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All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRSDate not supplied

NASA Ames Flight Instrument Group - MARS Exploration Efforts Overview

The NASA Ames Flight Instrument Group (FIG) MARS development activities include Aeolus, an integrated multi-probe mission to observe surface and atmospheric forcing and general circulation of Mars; the Mars Sonic Anemometer (MSA), a sonic-based, in-situ wind measuring instrument and the Saltation Sensor to detect the critical wind stress threshold for sand motion, which is believed to be a key aspect of dust lifting at Mars. These efforts are readying the instruments to fly, and their measurements are regarded as data of high scientific priority for future flight missions. Each of these efforts focuses on addressing a measurement or capability considered critical within the Agency and traceable to the decadal survey and MEPAG Goals. As we elevate the Technology Readiness Level (TRL) of these instruments to 6 through rigorous environmental testing, and participate in forming mission concepts, we make them viable for inclusion in flight mission proposals. Below, we outline FIG's highest priority advancements for Mars exploration.

Mars↗
NASA NTRSDate not supplied

NASA Ames Flight Instrument Group - MARS Exploration Efforts Overview

The NASA Ames Flight Instrument Group (FIG) MARS development activities include Aeolus, an integrated multi-probe mission to observe surface and atmospheric forcing and general circulation of Mars; the Mars Sonic Anemometer (MSA), a sonic-based, in-situ wind measuring instrument and the Saltation Sensor to detect the critical wind stress threshold for sand motion, which is believed to be a key aspect of dust lifting at Mars. These efforts are readying the instruments to fly, and their measurements are regarded as data of high scientific priority for future flight missions. Each of these efforts focuses on addressing a measurement or capability considered critical within the Agency and traceable to the decadal survey and MEPAG Goals. As we elevate the Technology Readiness Level (TRL) of these instruments to 6 through rigorous environmental testing, and participate in forming mission concepts, we make them viable for inclusion in flight mission proposals. Below, we outline FIG's highest priority advancements for Mars exploration.

Mars↗
NASA NTRSDate not supplied

String Potentiometers for Supersonic Split-Line Thrust Vector Amplification Factor Verification

The static fire of NASA’s Mars Ascent Vehicle (MAV) first stage Solid Rocket Motor (SRM1) Demonstration Motor-1 (DM-1) occurred at Edwards Air Force Base (AFB) on April 7, 2023. Among other objectives, this test successfully demonstrated the Thrust Vector Control (TVC) system, including the Technology Readiness Level (TRL) of the Supersonic Split-Line (SSSL) nozzle. An essential characteristic of the SSSL is the thrust vector amplification factor (TVAF) it exhibits; however, empirically quantifying this behavior is difficult due to the limitations of measuring the internal nozzle gas dynamics of a Solid Rocket Motor (SRM) during burn. Using four string potentiometers mounted inside the test chamber connected to the nozzle and motor case and a thrust measurement system (TMS), the TVAF can be derived from the known nozzle and motor geometry. Increasing the accuracy of the TVAF is essential for certain groups working on the MAV including the Guidance, Navigation, and Control (GN&C) group, who prior to DM-1, solely relied on Computational Fluid Dynamics (CFD) data in their Monte Carlo simulations for TVAF. The methodology shown in this paper can be generally applied to any test article implementing a SSSL nozzle, presuming string potentiometers are a viable option and the facility is conducive of their implementation.

Supersonic Split-Line↗
NASA NTRSDate not supplied

Deep Space Habitat Primary Structure - A Comparison between Metallic, Inflatable, and Composite Materials

This paper presents a comprehensive trade study comparing metallic, inflatable, and composite primary structure materials for a Mars Transit Habitat module. The study evaluates the impact of these materials on the overall mass, outfitting, and mission complexity of the habitat. The results show that the composite module outperforms the other options in terms of minimum mass, being 33% lighter than the metallic configurations and 41% lighter than the inflatable option. The study highlights the potential of composite habitats for future space missions and emphasizes the need for further development and testing to increase the Technology Readiness Level.

Matthew T. Ziglar↗
NASA NTRSDate not supplied

Overview of the National Airspace System (NAS) Digital Twin Simulation Environment

The National Airspace System (NAS) Digital Twin is an environment for building and running diverse, realistic simulations of current or future airspace operations. The environment allows for many different types of simulations including both fast-time and real-time operating modes. Playback of historical or live NAS traffic can be combined with simulated aircraft to create a detailed, live, virtual, and constructive environment. These capabilities go together to create an environment that allows for development of concepts through the entire Technology Readiness Levels scale from initial concept to field evaluations. This extended abstract will discuss details of the software-foundations of the NAS Digital Twin environment. Then, several example simulations and analyses will be presented to illustrate the breadth and power of the tool.

airspace simulation, digital twin↗
NASA NTRSDate not supplied

Performance Testing of TRL4-6 LISA Laser System

The Laser Interferometer Space Antenna (LISA) is an ESA-led future mission to measure gravitational waves from astronomical sources in space. LISA has been adopted as a formal mission by ESA in January 2024, and is expected to become a formal project at NASA within 2024. The laser system (LS), which includes four laser heads (LH) each containing a laser optical module (LOM) and laser electronics module (LEM), a frequency reference system (FRS, optical frequency reference) and four power monitor detectors (PMON), is one of the three U.S. contributions to LISA from NASA. The Lasers and Electro-Optics Branch at NASA GSFC has been developing and managing the design of the LISA LS. Currently, the TRL (technology readiness level) of the NASA LISA laser system is transitioning from 4 to 6. TRL 4/5 LISA LOM was sent to ESA in early 2023 and has undergone optical performance testing. [1] By late summer of 2024, NASA plans to deliver the TRL 6 LOM to ESA for performance evaluation. Since the delivery of the TRL4/5 LOM to ESA, we have taken steps to advance the TRL of the overall LS and have also started end-to-end system level testing involving other subsystems. They include 1) optical performance test of TRL6 LOM and TRL 5 LEM under thermal cycling, 2) end-to-end test of the laser head (LH) and the GSE (ground support equipment) FRS, driven by TRL 4 FRS electronics (FRS-E) provided by Ball Aerospace, 3) end-to-end test of the laser head (LH) with the GSE phase meter system (PMS) provided by Albert Einstein Institute, and 4) optical performance test of the LH with the PMON subsystem developed by NASA. The FRS, PMS, and PMON provide necessary frequency stability, relative phase stability between lasers, and output power stability, respectively. Since they are all vital for the sensitive laser interferometry performed in LISA, it is necessary to perform these system level testing by combining the LH and other subsystems, and to prove the optical performance at an early stage during the LS development. Our recent work has successfully demonstrated the intra-connectivity of the LS, as well as critical external interface with the PMS to meet the LISA’s performance requirements. In this talk, we will report on the latest status of the LH testing and system level test. We will also discuss the paths to bring each subsystem to TRL6+ and plans for future system level testing.

LISA↗
NASA NTRSDate not supplied

Overview of the National Airspace System (NAS) Digital Twin Simulation Environment

The National Airspace System (NAS) Digital Twin is an environment for building and running diverse, realistic simulations of current or future airspace operations. The environment allows for many different types of simulations including both fast-time and real-time operating modes. Playback of historical or live NAS traffic can be combined with simulated aircraft to create a detailed, live, virtual, and constructive environment. These capabilities go together to create an environment that allows for development of concepts through the entire Technology Readiness Levels scale from initial concept to field evaluations. This extended abstract will discuss details of the software-foundations of the NAS Digital Twin environment. Then, several example simulations and analyses will be presented to illustrate the breadth and power of the tool.

airspace simulation↗
NASA NTRSDate not supplied

Seeing the Future of Spaceflight: Applications of Extended Reality (XR) Technologies

INTRODUCTION Advances in Earth Independent Medical Operations (EIMO) focused capabilities will be crucial for completing successful beyond low-earth-orbit (LEO) missions, where traditional Earth-based medical support and near real-time communication are limited, intermittent, or absent. In such restricted or limited communication environments, emerging extended reality (ER or XR) technologies may play a vital role in ensuring crew health and safety. Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR) are common terms used to describe technologies that "generate or modify" while “extended reality” (ER or XR) is often used as an umbrella term for these technologies. This review explores how such cutting-edge “extended reality” information delivery systems are currently applied across various disciplines within NASA. The review focuses on their capabilities, limitations, and prospective future applications as they pertain to Earth-Independent Medical Operations and its components of pre-mission planning, medical decision making, resource management, and task load management. METHODS/DESIGN The review began with a literature search to identify relevant disciplines (e.g., medical education, austere environments) where XR technologies have been studied to highlight areas where evidence is lacking. Previous and current NASA XR projects and applications, as well as commercial partnerships, such as those with Small Business Innovation Research (SBIR), were identified. Discussions with technical experts involved in the design, development, and application of these technologies allowed for classification based on their respective spaceflight applications. RESULTS AND CONCLUSION This review highlights current and emerging XR technologies that have been developed, tested, and implemented both terrestrially and in spaceflight by NASA, its international partners, the U.S. Armed Forces, and various relevant commercial entities. While these novel information delivery systems vary in their respective technology readiness levels (TRL), they have the potential to be implemented on Earth, in LEO, and during deep space exploration. These systems have the potential for impacting and optimizing many aspects of EIMO.

Yevgeniy Zhivotovskiy↗
NASA NTRSDate not supplied

Overview of the NASA LISA Laser System Development

NASA Goddard Space Flight Center (GSFC) is developing the Laser System (LS) for the Laser Interferometer Space Antenna (LISA) mission, led by the European Space Agency (ESA) with a launch date of 2035. The LS under development at NASA GSFC consists of the Laser Head (LH), the Frequency Reference System (FRS), and the Power Monitor (PMON) Detector Assemblies. Since late 2017, we have been developing various models to advance the technology readiness level (TRL) for the LH from prototype (TRL4) to a system model demonstration in a relevant environment (TRL6). For the LH and FRS, the models further breakdown into the optical and electronics modules where the LH is made up of the Laser Optical Module (LOM) and the Laser Electronics Module (LEM) and the FRS consists of the FRS Optical Reference Cavity (FRS-O) and the FRS Electronics (FRS-E). The LS development follows the established NASA process in demonstrating the performance requirements [1] through the TRL4 effort and then advancing the form factor and package design to meet relevant environment requirements and qualifying the TRL6 design through rigorous testing and performance verification for space applications. The LOM for the LH is a main oscillator power amplifier (MOPA) with wavelength of 1064 nm and nominal output power of 2 Watt throughout the mission. The low-power, low-noise main oscillator (MO) is a custom micro non-planar ring oscillator (µNPRO) [2] that is phase modulated then amplified by the forward pumped ytterbium-dope fiber power amplifier (PA) stage to meet the output power requirement. The FRS is baselined on the GRACE Follow-On (GFO) [3] approach with updated FRS-E design to work with the LH-LEM. The PMON is located on the Optical Bench Assembly (OBA) [4] that samples a small portion of the LH output signal and provides the feedback signal to the LH-LEM for relative intensity noise (RIN) control. In this paper, we will report on the latest status of the LH testing and system level tests, explain the other subsystems involved in the test campaigns, and discuss the path to bring each LS subsystem to TRL6. We will also present the NASA GSFC roadmap in advancing the LISA LS to TRL6+ and plans for future system level testing as well as the preparation for space flight development to meet the LISA launch date of 2035.

amplifier↗
NASA NTRS2024

Lunar Vehicle Active Charge Control System (LVACCS)+

The Lunar Vehicle Active Charge Control System (LVACCS) is an instrument in development that will measure the electrical potential of a spacecraft or rover under both positive and negative charge conditions, actively discharge negative charge, and charge the vehicle to a safe positive potential. All surfaces immersed in a plasma charge to non-zero potentials. In very low-density plasma (< 100 cm^-3), space vehicle charging can interfere with plasma probe measurements, degrade avionics performance, or cause a total system failure. LVACCS provides real-time in-situ space situational awareness that overcome these challenges in a small package. LVACCS has been awarded a NASA PICASSO grant to bring the instrument to technology readiness level 5. LVACCS consists of two main components: a collimated photoelectron gun (CPEG) and a Spacecraft Charge Detector (SCD).Monitoring charge build up on the lunar surface isa critical first step to understand hazards for crew, rovers, and instrumentation operating there.The LVACCS instrument will be able to fill in this gap providing robust lunar surface potential measurements and active charge dissipation.

Moon↗
NASA NTRS2025

Transit Habitat Government-Reference Conceptual Design Reaction Control System Propulsion Concept Design Data Book

The function of Transit Habitat (TH) Reaction Control System (RCS) propulsion is to provide free-flying spacecraft capabilities and to augment Gateway stack control when docked on Gateway. The requirements of multiple propellant replenishments and extensive life operation have significant impacts on selection of the propulsion system concept and components for the RCS. The intent of this document is to provide insight into the government-reference conceptual design of a propulsion system for TH element. A pressure-fed hypergolic bi-propellant system is the assumed propulsion approach for the RCS. Its architectural concept is being traded within the NASA Moon to Mars architecture. A pressure-regulated system is examined. The propellants under consideration are Monomethyl Hydrazine (MMH) and Mixed Oxides of Nitrogen with 3% Nitric Oxide (MON3). A peer review was conducted to assess the flow schematic design and propulsion component selection, compliant with a set of assumed requirements. Redundant components to satisfy one-fault tolerance for function and two-fault tolerance against catastrophic events are incorporated in the propulsion concept design. Instrumentation laid out on the schematic would be used to gather data to monitor the health of the propulsion system and to support quantity gauging of the propulsion system fluids. Venting propellant ullage gas overboard during the refilling operations poses a significant concern to the external surfaces of the TH. A liquid/gas separator would be required to eliminate, or at least reduce, the amount of liquid propellant expelled in the vent gas mixture. The technology readiness level of the phase separator for the TH must be advanced. Metal diaphragm and non-positive-expulsion PMD propellant tank systems were traded against each other, with the PMD architecture being selected. A blowdown concept is also considered for the TH RCS propulsion. Its fluid schematic is derived from the pressure-regulated schematic with removal of assemblies involving the helium pressurization and ullage venting. Its system wet mass is 10% heavier than the pressure-regulated due to thruster performance loss and larger propellant tanks. There is no firm constraint on the propulsion system mass at this phase of the design. The blowdown concept can offer reduction in component count and operation, that would lead to a more reliable propulsion system. The blowdown concept would also benefit avionics, thermal, power, and structures on the TH. Assessing these benefits will be carried as a future work. Drawbacks of thrust and minimum impulse bit (MIB) variations due to the blowdown operation would be acceptable to Guidance, Navigation, and Control (GNC). Although the blowdown concept has been selected as a current baseline, further evaluation of the concept will be the subject of future work to ensure that the blowdown propulsion operation is appropriate for the HT RCS propulsion. This document also highlights key trade studies and design decisions, including pros and cons of the selected concept. Other appropriate options for components are pointed out for future assessments. Additional background information and documents for further review are referenced in this report.

spacecraft propulsion↗
NASA NTRSDate not supplied

Design, Development, and Test of the Advanced Apollo Orbital Assembly System

As spaceflight moves toward commercial solutions for Crew Vehicles and Space Stations, opportunity exists to lower costs with novel designs. Probe and cone docking systems provide a lightweight, low cost, and high-performance docking solution. This work revisits the Apollo probe and cone design and modifies it for the requirements of today’s computer-controlled spacecraft. This new system is called the Advanced Apollo Orbital Assembly (APOA) system, and is intended to support satellite, cargo, and space station assembly missions. A simulation of the APOA was programmed, components were sized, and a design was created by scaling the probe to the size of an EELV Secondary Payload Adapter (ESPA) tunnel. Prototype test hardware was 3D printed using Fused Deposition Modeling (FDM) methods with Polylactic Acid (PLA) material. Testing of the APOA-ESPA was conducted at Marshall Space Flight Center’s (MSFC) Flat Floor, and a test-correlated simulation is used to evaluate a Monte-Carlo of Initial Contact Conditions (ICC’s) to establish baseline performance. The successful development, test, and correlation of the APOA-ESPA proves the design validity and increases Technology Readiness Level (TRL) from 2 to 4. This work opens the door to construction of an APOA-ESPA from flight like materials, and to develop a larger scale prototype APOA. When the full scale APOA is incorporated with the Common Berthing Mechanism (CBM), becomes the Hybrid Berthing System (HBS), which allows for berthing without a robotic arm.

Berthing↗
NASA NTRSDate not supplied

Subscale Hardware-In-The-Loop Results for Hybrid Electric Turbofan Controls Use Cases

NASA is investigating hybrid electric turbine engine systems for commercial transport aircraft due to the potentially significant improvements hybrid electric technology offers in performance, fuel consumption, and operational and design flexibility. Recently, the technology has been tested at full scale in partnership with industry and advanced to Technology Readiness Level 4. This presentation will focus on a recent subscale hardware-in-the-loop test of an open source turbofan engine model developed by NASA. The Advanced Geared Turbofan 30,000 lbf – electrified (AGTF30-e) engine is used as a reference model to demonstrate control system design and use cases for an example mild hybrid electric system with no large-scale energy storage. This model is run in real-time in NASA’s Hybrid Propulsion Emulation Rig (HyPER) and is used to drive an emulation of the turbomachinery system using subscale electric machines. This dynamic scaled shaft emulation interacts with a subscale (<100 kW) hybrid system consisting of electric machines, motor controllers, and a programmable electronic load. Specific use cases demonstrated include the use of Turbine Electrified Energy Management to improve operation during transients, megawatt-scale power extraction from the AGTF30-e, and power transfer between engine spools. Results related to the effectiveness of hybrid systems are qualitatively compared to results from industry testing.

Hybrid↗
NASA NTRS1973

Atmosphere revitalization for manned spacecraft - An assessment of technology readiness

The level of proficiency attained by the most effective physical and chemical regenerative processes capable of providing a habitable atmospheric environment in a spacecraft is assessed. It is shown that both the Sabatier and Bosh reactions are in a mature stage of technological readiness and can effectively reduce the carbon dioxide in a spacecraft. An electrochemical method for concentrating CO2 from an air environment offers promise to approach low levels of pCO2 control. Technological advances in the fields of solid polymer electrolytes and oxygen evolution electrocatalysts have led to a water electrolysis system that can maintain efficient performance for several years. Nitrogen supply and control of the composition of the spacecraft atmosphere is effectively provided by the circulating electrolyte technique.

Samonski, F. H., Jr.↗
NASA NTRS2011

Airport Noise Tech Challenge Overview

The Supersonics Project, operating under NASA Aeronautics Mission Directorate#s Fundamental Aero Program, has been organized around the Technical Challenges that have historically precluded commercial supersonic flight. One of these Challenges is making aircraft that are capable of such high aerodynamic performance quiet enough around airports that they will not be objectionable. It is recognized that a successful civilian supersonic aircraft will be a system where many new technologies will come together, and for this to happen not only will new low noise propulsion concepts be required, but new engineering tools that predict the noise of the aircraft as these technologies are combined and compromised with the rest of the aircraft design. These are the two main objectives of the Airport Noise Tech Challenge. " ! As a Project in the Fundamental Aero Program, we work at a relatively low level of technology readiness. However, we have high level milestones which force us to integrate our efforts to impact systems-level activities. To keep the low-level work tied to delivering engineering tools and low-noise concepts, we have structured our milestones around development of the concepts and organized our activities around developing and applying our engineering tools to these concepts. The final deliverables in these milestones are noise prediction modules validated against the best embodiment of each concept. These will then be used in cross-disciplinary exercises to demonstrate the viability of aircraft designs to meet all the Technical Challenges. Some of the concepts being developed are shown: Fan Flow Diverters, Multi-jet Shielding, High-Aspect Ratio Embedded Nozzles, Plasma Actuated Instability Manipulation, Highly Variable Cycle Mixer- Ejectors, and Inverted Velocity Profiles. These concepts are being developed for reduced jet noise along with the design tools which describe how they perform when used in various aircraft configurations. Several key upcoming events are highlighted, including tests of the Highly Variable Cycle Mixer-Ejectors, and Inverted Velocity Profiles. Other key events are milestones to be delivered within the next calendar year.

Bridges, James↗
NASA NTRS1984

Low lift-to-drag aero-assisted orbit transfer vehicles

The results of systems analysis conducted on low life drag ratio (L/D) aero-assisted orbit transfer vehicle (AOTV's) are presented. The objectives for this class of vehicle and formulate technology development plans and funding levels to bring the required technologies to readiness levels, as well as develop a credible decision data base encompassing the entire range of low L/D concepts for use in future NASA Aeroassist Orbit Transfer Vehicles studies. Each candidate low L/D concept, the aerobrake, the lifting brake, and the aeromaneuvering concept could be made to work with technologies achievable by the early 1990's. All concepts require flexible structure with flexible thermal protection system (TPS) to be successfully integrated into the shuttle orbiter for launch, all required improvements in guidance and control to fly the dispersed atmospheres at high altitude, and all concepts had potential to evolve from ground-based to space-based operations.

Andrews, D. G.↗
NASA NTRS1985

Regenerative fuel cell systems for space station

Regenerative fuel cell (RFC) systems are the leading energy storage candidates for Space Station. Key design features are the advanced state of technology readiness and high degree of system level design flexibility. Technology readiness was demonstrated through testing at the single cell, cell stack, mechanical ancillary component, subsystem, and breadboard levels. Design flexibility characteristics include independent sizing of power and energy storage portions of the system, integration of common reactants with other space station systems, and a wide range of various maintenance approaches. The design features led to selection of a RFC system as the sole electrochemical energy storage technology option for the space station advanced development program.

Hoberecht, M. A.↗