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The Four Bed Carbon Dioxide Scrubber technology demonstration is presently operating onboard the International Space Station after being launched in August of 2021and activated in October. This work describes the ground and flight performance of the 4BCO2 and the methods used to determine performance on the ISS where limited sensor data is available.
BACKGROUND Astronauts experience postflight disturbances in postural and locomotor control due to sensorimotor adaptations during spaceflight. These alterations may have adverse consequences if a rapid egress is required after landing. Although exercise is partially effective for mitigating cardiovascular and muscular deconditioning, additional countermeasures are needed to further preserve sensorimotor function for exploration missions. We have identified proprioceptive training and electrical muscle stimulation (EMS) as promising in-flight countermeasures. Since prolonged head down bed rest (HDBR) is a spaceflight analog for body unloading and causes postural and locomotor control decrements that parallel those observed after spaceflight, it can be used to accelerate the development of these countermeasures. METHODS This study will determine the effects of proprioceptive training and EMS on functional task performance and sensorimotor function following 60 days of 6° HDBR. Subjects will be randomly assigned to one of four groups: 1) an EMS arm, 2) a proprioceptive training arm, 3) an exercise plus proprioceptive training arm, and 4) a control arm. The EMS countermeasure will include daily bilateral stimulation of the quadriceps femoris muscle (30 minutes per session). Proprioceptive training will be performed three days per week (20 minutes per session) consisting of body-loaded postural tasks in the horizontal position on an air bearing sled. Exercise training will mimic current protocols used on the International Space Station, but treadmill aerobic exercise will be replaced with additional cycling aerobic exercise. Primary outcome measures will include pre and post HDBR functional tests that are representative of high priority exploration mission tasks and require high demand for dynamic control of postural stability. Additional measures will be used to identify the key physiological factors contributing to countermeasure benefits. Given the constrained samples size, a Bayesian modelling approach will be used to quantify the probability that there is an effect of a given magnitude. COUNTERMEASURE UPDATES Proprioceptive countermeasure design enhancements and human in the loop pilot testing continued through the Crew Health Countermeasures (CHC) Systems Capability Leadership Team (SCLT). The primary goals of this work were to enhance the visual feedback system’s capabilities and develop a proprioceptive training program for 60 days of HDBR. Six healthy non-astronaut volunteers participated in four pilot training sessions to systematically examine how each training variable (e.g., axial load, foot placement, and software profile) affects the overall proprioceptive challenge. The resulting training program will maintain an appropriate challenge during 60 days of HDBR by progressively decreasing the subject’s base of support, increasing tilt board target distances, and increasing axial loads using both subjective verbal feedback and objective performance data. RELEVANCE The deliverable from this project will be proof-of-concept sensorimotor countermeasure designs for functional task performance with full assessment of efficacy in a spaceflight analog. If the countermeasures are effective, they will be translated for validation with the suite of operationally implemented in-flight countermeasures.
The Packed Bed Reactor Experiment (PBRE) focused on the hydrodynamics of gas-liquid flow in porous media, specifically on flow regime transition and pressure drop correlation. The reactor included a cylindrical test section of 60 cm in length, 5 cm in diameter and filled with 2 mm spherical glass beads. Liquid water and Nitrogen gas were flowed into a centrifugal phase separator after exiting the test section. Five absolute pressure transducers and two high-speed video cameras spanned the test section to measure the pressure drop and capture flow regime behavior. Video observations, analysis of pressure traces, and pressure drop data were used to identify flow patterns. It was found that the slope of pressure gradient data when plotted versus the gas or liquid Reynolds numbers changed when the flow regime changed. This observation was used to identify the flow regime boundaries. At high liquid flow rates (high interaction regime), dispersed bubble and pulse flow regimes were detected. At low liquid flow rates (low interaction regime), large bubble and gas channeling regimes were observed. The transition from the big bubble regime to the gas channeling regime occurred at a critical gas flow rate independent of the liquid flow rate. Similarly, the transition from the low interaction to the high interaction regime occurred at a critical liquid flow rate. For these different flow regimes, different two-phase flow friction factors and pressure gradient correlations were fitted as a function of the gas and liquid modified Reynolds numbers and Suratman number. It was found that in all the flow regimes the capillary contribution to the pressure drop is significant and can be as high as 90% of the total pressure drop.
Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.
NASA Marshall Space Flight Center’s Materials and Processes Department, with support from the Propulsion Systems Department has developed a test bed for exposing ablative thermal protection materials to an environment similar to that of solid rocket motors (SRMs) by using a hybrid-propellant combustor. The Solid Fuel Torch (SFT) is a pressurized. small-scale hybrid rocket motor which utilizes an aluminized solid fuel and a gaseous oxygen (GOx) oxidizer to vary internal environments which can be tailored to specific program needs. The baseline design for the SFT was developed to support the Space Shuttle Program and was redesigned to support Space Launch System (SLS) Booster program requirements. There are four configurations of the SFT testbed: 1.) Insulation configuration with the option of a “dome” or “converging cone” insulation test section, 2.) Super Sonic Blast Tube configuration to simulate nozzle exit cone environments, 3.) Flow Straightened configuration which includes an additional instrumented length between the fuel grain and the insulation, and 4.) Constant Diameter Throat configuration which includes a cylindrical phenolic test section to test samples with different ply angles under the same environment simultaneously. Motor pressures for each configuration can range from 150 to 1500 psi with heat fluxes up to 1200 BTU/sq.ft/s. This paper discusses the development of each configuration and the results obtained during the initial test series.
The Four Bed Carbon Dioxide Scrubber flight demonstration is presently operating onboard the International Space Station. After being launched in August and activated in September 2021, the system has been removing metabolic CO2 from the cabin as a supplement and replacement for other CO2 removal systems, specifically the two Carbon Dioxide Removal Assemblies. This paper describes on-orbit operations and changes (including installation of the Calnetix blower) during 2022 and early 2023. Performance of the system especially as affected by changes in the on-orbit configuration will be described. System reliability, software changes, and ongoing efforts will be summarized.
The ECLSS Digital Twin is a cloud-based simulation of the Four-Bed CO2 Scrubber, currently one of the primary means of removing carbon dioxide onboard the International Space Station, that operationalizes SME-developed multi-physics models and replicates conditions of the actual hardware in near real-time. In addition to providing insight into the system’s performance, it will enable prognostics, diagnostics, predictive maintenance, and simulated off-nominal scenarios. By leveraging digital representations, projects can save resources and gain a better understanding of their physical systems with the goal of building robust and reliable hardware for future deep space exploration. The use of data infrastructure in the cloud allows for streamlined analysis and visualization on a much larger scale than is possible with current tools.
The Four Bed Carbon Dioxide Scrubber flight demonstration is presently operating onboard the International Space Station. After being launched in August and activated in September 2021, the system has been removing metabolic CO2 from the cabin as a supplement and replacement for other CO2 removal systems, specifically the two Carbon Dioxide Removal Assemblies. This paper describes on-orbit operations and changes (including installation of the Calnetix blower) during 2022 and early 2023. Performance of the system especially as affected by changes in the on-orbit configuration will be described. System reliability, software changes, and ongoing efforts will be summarized.
BACKGROUND Astronauts experience postflight disturbances in postural and locomotor control due to sensorimotor adaptations during spaceflight. These alterations may have adverse consequences if a rapid egress is required after landing. Although exercise is partially effective for mitigating cardiovascular and muscular deconditioning, additional countermeasures are needed to further preserve sensorimotor function for exploration missions. We have identified proprioceptive training and electrical muscle stimulation (EMS) as promising in-flight countermeasures. Since prolonged head down bed rest (HDBR) is a spaceflight analog for body unloading and causes postural and locomotor control decrements that parallel those observed after spaceflight, it can be used to facilitate the development of these countermeasures. METHODS This study will determine the effects of proprioceptive training and EMS on functional task performance and sensorimotor function following 60 days of 6° HDBR. Subjects will be randomly assigned to one of four groups: 1)an EMS arm, 2) a proprioceptive training arm, 3) an exercise plus proprioceptive training arm, and 4) a control arm. The EMS countermeasure will include daily bilateral stimulation of selected bilateral lower extremity muscles (30 minutes per session). Proprioceptive training will be performed three days per week (20 minutes per session) consisting of body-loaded postural tasks in the horizontal position on an air bearing sled. Exercise training will mimic current protocols used on the International Space Station, but treadmill aerobic exercise will be replaced with additional cycling aerobic exercise. Primary outcome measures will include pre and post HDBR functional tests that are representative of high priority exploration mission tasks and require high demand for dynamic control of postural stability. Additional measures will be used to identify the key physiological factors contributing to countermeasure benefits. Given the constrained samples size, a Bayesian modelling approach will be used to quantify the probability that there is an effect of a given magnitude. HARDWARE AND PROTOCOL DEVELOPMENT Proprioceptive countermeasure design enhancements continued as part of the Mars Campaign Office (MCO) Crew Health and Performance (CHP) Crew Health Countermeasures (CHC). The primary goals of this work were to assemble a portable version of the countermeasure system that can be used at the :envihab facility, expand the software feedback system’s capabilities, and develop an actuator loading system that mimics what could be used on the International Space Station. In addition, one major piece of exercise hardware used in previous HDBR studies, the Horizontal Squat Device, was reassembled and restored to full functionality. Human-in-the-loop pilot testing is ongoing, prior to shipping both devices to the :envihab HDBR facility. Evaluations are also underway for the best EMS device technologies and specific methods. Finally, assessment techniques are being translated for administration in the horizontal position (e.g., leg dexterity and foot sole skin sensitivity). Our current goals are to refine the countermeasure training and assessment techniques and integrate protocols across multiple modalities. RELEVANCE The deliverable from this project will be proof-of-concept sensorimotor countermeasure designs for functional task performance with full assessment of efficacy in a spaceflight analog. If one or more countermeasures are effective, they will be translated for validation with the suite of operationally implemented in-flight countermeasures. ACKNOWLEDGEMENT This work is supported by NASA’s Human Research Program Human Health Countermeasures Element and by the Canadian Space Agency (L. Bent).
Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.
A persistent azimuthal pattern featuring alternate high and low concentration of ejecta emanating from the area where a supersonic jet (Mach 5.3) impinges on a bed of particles in a near-lunar vacuum condition is studied experimentally. Although this peculiar phenomenon has been documented in early studies motivated by extraterrestrial landing, the mechanism of this pattern is not clearly understood. Recently, a series of experiments were conducted at NASA Marshall Space Flight Center inside a 4.5 m vacuum chamber over a range of reduced ambient pressure. Experimental results show vibrant azimuthal patterns, which are clearest at low ambient pressure. The pattern is shown to be driven by the flow instability at low Reynolds number, despite the supersonic jet employed. The flow instability leads to azimuthal vortex lines, which expel ejecta into streaks between two neighboring vortex lines. A simple model is proposed to explain the observed phenomenon.
Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (LP-DED) additive manufacture C103 is in development for propulsion applications that operate under extreme environments. The standard post-process heat treatment has called for vacuum stress relief, however, depending on the application or certification requirements hot isostatic press (HIP) may be required. Although C103 density responds well to HIP the associated grain growth results in a reduction in mechanical properties. An investigation was conducted to look at the potential benefit of leveraging HIP followed by rapid cooling to minimize grain growth. A series of heat treatment schedules varying temperature and pressure were conducted followed by microstructural and mechanical characterization.
Post processing X-ray computational tomography (CT) inspection data for additively manufactured (AM) components can induce deviations in defect quantification, affecting subsequent fatigue and failure predictions. To assess the influence and potential impact of segmentation-induced measurement deviations, this paper applies several segmentation techniques to X-ray CT data for powder bed fusion Ti-6Al-4V specimens exhibiting porosity conditions. X-ray CT reconstructions were segmented with varying techniques including Otsu’s thresholding, random forest, k-nearest neighbors, and the multilayer perceptron. Metrics such as pore size and global porosity were compared for internal validity. Then, top-down X-ray CT measurements of surface-breaking porosity were compared to optical profilometry for cross-validation.
A new Space Suit Exploration Portable Life Support System (xPLSS) is being designed, built, integrated, and tested into the Extra-Vehicular Mobility Unit (xEMU). The Trace Contaminant Control (TCC) system is a component in the oxygen ventilation loop of xPLSS that removes contaminants generated by the crewmembers’ metabolic processes. The primary trace contaminants that must be removed include ammonia (NH3), carbon monoxide (CO), formaldehyde (CH2O), and methyl mercaptan (CH3SH). The current state-of-the-art TCC sorbent is non-regenerable activated carbon. As a non-regenerable sorbent, its use negatively impacts the logistics for future missions. Thus, an ideal solution can be a vacuum-regenerable sorbent integrated with the xPLSS CO2/H2O removal system. To test new designs and sorbents, XploSafe has constructed a recirculating test bed that mimics the environment within the xPLSS by providing concentrations of the trace contaminant analytes generated at the operating temperature, humidity, pressure, and flow rates of the xPLSS. This system can perform regeneration or desorption by exposing the sorbent to a pressure swing from 4.3 psia to <1 torr over approximately 2 minutes. Using this test system, XploSafe evaluated various TCC prototypes constructed using rapid prototyping techniques and identified a process that allows vacuum regenerative TCC designs to be quickly examined for flow, pressure drop, and performance. By using toluene as a segregate for volatile organics, this test system was evaluated using both vacuum regenerable and non-regenerable sorbents to demonstrate the operational effectiveness of these sorbents in maintaining the concentrations of the trace contaminant analytes below the 7-day Spacecraft Maximum Allowable Concentrations.
Consequences of sleep and circadian rhythm disturbances include many neurophysiological sequelae, especially when combined with spaceflight stressors, and are therefore hypothesized to contribute to the development of optic disc edema observed in astronauts. Additionally, chronically elevated carbon dioxide (CO 2 ) levels on the International Space Station may contribute to the observed sleep disturbances in astronauts. Here we determined if the spaceflight analogue head-down tilt bed rest (HDTBR) combined with elevated CO 2 levels influenced sleep and core temperature and was associated the development of optic disc edema. Healthy participants (5 female, 6 male) aged 25-50 years, underwent thirty days of strict 6° HDTBR in a mild hypercapnic environment (ambient PCO 2 = 4 mmHg) with measures of sleep, 24-hour core temperature, overnight arterialized CO2, and Frisén grade edema collected pre-HDTBR, on HDTBR days 4, 17, 28, and post-HDTBR days 4 and 10. During all HDTBR time points, sleep, core temperature, and overnight arterialized CO 2 were not statistically significantly different than the pre-HDTBR measurements. However, independent of the HDTBR intervention, the odds ratios (mean [95% CI]) for developing Frisén grade optic disc edema were statistically significant for each hour below the mean total sleep time (2.2 [1.1-4.4]) and stage 2 NREM sleep (4.8 [1.3-18.6]), and above the mean for wake after sleep onset (3.6 [1.2-10.6]) and for each 0.1°C decrease in core temperature amplitude below the mean (4.0 [1.4-11.7]).These data suggest that optic disc edema occurring during HDTBR was more likely to occur in those with short sleep duration and blunted temperature amplitude.
The Four Bed Carbon Dioxide Scrubber (FBCO2) flight demonstration is presently operating as a primary CO 2 removal system onboard the International Space Station (ISS). After activation in October 2021, FBCO2 has been removing metabolic CO 2 from the ISS cabin where it is supplementing or fully replacing the heritage systems. This paper describes the past year’s accomplishments and forward outlook. The performance of the new blower, efforts toward closed-loop operation, and further on-orbit modifications will also be detailed. System reliability, software changes, and ongoing efforts will be summarized.
Process variations and process-induced defects like porosity cause significant uncertainty in the microstructure and mechanical behavior of additively manufactured metals. Establishing process-structure-property (PSP) relationships and quantifying uncertainty using experiments alone is costly, especially for structural applications where mechanical allowables must be established for qualification and certification. This work presents a PSP simulation framework for laser powder bed fusion with a focus on uncertainty quantification through probabilistic calibration and multi-fidelity uncertainty propagation. Motivated by phenomenological input parameters related to grain nucleation and growth that are difficult to characterize, a global sensitivity analysis (GSA) is completed. Through GSA, the most important input parameters are identified based on their influence on the statistical distributions of microstructural metrics that influence mechanical behavior, including grain size, morphology, and crystallographic texture. The results provide insight on what experiments are necessary to quantify and control PSP uncertainties, particularly those associated with the more challenging input parameters.
The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.