical shells have been electroformed from nickel. The mirrors were fabricated utilizing each of two nickel alloy plated aluminum substrates twice. A wide variety of testing has been completed by NASA MSFC and UAH. This testing includes heat treatment control tests, subscale plating and fixture testing, alloy control of the electroless nickel, adhesion and release testing of the gold to electroless nickel, electroforming instrumentation and software and fabrication of subscale models. The full scale shells are one millimeter thick nickel electrodeposited over a thin gold layer which in turn has the optical surface on the inside. The optical surface is the replicate of the surface prepared on the substrate. Appendix I briefly outlines the fabrication process. Major objectives which were shared by UAH and MSFC include the design of facilities, equipment and tooling and procurement of materials and equipment. Process development followed with the fabrication of small scale pilot units. Procurement commenced immediately and equipment and materials were ordered to implement the fabrication of first surface full scale substrates (mandrels) and the second surface electroformed optical components. All principal objectives have been achieved. Inspection of the mirrors in visible and x-ray modes validates that the required performance and the quality can be achieved by an electroforming replication process. A very distinct progressive improvement has been achieved with each of the four mirrors produced. The final mirror exceeded the original goals and set an improved standard for flight hardware. The future goal of a 30 arc second resolution at 8 KEV x-ray appears to be achievable by this process when proper cleanliness and process control is utilized.
The Flight Hardware Support Request System (FHSRS) is a computer program that relieves engineers at Marshall Space Flight Center (MSFC) of most of the non-engineering administrative burden of managing an inventory of flight hardware. The FHSRS can also be adapted to perform similar functions for other organizations. The FHSRS affords a combination of capabilities, including those formerly provided by three separate programs in purchasing, inventorying, and inspecting hardware. The FHSRS provides a Web-based interface with a server computer that supports a relational database of inventory; electronic routing of requests and approvals; and electronic documentation from initial request through implementation of quality criteria, acquisition, receipt, inspection, storage, and final issue of flight materials and components. The database lists both hardware acquired for current projects and residual hardware from previous projects. The increased visibility of residual flight components provided by the FHSRS has dramatically improved the re-utilization of materials in lieu of new procurements, resulting in a cost savings of over $1.7 million. The FHSRS includes subprograms for manipulating the data in the database, informing of the status of a request or an item of hardware, and searching the database on any physical or other technical characteristic of a component or material. The software structure forces normalization of the data to facilitate inquiries and searches for which users have entered mixed or inconsistent values.