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NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗
NASA NTRS2007

X-Band Radar for Studies of Tropical Storms from High Altitude UAV Platform

The increased role of unmanned aerial vehicles (UAV) in NASA's suborbital program has created a strong interest in the development of instruments with new capabilities, more compact sizes and reduced weights than the instruments currently operated on manned aircrafts. There is a strong demand and tremendous potential for using high altitude UAV (HUAV) to carry weather radars for measurements of reflectivity and wind fields from tropical storms. Tropical storm genesis frequently occurs in ocean regions that are inaccessible to piloted aircraft due to the long off shore range and the required periods of time to gather significant data. Important factors of interest for the study of hurricane genesis include surface winds, profiled winds, sea surface temperatures, precipitation, and boundary layer conditions. Current satellite precipitation and surface wind sensors have resolutions that are too large and revisit times that are too infrequent to study this problem. Furthermore, none of the spaceborne sensors measure winds within the storm itself. A dual beam X-band Doppler radar, UAV Radar (URAD), is under development at the NASA Goddard Space Flight Center for the study of tropical storms from HUAV platforms, such as a Global Hawk. X-band is the most desirable frequency for airborne weather radars since these can be built in a relatively compact size using off-the-shelf components which cost significantly less than other higher frequency radars. Furthermore, X-band radars provide good sensitivity with tolerable attenuation in storms. The low-cost and light-weight URAD will provide new capabilities for studying hurricane genesis by analyzing the vertical structure of tropical cyclones as well as 3D reflectivity and wind fields in clouds. It will enable us to measure both the 3D precipitation structure and surface winds by using two antenna beams: fixed nadir and conical scanning each produced by its associated subsystem. The nadir subsystem is a magnetron based radar modified from a marine radar transceiver. It is capable of measuring vertical reflectivity and velocity profile while being a lower-cost, smaller size, and lighter weight version of the NASA ER-2 Doppler Radar (EDOP), which has flown during many NASA field campaigns and has provided valuable scientific information on hurricanes and weather phenomena. Unfortunately, EDOP is too large and heavy for most UAV platforms, but the experience gained with this instrument provided us with the heritage to build a new low-cost, light-weight, smaller system that will be capable of flying on UAVs. The scanning subsystem uses a TWT transmitter and provides measurements of 3D reflectivity/wind fields in-clouds. Conical scanning of the radar beam at a 35 deg. incidence angle will also provide information of surface wind speed and direction derived from the surface return over a single 360 deg. sweep. URAD data system will be Linux based with the capability of autonomous operation. It will utilize cutting edge digital receiver and FPGA technologies to carry out the data acquisition and processing tasks. High speed navigation data from the aircraft will also be captured and saved along with radar data for 3D measurement field reconstruction and aircraft motion correction. There is a tremendous potential for UAVs to carry down-looking weather radars for measurements of reflectivity, horizontal and vertical winds from tropical storms. With operation from HUAV platforms, the dual beam X-band radar under development promises to provide greatly needed information for tropical storm research.

Rodriquez, Shannon↗
NASA NTRS2018

Climate Modeling of a Potential ExoVenus

The planetary mass and radius sensitivity of exoplanet discovery capabilities has reached into the terrestrial regime. The focus of such investigations is to search within the Habitable Zone where a modern Earth-like atmosphere maybe a viable comparison. However, the detection bias of the transit and radial velocity methods lies close to the host star where the received flux at the planet may push the atmosphere into a runaway greenhouse state. One such exoplanet discovery, Kepler-1649b, receives a similar flux from its star as modern Venus does from the Sun, and so was categorized as a possible exoVenus. Here we discuss the planetary parameters of Kepler-1649b in relation to Venus to establish its potential as a Venus analog. We utilize the general circulation model ROCKE-3D (Resolving Orbital and Climate Keys of Earth and Extraterrestrial Environments with Dynamics) to simulate the evolution of the surface temperature of Kepler-1649b under various assumptions, including relative atmospheric abundances. We show that in all our simulations the atmospheric model rapidly diverges from temperate surface conditions toward a runaway greenhouse with rapidly escalating surface temperatures. We calculate transmission spectra for the evolved atmosphere and discuss these spectra within the context of the James Webb Space Telescope Near-Infrared Spectrograph capabilities. We thus demonstrate the detectability of the key atmospheric signatures of possible runaway greenhouse transition states and outline the future prospects of characterizing potential Venus analogs.

Astrobiology↗
NASA NTRS2019

Loftid Aeroshell Engineering Development Unit Structural Testing

NASA’s Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology was selected for a Technology Demonstration Mission under the Space Technology Mission Directorate in 2017. HIAD is an enabling technology that can facilitate atmospheric entry of heavy payloads to planets such as Earth and Mars using a deployable aeroshell. The deployable nature of the HIAD technology allows it to avoid the size constraints imposed on current rigid aeroshell entry systems. This enables use of larger aeroshells resulting in increased entry system performance (e.g. higher pay-load mass and/or volume, higher landing altitude at Mars). The Low Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) is currently scheduled for late-2021. LOFTID will be launched out of Vandenberg Air Force Base as a secondary payload on an Atlas V rocket. The flight test features a 6m diameter, 70-deg sphere-cone aeroshell and will provide invaluable high-energy orbital re-entry flight data. This data will be essential in supporting the HIAD team to mature the technology to diameters of 10m and greater. Aeroshells of this scale are applicable to potential near-term commercial applications and future NASA missions. Currently the LOFTID project has completed fabrication of the engineering design unit (EDU) inflatable structure (IS) and the flexible thermal protection system (F-TPS). These two components along with the rigid nose and center body comprise the HIAD aeroshell system. This EDU aeroshell is the precursor to the LOFTID aeroshell that will be used for flight. The EDU was built to verify the design given the subtle differences between the LOFTID aeroshell and past aeroshell designs that have been fabricated under the NASA HIAD project. To characterize the structural performance of the LOFTID aeroshell design, three structural tests will be performed. The first test to be conducted is static load testing, which will induce a uniform load across the forward surface of the aeroshell to simulate the expected pressure forces during atmospheric entry. The IS integrated with the rigid center body will first be tested alone to provide data for analytical model correlation, and then the F-TPS will be integrated for a second series of static load testing of the full aeroshell system. Instrumentation will be employed during the test series to measure component loads during testing, and a laser scanner will be used to generate a 3D map of the aeroshell surface to verify that the shape of the structure is acceptable at the simulated flight loads. After static load testing, pack and deployment testing will be conducted multiple times on the integrated system to demonstrate the aeroshell’s ability to fit within the required packed volume for the LOFTID mission without experiencing significant damage. Finally, the aeroshell will undergo modal testing to characterize its structural response. This presentation will discuss the setup and execution of each of the three tests that the EDU aeroshell will undergo. In addition, initial results of the testing will be presented outlining key findings as LOFTID moves for-ward with fabrication of the flight aeroshell.

Swanson, G. T.↗
NASA NTRS1983

Analytical calculation of a single jet in cross-flow and comparison with experiment

A series of progressively finer grid systems to calculate the single jet in cross-flow experimentally measured were employed. The experimental measurements provide a collection of velocities, turbulence intensities, and jet concentration profiles with measurements of the inlet field. The use of a series of progressively finer grid systems allows a differentiation between numerical errors and the hydrodynamic modeling assumptions embodied in the 3D combustor code.

Claus, R. W.↗
NASA NTRS1991

Pictorial communication in virtual and real environments

Papers about the communication between human users and machines in real and synthetic environments are presented. Individual topics addressed include: pictorial communication, distortions in memory for visual displays, cartography and map displays, efficiency of graphical perception, volumetric visualization of 3D data, spatial displays to increase pilot situational awareness, teleoperation of land vehicles, computer graphics system for visualizing spacecraft in orbit, visual display aid for orbital maneuvering, multiaxis control in telemanipulation and vehicle guidance, visual enhancements in pick-and-place tasks, target axis effects under transformed visual-motor mappings, adapting to variable prismatic displacement. Also discussed are: spatial vision within egocentric and exocentric frames of reference, sensory conflict in motion sickness, interactions of form and orientation, perception of geometrical structure from congruence, prediction of three-dimensionality across continuous surfaces, effects of viewpoint in the virtual space of pictures, visual slant underestimation, spatial constraints of stereopsis in video displays, stereoscopic stance perception, paradoxical monocular stereopsis and perspective vergence. (No individual items are abstracted in this volume)

Ellis, Stephen R.↗
NASA NTRS1997

The polar solar wind: An additional acceleration due to the rotation of the magnetic sun

The influence of the solar rotation of the polar solar wind acceleration was analyzed theoretically. Data from the Solar and Heliospheric Observatory (SOHO) ultraviolet instruments were used to test the theoretical predictions. These predictions are: the double electric layer at the heliocentric distance of 2.6 solar radii, and the system of field-aligned electric currents above 2.6 solar radii. The model provides a 3D analytical discontinuous stationary solution of the magnetohydrodynamic equations in the non-inertial frame of reference.

Pisanko, Y. V.↗
NASA NTRS1998

Model Simulations of Ozone in the Summer Lower Stratosphere

The Goddard 3D chemistry and transport model (CTM) uses winds and temperatures from the Goddard Earth Observing System Data Assimilation System (GEOS DAS); thus CTM simulations can be compared directly with observations from satellite, balloon and aircraft. In general, aspects of these comparisons show remarkable agreement between observation and model. One significant difference is that the model ozone is high biased below the ozone peak. The bias is apparently largest at high latitudes during the summer months. At the same time, comparisons with HALOE observations show that at mid to high latitudes, the ozone mixing ratio peak appears persistently at a lower altitude than observed by HALOE; the peak mixing ratio is also overestimated by the model. Both transport and photochemistry are possible contributors to the biased ozone in the lower stratosphere - excessive downward motion would increase lower stratospheric ozone, as would a too large vertical gradient in ozone. On the other hand, comparisons of model N2O and NOy with observations suggest transport deficiencies in the opposite sense, i.e., model N2O can be high relative to observations (particularly during winter), suggesting the need for stronger downward transport. Sensitivity studies have been carried out using parameterizations for ozone production and loss, NOy production and loss, and N2O loss. The goal of these studies is to clarify how problems in the photochemical scheme at and above the ozone peak influence the lower stratospheric ozone.

Douglass, Anne R.↗
NASA NTRS2005

The Effect of Fiber Architecture on Matrix Cracking in Sic/sic Cmc's

Applications incorporating silicon carbide fiber reinforced silicon carbide matrix composites (CMC's) will require a wide range of fiber architectures in order to fabricate complex shape. The stress-strain response of a given SiC/SiC system for different architectures and orientations will be required in order to design and effectively life-model future components. The mechanism for non-linear stress-strain behavior in CMC's is the formation and propagation of bridged-matrix cracks throughout the composite. A considerable amount of understanding has been achieved for the stress-dependent matrix cracking behavior of SiC fiber reinforced SiC matrix systems containing melt-infiltrated Si. This presentation will outline the effect of 2D and 3D architectures and orientation on stress-dependent matrix-cracking and how this information can be used to model material behavior and serve as the starting point foe mechanistic-based life-models.

Morscher, Gregory N.↗
NASA NTRS2018

Sizing and Margin Methodology for Dual-Layer Thermal Protection Systems

This presentation introduces a new sizing and margin methodology for dual-layer Thermal Protection Systems (TPS). The methodology has been tailored for application to a dual-layer 3D-woven TPS called Heat-shield for Extreme Entry Environments Technology (HEEET). Sizing is performed for a reference Saturn probe mission to show how uncertainties in trajectory, aerothermal modelling and TPS response impact the sizing of each layer.

Sizing↗
NASA NTRS1991

An interactive system for analysis of global cloud imagery

Synoptic images of the global cloud pattern composited from six contemporaneous satellites provide an unprecedented view of the global cloud field. Having horizontal resolution of about 0.5 deg and temporal resolution of 3 h, the global cloud imagery (GCI) resolves most of the variability of organized convection, including several harmonics of the diurnal cycle. Although the GCI has these attractive features, the dense and 3D nature of that data make it a formidable volume of information to treat in a practical and efficient manner. An interactive image-analysis system (IAS) has been developed to investigate the space-time variability of global cloud behavior. In the IAS, data, hardware, and software are integrated into a single system providing a variety of space-time covariance analyses in a menu-driven format. Owing to its customized architecture and certain homogeneous properties of the GCI, the IAS calculates such quantities effectively. Many covariance statistics are derived from 3D data with interactive speed, allowing the user to interrogate the archive iteratively in a single session. The 3D nature of those analyses and the speed with which they are performed distinguish the IAS from conventional image processing of 2D data.

Woodberry, Karen↗
NASA NTRS2008

SPICE Module for the Satellite Orbit Analysis Program (SOAP)

A SPICE module for the Satellite Orbit Analysis Program (SOAP) precisely represents complex motion and maneuvers in an interactive, 3D animated environment with support for user-defined quantitative outputs. (SPICE stands for Spacecraft, Planet, Instrument, Camera-matrix, and Events). This module enables the SOAP software to exploit NASA mission ephemeris represented in the JPL Ancillary Information Facility (NAIF) SPICE formats. Ephemeris types supported include position, velocity, and orientation for spacecraft and planetary bodies including the Sun, planets, natural satellites, comets, and asteroids. Entire missions can now be imported into SOAP for 3D visualization, playback, and analysis. The SOAP analysis and display features can now leverage detailed mission files to offer the analyst both a numerically correct and aesthetically pleasing combination of results that can be varied to study many hypothetical scenarios. The software provides a modeling and simulation environment that can encompass a broad variety of problems using orbital prediction. For example, ground coverage analysis, communications analysis, power and thermal analysis, and 3D visualization that provide the user with insight into complex geometric relations are included. The SOAP SPICE module allows distributed science and engineering teams to share common mission models of known pedigree, which greatly reduces duplication of effort and the potential for error. The use of the software spans all phases of the space system lifecycle, from the study of future concepts to operations and anomaly analysis. It allows SOAP software to correctly position and orient all of the principal bodies of the Solar System within a single simulation session along with multiple spacecraft trajectories and the orientation of mission payloads. In addition to the 3D visualization, the user can define numeric variables and x-y plots to quantitatively assess metrics of interest.

Coggi, John↗
NASA NTRS2019

Simulated Phase-dependent Spectra of Terrestrial Aquaplanets in M Dwarf Systems

Orbital phase-dependent variations in thermal emission and reflected stellar energy spectra can provide meaningful constraints on the climate states of terrestrial extrasolar planets orbiting M dwarf stars. Spatial distributions of water vapor, clouds, and surface ice are controlled by climate. In turn, water, in each of its thermodynamic phases, imposes significant modulations to thermal and reflected planetary spectra. Here we explore these characteristic spectral signals, based on 3D climate simulations of Earth-sized aquaplanets orbiting M dwarf stars near the habitable zone. By using 3D models, we can self-consistently predict surface temperatures and the location ofwater vapor, clouds, and surface ice in the climate system. Habitable zone planets in M dwarf systems are expected to be in synchronous rotation with their host star and thus present distinct differences in emitted and reflected energy fluxes depending on the observed hemisphere. Here we illustrate that icy, temperate, and incipient runaway greenhouse climate states exhibit phase-dependent spectral signals that enable their characterization.

Wolf, E. T.↗
NASA NTRS2001

[Real time 3D echocardiography]

Three-dimensional representation of the heart is an old concern. Usually, 3D reconstruction of the cardiac mass is made by successive acquisition of 2D sections, the spatial localisation and orientation of which require complex guiding systems. More recently, the concept of volumetric acquisition has been introduced. A matricial emitter-receiver probe complex with parallel data processing provides instantaneous of a pyramidal 64 degrees x 64 degrees volume. The image is restituted in real time and is composed of 3 planes (planes B and C) which can be displaced in all spatial directions at any time during acquisition. The flexibility of this system of acquisition allows volume and mass measurement with greater accuracy and reproducibility, limiting inter-observer variability. Free navigation of the planes of investigation allows reconstruction for qualitative and quantitative analysis of valvular heart disease and other pathologies. Although real time 3D echocardiography is ready for clinical usage, some improvements are still necessary to improve its conviviality. Then real time 3D echocardiography could be the essential tool for understanding, diagnosis and management of patients.

Review↗
NASA NTRS2012

Vehicle Detection for RCTA/ANS (Autonomous Navigation System)

Using a stereo camera pair, imagery is acquired and processed through the JPLV stereo processing pipeline. From this stereo data, large 3D blobs are found. These blobs are then described and classified by their shape to determine which are vehicles and which are not. Prior vehicle detection algorithms are either targeted to specific domains, such as following lead cars, or are intensity- based methods that involve learning typical vehicle appearances from a large corpus of training data. In order to detect vehicles, the JPL Vehicle Detection (JVD) algorithm goes through the following steps: 1. Take as input a left disparity image and left rectified image from JPLV stereo. 2. Project the disparity data onto a two-dimensional Cartesian map. 3. Perform some post-processing of the map built in the previous step in order to clean it up. 4. Take the processed map and find peaks. For each peak, grow it out into a map blob. These map blobs represent large, roughly vehicle-sized objects in the scene. 5. Take these map blobs and reject those that do not meet certain criteria. Build descriptors for the ones that remain. Pass these descriptors onto a classifier, which determines if the blob is a vehicle or not. The probability of detection is the probability that if a vehicle is present in the image, is visible, and un-occluded, then it will be detected by the JVD algorithm. In order to estimate this probability, eight sequences were ground-truthed from the RCTA (Robotics Collaborative Technology Alliances) program, totaling over 4,000 frames with 15 unique vehicles. Since these vehicles were observed at varying ranges, one is able to find the probability of detection as a function of range. At the time of this reporting, the JVD algorithm was tuned to perform best at cars seen from the front, rear, or either side, and perform poorly on vehicles seen from oblique angles.

Brennan, Shane↗
NASA NTRS2024

Derivation of Equations of Motion and Model-based Control for 3D Rigid Body Approximation of LUVOIR

The Large UV/Optical/IR Surveyor (LUVOIR) is a conceptual space observatory under development by NASA Goddard Space Flight Center for the Astronomy and Astrophysics Decadal Survey. As with similar space telescopes, e.g., James Webb, this spacecraft will have ultra-stringent pointing stability requirements, i.e., on the order of miliarcseconds. Thus, the design of the LUVOIR attitude control system (ACS) may benefit from a model-based approach. In this document, we present an approximate model of the LUVOIR composed of two 3D rigid bodies connected by a 1-DOF rotary joint. From this model, we derive the nonlinear equations of motion, following the approach of Eric T. Stoneking [1], and linearize them about an arbitrary reference orientation. Using the subsequent state space representation, it is straightforward to compute a set of control gains (e.g., via the ”lqr” or ”place” commands in MATLAB). We conclude this memo with a comparison of our LQR approach with the existing PID slew controller designed by a former NASA intern.

William Bentz↗