Space Construction Automated Fabrication Experiment Definition Study (SCAFEDS). Volume 2: Study results
For abstract, see N78-25111.
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For abstract, see N78-25111.
Carbon fibers have opened a wealth of new structural engineering and consumer product opportunities. The potential benefits are higher strength, and lighter weight military and commercial products, which portend energy savings and increases safety. Unfortunately, these benefits are not realized without risk. Inadvertent fiber release, during manufacture or by destruction of the resin binder in fire, is the major hazard associated with composites. The carbon (or graphite) fibers are finer than human hair and if released into the air, they can be easily transported by winds or currents. In contact with electrical devices, they can create resistive loading, short circuits, and arcing, resulting in stoppages or destruction. Their health impact is not fully known and requires careful research and analysis before any firm conclusions can be reached; however, based upon current available information, they are primarily an irritant to the eyes and skin, like fiberglass, rather than carcinogenic or destructive to lung tissue. Major manufacturers are aware of the unique problems associated with these materials and have successfully applied controls to avoid the inplant problems.
The existing designs of the X-3060 and X-3075 klystrons were critically examined to determine whether or not realistic redesign goals could be established. Additionally, failure analyses and field failure reports were examined to identify any design weaknesses. Results of this critical analysis indicate that substantial improvements can be made to the overall design of both the X-3060 and X-3075 klystrons. Pertinent and detailed data concerning these improvements are reported herein.
There are no author-identified significant results in this report.
Six samples from the upper core 60010 of the double drive core 60009/60010 were analyzed for grain size distribution, petrographic particle types and abundances, magnetic fraction, and ferromagnetic resonance. It was found that the magnetic fraction of these soils is not equivalent to the agglutinate fraction, and magnetic separation partitions high-FeO agglutinate from low-FeO agglutinates. Various maturity indices are in essential agreement. The deposition of most or all of the core could have occurred in a single event. If that is the case, the core units have no time-stratigraphic significance and do not reflect individual cratering events.
The methodology and rationale used in the development of costs for engineering, manufacturing, testing and operating a low thrust system for placing automated shuttle payloads into earth orbits are described. Cost related information for the recommended propulsion approach is included.
Solar cells and optical configurations for the SSPS were examined. In this task, three specific solar cell materials were examined: single crystal silicon, single crystal gallium arsenide, and polycrystalline cadmium sulfide. The comparison of the three different cells on the basis of a subsystem parametric cost per kW of SSPS-generated power at the terrestrial utility interface showed that gallium arsenide was the most promising solar cell material at high concentration ratios. The most promising solar cell material with no concentration, was dependent upon the particular combination of parameters representing cost, mass and performance that were chosen to represent each cell in this deterministic comparative analysis. The potential for mass production, based on the projections of the present state-of-the-art would tend to favor cadmium sulfide in lieu of single crystal silicon or gallium arsenide solar cells.
Specific areas were analyzed and identified as high priority for more in-depth analysis. These areas were: (1) rectenna constructability; (2) satellite constructability; (3) support systems constructability; (4) space environmental analysis, and (5) special end-to-end analyses. Baseline requirements specified coplanar solar blankets and an end mounted antenna, utilizing either GaAlAs solar cells and employing a CR of 2, or Si cells. Several configurations were analyzed. Utilizing the preferred configuration as a baseline, a satellite construction base was defined, precursor operations incident to establishment of orbital support facilities identified, and the satellite construction sequence and procedures developed. Since the baseline specifies sixty instead of one hundred and twenty satellites to be constructed in a thirty year period, mass flow to orbit requirements were revised and new traffic models established. Launch site requirements (exclusive of actual launch operations) in terms of manpower and building space were defined.
Models of transportation mode decision making were developed. The user's view of the present and future air cargo systems is discussed. Issues summarized include: (1) organization of the distribution function; (2) mode choice decision making; (3) air freight system; and (4) the future of air freight.
The hydrogen oxygen engine used in the orbiter transfer vehicle is described. The engine design is analyzed and minimum engine performance and man rating requirements are discussed. Reliability and safety analysis test results are presented and payload, risk and cost, and engine installation parameters are defined. Engine tests were performed including performance analysis, structural analysis, thermal analysis, turbomachinery analysis, controls analysis, and cycle analysis.
The preliminary requirements and technology advances required for cost effective space power management systems for multi-100 kilowatt requirements were identified. System requirements were defined by establishing a baseline space platform in the 250 KE KWe range and examining typical user loads and interfaces. The most critical design parameters identified for detailed analysis include: increased distribution voltages and space plasma losses, the choice between ac and dc distribution systems, shuttle servicing effects on reliability, life cycle costs, and frequency impacts to power management system and payload systems for AC transmission. The first choice for a power management system for this kind of application and size range is a hybrid ac/dc combination with the following major features: modular design and construction-sized minimum weight/life cycle cost; high voltage transmission (100 Vac RMS); medium voltage array or = 440 Vdc); resonant inversion; transformer rotary joint; high frequency power transmission line or = 20 KHz); energy storage on array side or rotary joint; fully redundant; and 10 year life with minimal replacement and repair.
Satellite configurations based on the Satellite Power System baseline requirements were analyzed and a preferred concept selected. A satellite construction base was defined, precursor operations incident to establishment of orbital support facilities identified, and the satellite construction sequence and procedures developed. Rectenna construction requirement were also addressed. Mass flow to orbit requirements were revised and traffic models established based on construction of 60 instead of 120 satellites. Analyses were conducted to determine satellite control, resources, manufacturing, and propellant requirements. The impact of the laser beam used for space-to-Earth power transmission upon the intervening atmosphere was examined as well as the inverse effect. The significant space environments and their effects on spacecraft components were investigated to define the design and operational limits imposed by the environments on an orbit transfer vehicle. The results show that LEO altitude 300 nmi and transfer orbit duration 6 months are preferrable.
The environmental impact of space to Earth power transmission using space borne laser subsystems is emphasized. A laser system is defined, estimates of relevant efficiencies for laser power generation and atmospheric transmission are developed, and a comparison is made to a microwave system. Ancillary issues, such as laser beam spreading, safety and security, mass and volume estimates and technology growth are considered.
Program cost and planning data based on 1980 technology and shown in 1979 dollars for a 20K lb Thrust Staged Combustion Cycle Engine are presented. These data were compared with those for the Advanced Expander Cycle Engine at 10K lb and 20K lb thrust levels.
The design characteristics of the baseline engine configuration of the advanced expander cycle engine are described. Several aspects of engine optimization are considered which directly impact the design of the baseline thrust chamber. Four major areas of the power cycle optimization are emphasized: main turbine arrangement; cycle engine source; high pressure pump design; and boost pump drive.
The synchronous orbit of the IUE carries the satellite through Earth's outer electron belt. A 40 mCi Sr90 source was used to simulate these electrons. A 5 mCi source of Co60 was used to simulate bremmstrahlung. A 10 MeV electron Linac and a 1.7 MeV electron Van de Graaf wer used to investigate the energy dependence of radiation effects and to perform radiations at a high flux rate. A 100 MeV proton cyclotron was used to simulate cosmic rays. Results are presented for three instrument systems of the IUE and measurements for specific components are reported. The three instrument systems were the ultraviolet converter, the fine error sensor (FES), and the SEC vidicon camera tube. The components were optical glasses, electronic components, silicon photodiodes, and UV window materials.
Detailed computer models of the engine were developed to predict both the steady state and transient operation of the engine system. Mechanical design layout drawings were prepared for the following components: thrust chamber and nozzle; extendible nozzle actuating mechanism and seal; LOX turbopump and boost pump; hydrogen turbopump and boost pump; and the propellant control valves. The necessary heat transfer, stress, fluid flow, dynamic, and performance analyses were performed to support the mechanical design.
The feasibility of modifying resin matrix composites to reduce the potential of electrical shorting from fire released fiber was explored. The effort included modifications to or coatings for graphite fibers, alternative fibers, modifications to matrix materials, and hybrid composites. The objectives included reduction of the conductivity of the graphite fiber, char formation to reduce fiber release, glass formation to prevent fiber release, catalysis to assure fiber consumption in a fire, and replacement of the graphite fibers with nonconductive fibers of similar mechanical potential.