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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Protz, Christopher↗
NASA NTRS2016

Additively Manufactured Low Cost Upper Stage Combustion Chamber

Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

Protz, Christopher↗
DOE OSTI2020

Completion design improvement using a deep convolutional network

Maximizing stimulated natural and hydraulic fracture network is one of the primary hydraulic fracturing concerns for economic production from a horizontal shale gas well. Geomechanical facies and preexisting fractures in each stage are identified based on similarities in formation characteristics to optimize the locations of perforation clusters. This often requires analyzing large volumes of drilling, Logging While Drilling (LWD) and Measurement While Drilling (MWD) data. In this paper, we develop a methodology that calculates the mechanical specific energy (MSE) using real-time drill string acceleration signals directly from its definition. High resolution vibration signals have been collected using a tri-axial accerlometer, which was an auxiliary tool included in acoustic borehole imager. This technique provides a cost-efficient solution for engineered completion design. Furthermore, we adopt deep Convolutional Neural Network (CNN) with signal processing to build a data pipeline that effectively extracts patterns from dynamic acceleration signals for rock lateral MSE classification. First, we apply discrete wavelet transform and Short-Time Fourier Transform (STFT) for signal denoising and pattern recognition. Then we construct an image dataset using multi-scale image fusion at pixel level from 3 sensor channels, including axial, lateral acceleration spectrograms and zero-padded revolutions per minute (RPM). The resulted RGB image dataset includes 4,000 images of 5 MSE ranges with various rock strength conditions. Our results demonstrate that the proposed deep learning model can achieve more than 90% classification accuracy. The deep learning results, as a reference source, were applied in selected Marcellus Shale Energy and Environmental Lab (MSEEL) wells engineered completion located in the Marcellus shale gas site.

03 NATURAL GAS↗
DOE OSTI2024

Identification of Climatological Representative Days in the Mid-Atlantic for High-Fidelity Offshore Wind Energy Modeling

The goal of reaching 30 GW of offshore wind energy by 2030 becomes more realistic with the continued approval of offshore wind energy areas by the Biden Administration. In the Mid-Atlantic, where wind energy projects are in the most advanced stages of development, there is increased research focus on the eventual interaction of these wind farms. These interactions, in the form of wakes and cluster wakes, or wakes from multiple wind farms, could have detrimental effects on power production and forecastability for downwind wind farms (Pryor et al. 2022, Golbazi et al. 2022, Rosencrans et al. 2023). To help alleviate these issues, numerical simulations in the form of numerical weather prediction (NWP) and large eddy simulations (LES) can provide insight into when cluster wake situations may occur, but running such simulations can be expensive and difficult to run for multiple years. In this study, we leverage and build upon existing techniques in the literature (Fischereit et al. 2022) to identify climatologically representative days for wind energy areas in the Mid-Atlantic where conditions would promote cluster wake situations. We select meteorological variables (wind speed, wind direction, atmospheric stability, boundary-layer height, TKE) critical to understanding wind energy production and wake propagation. We then consider two different NWP datasets of varying spatial and temporal resolution: ERA5 provides data at hourly intervals from 1940 to present at 0.25 deg (31 km) spatial resolution (Hersbach et al. 2020), and the NOW-23 dataset provides data at 5-minute resolution for 21 years at 2-km spatial resolution (Bodini et al. 2020). Our first step is to compare these two datasets for an overlapping 21-year time period. Initial results show that the required number of days to represent the long-term climate increases with each additional variable considered. In their study of the German Bight, Fischereit et al. (2022) found that they could represent the long-term wind and wave climate in a "near-perfect" way with -180 days, by reaching a Perkins Skill Score (PSS) of 0.9; our investigation of the mid-Atlantic wind resource region with ERA5 and NOW-23 data suggests that we will need -100 days to reach a PSS of 0.9. As we expand our parameter space to include multiple variables, the number of required days will likely grow. These results will ultimately be used to select case studies to best represent cluster wake conditions that apply to this region for the lifetime of likely wind farms in this mid-Atlantic region.

clusterwakes↗
DOE OSTI2026

Phase change material-to-refrigerant heat exchangers: Experimental validation and uneven melting analysis

Thermal energy storage (TES) using phase change materials (PCMs) enables load shifting and reduces mismatches between the building's thermal demand and the heat pump (HP) system's thermal capacity. While most TES studies have focused on single-phase heat transfer fluids, PCM-to-refrigerant heat exchangers (PRHX), in which the refrigerant undergoes liquid-vapor phase change, remain largely underexplored. Here, to address this gap, this study systematically investigates a shell-and-tube PRHX operating as the condenser in an HP through experiments and simulations. A two-dimensional enthalpy-based finite-volume PRHX model was developed and validated against experimental data, including refrigerant and PCM temperature profiles, PRHX capacity, and system-level performance. Results show three characteristic stages: Stage I, the condenser temperature rapidly increases with PCM in the solid state absorbing sensible heat; Stage II, stable operation during PCM phase change; and Stage III, performance decline once part of the PCM becomes fully melted. Heat transfer analysis revealed that uneven PCM melting along the condenser length was driven primarily by variations in the refrigerant-side heat transfer coefficient, rather than local approach temperature differences. Further study demonstrated that minimizing refrigerant outlet subcooling led to more uniform PCM melting and extended Stages I and II by up to 89%. This paper provides a validated PRHX model, clarifies the mechanisms of uneven PCM melting, and highlights subcooling control as an effective strategy to improve TES performance in HP systems without requiring secondary loops.

Graphite matrix↗
NASA NTRS1992

Introduction to Space Station Freedom

NASA field centers and contractors are organized to develop 'work packages' for Space Station Freedom. Marshall Space Flight Center and Boeing are building the U.S. laboratory and habitation modules, nodes, and environmental control and life support system; Johnson Space Center and McDonnell Douglas are responsible for truss structure, data management, propulsion systems, thermal control, and communications and guidance; Lewis Research Center and Rocketdyne are developing the power system. The Canadian Space Agency (CSA) is contributing a Mobile Servicing Center, Special Dextrous Manipulator, and Mobile Servicing Center Maintenance Depot. The National Space Development Agency of Japan (NASDA) is contributing a Japanese Experiment Module (JEM), which includes a pressurized module, logistics module, and exposed experiment facility. The European Space Agency (ESA) is contributing the Columbus laboratory module. NASA ground facilities, now in various stages of development to support Space Station Freedom, include: Marshall Space Flight Center's Payload Operations Integration Center and Payload Training Complex (Alabama), Johnson Space Center's Space Station Control Center and Space Station Training Facility (Texas), Lewis Research Center's Power System Facility (Ohio), and Kennedy Space Center's Space Station Processing Facility (Florida). Budget appropriations impact the development of the Space Station. In Fiscal Year 1988, Congress appropriated only half of the funds that NASA requested for the space station program ($393 million vs. $767 million). In FY 89, NASA sought $967 million for the program, and Congress appropriated $900 million. NASA's FY 90 request was $2.05 billion compared to an appropriation of $1.75 billion; the FY 91 request was $2.45 billion, and the appropriation was $1.9 billion. After NASA restructured the Space Station Freedom program in response to directions from Congress, the agency's full budget request of $2.029 billion for Space Station Freedom in FY 92 was appropriated. For FY 93, NASA is seeking $2.25 billion for the program; the planned budget for FY 94 is $2.5 billion. Further alterations to the hardware configuration for Freedom would be a serious setback; NASA intends 'to stick with the current baseline' and continue planning for utilization.

Kohrs, Richard↗
NASA NTRS2023

Development Unit for In-Space Pneumatic Helium Transfer Compressor

High-pressure gaseous helium (GHe) plays a critical role in spacecraft propulsion due to its near exclusive use for pressurization of propellant tanks. Several different designs for helium compressor technologies have been developed for use on Earth; however, significant design changes are required to meet the power, thermal/heat dissipation, vacuum, vibration/shock, size, mass, and efficiency requirements needed for space and launch environments. Currently, no capability exists for mass efficient on-orbit GHe (or xenon) transfer, nor has it ever been attempted. This effort proposed several challenging requirements for the vendor to develop a one-of-a-kind pneumatic compressor prototype. In order to develop a compressor prototype at a TRL 4, a partnership with Air Squared, Inc. was established. This CIF project concluded with the receipt of a prototype along with a proposed design for a flight unit; however, it will not be built due to funding limitations. The vendor had moderate success with initial testing of the prototype at lower pressures (with shimming configured for low pressure). There were delays with testing since the unit was built for higher pressures and the low pressure shimming was challenging to implement. It was found that operation of the compressor at lower pressures caused increased friction on the motor shaft which resulted in the unit drawing more power (current). This was initially thought to be a motor or controller defect. Subsequent high pressure testing at KSC showed that the friction was reduced for the optimal design point (with a high pressure shimming configuration) and the motor (and controller) performed nominally. Following the vendor testing, the unit was tuned/shimmed for a nominal inlet pressure and shipped to KSC for high pressure testing using the custom-designed setup in the Vehicle Assembly Building. The unit performed well, showing the capability to achieve over higher pressure of compression. The pressure differential could likely increase, however, the maximum output of the power supply used for testing was reached, limiting the compressor motor’s capability. Following the GN2 testing, the test setup was converted to GHe with at high pressure. It was shown that although the unit was unable to achieve similar high pressure differentials due to reverse leakage of the GHe through the scroll tip seals, it did achieve the desired GHe compression. This may still be useful for some applications, however, for the purpose of on-orbit GHe transfer, the single stage design would need to be changed to include multiple stages to achieve the compression goals initially proposed by the project.

Brian Nufer↗
DOE OSTI2026

Experimental Evaluation of a High-Performance Cold-Climate Heat Pump Using Tandem Vapor-Injection Compressors

A high-performance cold-climate heat pump (CCHP) was developed and experimentally validated through comprehensive laboratory and field testing. The system utilized two equal-size tandem vapor-injection (VI) compressors with an inter-stage flash tank to improve efficiency and capacity retention under subfreezing conditions. Laboratory testing was conducted on a 3-ton prototype in a controlled environmental chamber equipped with calibrated thermocouples, refrigerant-side mass flow and pressure transducers, and precision airflow measurement for energy balance verification. The prototype achieved heating coefficients of performance (COPs) of 4.4 at 47 °F, 3.1 at 17 °F, and 2.0 at –13 °F, while maintaining 88% of its rated heating capacity at –13°F. These results confirm strong low-temperature performance and indicate the potential for significant reductions in electric resistance backup use. A field prototype was installed and monitored in a residential building in Fairbanks, Alaska, during a heating season. Instrumentation included real-time power, temperature, and refrigerant state measurements to evaluate performance under dynamic outdoor conditions. The heat pump operated reliably down to –30 °F, delivering 75% of its rated heating capacity with a COP of 1.8, while maintaining stable operation, effective defrost control, and indoor comfort without auxiliary heating. The combined laboratory and field results demonstrate that the tandem VI compressor configuration provides a practical and energy-efficient approach for residential heat pumps designed for cold and very cold climate regions.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI2025

Bulk-scale stress–strain hysteresis in layered crystalline solids: A study of graphite and Ti 3 SiC 2

Polycrystalline graphite and the MAX phase Ti 3 SiC 2 are layered crystalline solids with similar deformation mechanisms, including basal slip, ripplocation boundaries (RBs), kink boundaries (KBs), and cracking. The interplay of these mechanisms, notably in energy dissipation, has been much discussed in the past twenty-five years. This study builds upon previous work, investigating deformation with a renewed emphasis on the bulk-scale and given recent findings concerning RBs. Our investigation compares the evolution of energy dissipation, nonlinear recoverable and irrecoverable strain, and damage upon increasing stress for graphite and Ti 3 SiC 2 . Benitez et al.’s (2016) methodology of compressive cyclic loading and post-mortem electron backscatter diffraction (EBSD) to assess the prevalence of kinking based on low-angle grain boundaries (LAGBs) was used. Strains were measured with digital image correlation and EBSD was conducted on Ti 3 SiC 2 leveraging dictionary indexing, which was necessary herein to identify LAGBs accurately. The stress–strain stages of Ti 3 SiC 2 agree with literature on Ti 2 AlC. Damage and energy dissipation were more accelerated in graphite. No significant difference was observed in the fraction of LAGBs between pristine and unloaded Ti 3 SiC 2 . Trends observed and EBSD evidence that KBs were not dominant suggest that RBs are the primary dissipator of energy in both materials.

36 MATERIALS SCIENCE↗
NASA NTRS2003

The Clock Is Ticking

Recently, I worked on creating a one-of-a-kind device for a Space Station group studying exercise physiology at another NASA Center. They approached my department at Ames Research Center to design and build an exercise bed that allowed users to perform the motions that they needed for ground-based research. The real challenge was that they needed the device designed, built, and delivered in just one month. The bed was intended to simulate doing squats while in a horizontal position as if on a moving sled. They wanted to incorporate a resistant device called an Interim Resistive Exercise Device (IRED), an adjustable cable tied into a reel to provide a measured amount of resistance. This device was used on the Station for exercising in space; we were taking the same resistant reel and incorporating it in this bed. In the early stages of a design project, I communicate with a customer as much as I can and as often as they will tolerate. There s a lot of learning that needs to go on, and I prefer to spend a little bit of extra time here because that can save a lot of time later. In the beginning, you need to volley the information back-and-forth, so that you understand the customer s requirements and they know what you re capable of doing.

Gundo, Dan↗
NASA NTRS2018

NASA's Space Launch System: Unprecedented Payload Capabilities

As part of a renewed focus on deep space exploration, NASA and its private sector and international partners are building a new super heavy-lift launch vehicle, the Space Launch System (SLS), as well as the new Orion crew vehicle, and upgrading launch facilities at Kennedy Space Center. Progress made on the Block 1 vehicle, as well as its expected performance metrics and fiscal support from the U.S. administration and Congress, have opened up additional manifest possibilities that the Agency continues to evaluate. Offering a combination of power, payload capacity and departure energy unmatched in contemporary boosters, the SLS family of launch vehicles features the world's most-proven propulsion system: solid rocket boosters and RS-25 main engines with a modified existing cryogenic in-space stage. The initial SLS configuration, Block 1, will deliver at least 26 metric tons (t) of payload to trans-lunar injection (TLI). The vehicle's flexible architecture will enable the rocket to evolve over the next decade to meet the most demanding deep space mission requirements. The second configuration, Block 1B, will deliver at least 34 to 40 t to TLI, depending on whether the crewed or cargo variant is selected. Although designed to facilitate human exploration of deep space, the vehicle also provides game-changing benefits for large science payloads and even harnesses excess capacity to provide small satellites with affordable access to deep space. For the first integrated mission of SLS and Orion, launching from Kennedy Space Center in fiscal year 2020, SLS Block 1 will send Orion on a 25.5-day mission to a distant retrograde lunar orbit with the primary objective to test and validate new systems and procedures. That first mission, called Exploration Mission-1 (EM-1), also has 13 6U-class CubeSat payloads manifested. Those payloads, which will carry out a variety of scientific experiments and technology demonstrations, will deploy in several locations along the trajectory after Orion has separated from SLS. Contractors and suppliers have made significant progress since last year manufacturing the Block 1 vehicle for EM-1. The upper stage and adapters are complete as are the four RS-25 engines. All other major components are constructed and being outfitted for flight. In fact, hardware for the second flight is currently being manufactured at locations across the United States. This paper will outline hardware, avionics and testing progress toward the first and second flights of SLS. Manifest opportunities for primary, co-manifested and secondary payloads will be discussed. An in-depth look at payload utilization and integration will be provided, as well as lessons learned from installing a secondary payload deployment system for EM-1.

Creech, Steve↗
NASA NTRS1998

Urine Pretreatment Configuration and Test Results for Space Applications

Pretreatment of urine using Oxone and sulfuric acid is baselined in the International Space Station (ISS) waste water reclamation system to control odors, fix urea and control microbial growth. In addition, pretreatment is recommended for long term flight use of urine collection and two phase separation to reduce or eliminate fouling of the associated hardware and plumbing with urine precipitates. This is important for ISS application because the amount of maintenance time for cleaning and repairing hardware must be minimized. This paper describes the development of a chemical pretreatment system based on solid tablet shapes which are positioned in the urine collection hose and are dissolved by the intrained urine at the proper ratio of pretreatment to urine. Building upon the prior success of the developed and tested solid Oxone tablet a trade study was completed to confirm if a similar approach, or alternative, would be appropriate for the sulfuric acid injection method. In addition, a recommended handling and packaging approach of the solid tablets for long term, safe and convenient use on ISS was addressed. Consequently, the solid tablet concept with suitable packaging was identified as the Urine Pretreat / Prefilter Assembly (UPPA). Testing of the UPPA configuration confirmed the disolution rates and ratios required by ISS were achieved. This testing included laboratory controlled methods as well as a 'real world' test evaluation that occurred during the 150 day Stage 10 Water Recovery Test (WRT) conducted at NASA Marshall Space Flight Center (MSFC).

Howard, Stanley G.↗
DOE OSTI2025

Utilizing Single-Crystalline Transformations for Precise Atom Placement in Multicomponent Cluster-Based Coordination Networks

The assembly of cluster or superatom building-blocks into extended solids has revolutionized materials design, enabling the synthesis of modular semiconductors with well-defined structures and tunable electronic, magnetic or optical properties. This strategy has recently advanced the synthesis of complex metal oxides with multifunctional or emergent behaviors, but precise atom placement of multiple elements with similar chemistries or preferred coordination environments remains a significant challenge. Here, in this study, we present a strategy for synthesizing polyoxometalate (POM)-based coordination networks with up to three different cations in precisely defined positions. Our approach leverages a single-crystal-to-single-crystal (SCSC) transformation in which the spatial placement of cations is governed by their availability at distinct stages of crystallization and transformation. Specifically, [ZP 5 W 30 O 110 ] (15-n)- (Z = Na + , K + , Ca 2+ , Ag + , Bi 3+ , Y 3+ , any Ln 3+ , Th 4+ ) is coordinatively assembled with various bridging metal cations (Y 3+ , any Ln 3+ , Th 4+ ). By using the encapsulated cation (Z) to "label" the POM, we track the phase-transformation and confirm the retention of single crystallinity. The integrated use of POM labeling and SCSC transformation enables rational control over cation distribution and establishes a versatile strategy for constructing multicomponent materials with high compositional and spatial precision.

Chen, Linfeng [Univ. of California, San Diego, CA ↗
DOE OSTI2023

PathTrace and MPVEASI: A Path Analysis Comparative Validation Study

Developed in 2018, PathTrace is a software package built with the intention of making path analysis simple and intuitive. PathTrace is a top-down pathway analysis software where a user is able to explore vulnerable pathways into a facility. The intention of utilizing a software tool like PathTrace is to characterize an existing physical protection system (PPS) and to upgrade the system to achieve a high level of response interruption, or probability of interruption (P I ) of the adversary. There are four steps for conducting path analysis using PathTrace. The first step is to identify an image to use to build the model and scale the model within PathTrace using a section of known distance (wall or fence perimeter, for example). The scaling process will produce a grid of cells through which the user is able to build a model. The second step is to fill out the grid of cells with four categories of materials: Barriers, Detection Areas, Jumps, and Targets. These materials apply associated delay and detection values to the cells in which they are applied. The third step is to represent the adversary and response forces. The adversaries are represented by their capabilities in interacting with the materials identified in step two, and the response is represented by how quickly they will be able to respond to an adversary attack. Finally, the user is able to take all of the information from the previous three steps and perform a Most Vulnerable Path (MVP) analysis. In this stage, the user is able to visualize vulnerable adversary pathways and reason about how to upgrade these pathways to provide a high level of P I .

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Analyses of Dose Rates for Second Inner Reflector Plug Replacement at Spallation Neutron Source

The Inner Reflector Plug (IRP) is a central component of the Spallation Neutron Source (SNS) target monolith, which houses the liquid mercury target and four liter-sized neutron moderator units. It is exposed to high-level radiation fields during routine operation and builds up significant activity. The IRP needs to be replaced due to moderator neutron poison and decoupler burn-out, which is used for shaping neutron pulses. The first IRP exchange took place in March 2018 and next one, which is IRP2, is planned to be replaced during the facility maintenance period in the end of December 2025, beginning of January 2026 calendar year. The replacement of IRP is a complex task due to its location in the area receiving high irradiation, being under significant amount of shielding, and size, which requires removal in segments. For planning the replacement workflow to help to reduce radiation exposure to workers dose rates for each stage of extraction/replacement operation are predicted.

42 ENGINEERING↗
DOE OSTI2026

Proliferated Resilient Economical Half-Meter Aperture Space Telescopes (PREEMPT)

The PREEMPT LDRD was motivated by a major national need for better space-based imaging systems that are both high performing and affordable for the US Government. Current optical payloads for intelligence, surveillance and reconnaissance (ISR) and space domain awareness (SDA) missions can cost hundreds of millions of dollars and take years to develop, which makes it difficult to build the large constellations required for persistent, world-wide coverage. To address this, the team aimed to advance a different kind of large-aperture (>25 cm) telescope, called a monolithic telescope, in which key optical surfaces are built into a single piece of fused silica. This design greatly reduces payload and spacecraft complexity, the need for precision focus actuators, improves mechanical and thermal robustness, and lowers cost when compared with traditional Cassegrain telescopes that rely on many precisely aligned components. The project focused on five primary thrusts. The first thrust was to advance the concept of a V10, 25 cm, monolithic telescope forward from optical design to flight-ready stage. This was accomplished in partnership with Optimax, who delivered the first test unit in the early stages of the LDRD. The team developed several technologies necessary for this optic to be integrated into a flight demonstration. These include carbon fiber housings, highly detailed structural and thermal models and stress-reducing elastic averaging Hirth groove designs. These technologies resulted in a successful maturation of the optic, which is now slated to fly in late 2026/early 2027 for a demonstration mission. The second thrust was to advance the manufacturability of these optics. In collaboration with NIF’s optical manufacturing shop, we reduced polishing time from 480 hours to 65 hours through the implementation of optimized processes and new tools. The NIF team utilized a conceptual V8 (18 cm) optic to demonstrate this optimization, though it can be applied to the rest of the monolithic optic portfolio. Third, the team developed the first conceptual V20 (50 cm) payload, which is slated to be the next generation of LLNL optical payload systems. A set of structural, dynamic and thermal simulations were performed to identify potential challenges in the future development of this payload. Early-stage simulations suggest the payload is feasible, though thermal management will be the key focus area to maintain optimal performance. Fourth, a non-linear model of Viton was developed, to further enhance the reliability of our structural and dynamic models for future payloads. Viton acts as the primary interface material between the optic and its housing. Lastly, the team focused on successfully displaying the feasibility of using additively manufactured metal composites for optical space payloads. The team successfully demonstrated layer by layer deposition of Al-SiC composites, which have highly tunable structural and coefficient of thermal expansion (CTE) properties. These are crucial for optical payloads because CTE mismatch is one of the causes for degraded optical performance for telescopes in orbit. Overall, the work showed that monolithic telescopes could become a practical, lower-cost path to high-resolution space imaging for both national security and scientific missions.

42 ENGINEERING↗
NASA NTRS2008

Reusability Studies for Ares I and Ares V Propulsion

With a mission to continue to support the goals of the International Space Station (ISS) and explore beyond Earth orbit, the United States National Aeronautics and Space Administration (NASA) is in the process of launching an entirely new space exploration initiative, the Constellation Program. Even as the Space Shuttle moves toward its final voyage, Constellation is building from nearly half a century of NASA spaceflight experience, and technological advances, including the legacy of Shuttle and earlier programs such as Apollo and the Saturn V rocket. Out of Constellation will come two new launch vehicles: the Ares I crew launch vehicle and the Ares V cargo launch vehicle. With the initial goal to seamlessly continue where the Space Shuttle leaves off, Ares will firstly service the Space Station. Ultimately, however, the intent is to push further: to establish an outpost on the Moon, and then to explore other destinations. With significant experience and a strong foundation in aerospace, NASA is now progressing toward the final design of the First Stage propulsion system for the Ares I. The new launch vehicle design will considerably increase safety and reliability, reduce the cost of accessing space, and provide a viable growth path for human space exploration. To achieve these goals, NASA is taking advantage of Space Shuttle hardware, safety, reliability, and experience. With efforts to minimize technical risk and life-cycle costs, the First Stage office is again pulling from NASA s strong legacy in aerospace exploration and development, most specifically the Space Shuttle Program. Trade studies have been conducted to evaluate life-cycle costs, expendability, and risk reduction. While many first stage features have already been determined, these trade studies are helping to resolve the operational requisites and configuration of the first stage element. This paper first presents an overview of the Ares missions and the genesis of the Ares vehicle design. It then looks at one of the most important trade studies to date, the "Ares I First Stage Expendability Trade Study." The purpose of this study was to determine the utility of flying the first stage as an expendable booster rather than making it reusable. To lower the study complexity, four operational scenarios (or cases) were defined. This assessment then included an evaluation of the development, reliability, performance, and transition impacts associated with an expendable solution. This paper looks at these scenarios from the perspectives of cost, reliability, and performance.

Williams, Thomas J.↗
NASA NTRS2008

Reusability Studies for Ares I and Ares V Propulsion

With a mission to continue to support the goals of the International Space Station (ISS) and explore beyond Earth orbit, the United States National Aeronautics and Space Administration (NASA) is in the process of launching an entirely new space exploration initiative, the Constellation Program. Even as the Space Shuttle moves toward its final voyage, Constellation is building from nearly half a century of NASA spaceflight experience, and technological advances, including the legacy of Shuttle and earlier programs such as Apollo and the Saturn V rocket. Out of Constellation will come two new launch vehicles: the Ares I crew launch vehicle and the Ares V cargo launch vehicle. With the initial goal to seamlessly continue where the Space Shuttle leaves off, Ares will firstly service the Space Station. Ultimately, however, the intent is to push further: to establish an outpost on the Moon, and then to explore other destinations. With significant experience and a strong foundation in aerospace, NASA is now progressing toward the final design of the First Stage propulsion system for the Ares I. The new launch vehicle design will considerably increase safety and reliability, reduce the cost of accessing space, and provide a viable growth path for human space exploration. To achieve these goals, NASA is taking advantage of Space Shuttle hardware, safety, reliability, and experience. With efforts to minimize technical risk and life-cycle costs, the First Stage office is again pulling from NASA's strong legacy in aerospace exploration and development, most specifically the Space Shuttle Program. Trade studies have been conducted to evaluate lifecycle costs, expendability, and risk reduction. While many first stage features have already been determined, these trade studies are helping to resolve the operational requisites and configuration of the first stage element. This paper first presents an overview of the Ares missions and the genesis of the Ares vehicle design. It then looks at one of the most important trade studies to date, the "Ares I First Stage Expendability Trade Study." The purpose of this study was to determine the utility of flying the first stage as an expendable booster rather than making it reusable. To lower the study complexity, four operational scenarios (or cases) were defined. This assessment then included an evaluation of the development, reliability, performance, and transition impacts associated with an expendable solution. The paper looks at these scenarios from the perspectives of cost, reliability, and performance. The presentation provides an overview of the paper.

Williams, Thomas J.↗