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Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Centennial challenge

Revisiting the West Clearwater Lake Impact Structure, Canada

The West and East Clearwater Lake impact structures are two of the most distinctive and recognizable impact structures on Earth. Known regionally as the "Clearwater Lake Complex", these structures are located in northern Quebec, Canada (56 deg 10 N, 74 deg 20 W) approximately 125 km east of Hudson Bay. The currently accepted diameters are 36 km and 26 km for the West and East structures, respectively. Long thought to represent a rare example of a double impact, recent age dating has called this into question with ages of approximately 286 Ma and approximately 460-470 Ma being proposed for the West and East structures, respectively. Relatively little is known about the East Clearwater Lake structure. There is no surface exposure and what information there is comes from geophysics and two drill cores obtained in the 1960s. In contrast, the West Clearwater Lake structure is relatively well preserved with large ring of islands in the approximately 30 km diameter lake. Much of the work done on West Clearwater stems from field investigations carried out in 1977 driven by the Apollo program, with a focus on the impact melt rocks and other impactites, which are well exposed on the ring of islands. To our knowledge, the Clearwater Lake impact structures have not been the focus of detailed impact geology field investigations since the 1977 expedition and the only geological map that exists is from the 1960s and is at the reconnaissance level. Our knowledge of impact cratering processes have increased substantially since this time, as have the analytical techniques available for samples. This provided the motivation for a joint Canadian-US-UK expedition to the West Clearwater Lake impact structure in August and September 2015, under the auspices of the FINESSE (Field Investigations to Enable Solar System Science and Exploration) project, part of NASA's Solar System Exploration Research Virtual Institute (SSERVI). We focus here on the impactites of the West Clearwater Lake impact structure. Other ongoing studies, also presented at this conference, focus on central uplift formation, the impact-generated hydrothermal system, xxxx and using WCIS as an analog test site for crew studies of sampling protocols].

West Clearwater Lake

Visualization of a Capsule Entry Vehicle Reaction-Control System (RCS) Thruster

Planar laser-induced fluorescence (PLIF) was used to visualize the reaction control system (RCS) jet flow emanating from the aft-body of an Apollo-geometry capsule test article in the NASA Langley Research Center 31-Inch Mach 10 Air wind tunnel. The RCS jet was oriented normal to the aft surface of the model and had a nominal Mach number of 2.94. The composition of the jet gas by mass was 95% nitrogen (N2) and 5% nitric oxide (NO). The RCS jet flowrate varied between zero and 0.5 standard liters per minute and the angle of attack and tunnel stagnation pressure were also varied. PLIF was used to excite the NO molecules for flow visualization. These flow visualization images were processed to determine the trajectory and to quantify the flapping of the RCS jet. The spatial resolution of the jet trajectory measurement was about 1 mm and the single-shot precision of the measurement was estimated to be 0.02 mm in the far field of the jet plume. The jet flapping, measured by the standard deviation of the jet centerline position was as large as 0.9 mm, while the jet was 1.5-4 mm in diameter (full width at half maximum). Schlieren flow visualization images were obtained for comparison with the PLIF. Surface pressures were also measured and presented. Virtual Diagnostics Interface (VIDI) technology developed at NASA Langley was used to superimpose and visualize the data sets. The measurements demonstrate some of the capabilities of the PLIF method while providing a test case for computational fluid dynamics (CFD) validation.

Danehy, P. M.

Emergent Capabilities Converging into M and S 2.0

The continued operational environment complexity faced by the Department of Defense, despite a restricted resource environment, is a mandate for greater adaptability and availability in joint training. To address these constraints, this paper proposes a model for the potential integration of adaptability training, virtual world capabilities and immersive training into the wider Joint Live Virtual and Constructive (JLVC) Federation, supported by human, social, cultural and behavior modeling, and measurement and assessment. By fusing those capabilities and modeling and simulation enhancements into the JLVC federation, it will create a force who is more apt to arrive at and implement correct decisions, and more able to appropriately seize initiative in the field. The model would allow for the testing and training of capabilities and TTPs that cannot be reasonably explored to their logical conclusions in a 'live' environment, as well as enhance training fidelity for all echelons and tasks.

Reitz, Emilie

Real-Time Aerodynamic Flow and Data Visualization in an Interactive Virtual Environment

Significant advances have been made to non-intrusive flow field diagnostics in the past decade. Camera based techniques are now capable of determining physical qualities such as surface deformation, surface pressure and temperature, flow velocities, and molecular species concentration. In each case, extracting the pertinent information from the large volume of acquired data requires powerful and efficient data visualization tools. The additional requirement for real time visualization is fueled by an increased emphasis on minimizing test time in expensive facilities. This paper will address a capability titled LiveView3D, which is the first step in the development phase of an in depth, real time data visualization and analysis tool for use in aerospace testing facilities.

Schwartz, Richard J.

Reliability modeling of fault-tolerant computer based systems

Digital fault-tolerant computer-based systems have become commonplace in military and commercial avionics. These systems hold the promise of increased availability, reliability, and maintainability over conventional analog-based systems through the application of replicated digital computers arranged in fault-tolerant configurations. Three tightly coupled factors of paramount importance, ultimately determining the viability of these systems, are reliability, safety, and profitability. Reliability, the major driver affects virtually every aspect of design, packaging, and field operations, and eventually produces profit for commercial applications or increased national security. However, the utilization of digital computer systems makes the task of producing credible reliability assessment a formidable one for the reliability engineer. The root of the problem lies in the digital computer's unique adaptability to changing requirements, computational power, and ability to test itself efficiently. Addressed here are the nuances of modeling the reliability of systems with large state sizes, in the Markov sense, which result from systems based on replicated redundant hardware and to discuss the modeling of factors which can reduce reliability without concomitant depletion of hardware. Advanced fault-handling models are described and methods of acquiring and measuring parameters for these models are delineated.

Bavuso, Salvatore J.

Virtual Diagnostics Interface (ViDI) for Planning Laser-Based Wind Tunnel Experiments

Virtual Diagnostics Interface (ViDI), originally introduced by Richard Schwartz in 2004 and described again by Alderfer, et. al., in 2007, is an interactive 3D software tool developed at NASA Langley Research Center to serve three main purposes: assist in pre-test planning, enhance post-test image analysis and visualization, and serve as a central location for data storage and distribution.1,2 ViDI is composed of custom-developed software and Autodesk® 3ds Max® as it incorporates Computer Aided Design (CAD) models with the results obtained from optical diagnostics.3 This software tool has proven useful in the field of optical diagnostics where pre-test planning of beam paths, optical elements, and test articles must be carried out to avoid interference, ensure spatial resolution is sufficient, and the camera Field of View (FoV) is adequate for the field of interest. Typically, practical considerations such as the distance a camera is from the region of interest, the angles at which the camera is oriented and issues such as the size of the camera and its sensor and size and focal length lens as well as the path of the laser need to be taken into account to predict a successful measurement. An example application of ViDI is shown in Fig.1 where an experiment to investigate flow separation over the wing of the High Lift Common Research Model (HL-CRM) is currently being planned in the National Transonic Facility (NTF) at NASA Langley Research Center.

virtual diagnostics interface

NASA Brief: Q-Thruster Physics

Q-thrusters are a low-TRL form of electric propulsion that operates on the principle of pushing off of the quantum vacuum. A terrestrial analog to this is to consider how a submarine uses its propeller to push a column of water in one direction, while the sub recoils in the other to conserve momentum -the submarine does not carry a "tank" of sea water to be used as propellant. In our case, we use the tools of Magnetohydrodynamics (MHD) to show how the thruster pushes off of the quantum vacuum which can be thought of as a sea of virtual particles -principally electrons and positrons that pop into and out of existence, and where fields are stronger, there are more virtual particles. The idea of pushing off the quantum vacuum has been in the technical literature for a few decades, but to date, the obstacle has been the magnitude of the predicted thrust which has been derived analytically to be very small, and therefore not likely to be useful for human spaceflight. Our recent theoretical model development and test data suggests that we can greatly increase the magnitude of the negative pressure of the quantum vacuum and generate a specific force such that technology based on this approach can be competitive for in-space propulsion approx. 0.1N/kW), and possibly for terrestrial applications (approx. 10N/kW). As an additional validation of the approach, the theory allows calculation of physics constants from first principles: Gravitational constant, Planck constant, Bohr radius, dark energy fraction, electron mass.

White, Harold

Harnessing Virtual Power Plants Reliably: Enabling tools for increased observability, controllability, operation, and aggregation of distributed energy resources

Harnessing virtual power plants enhances the integration of distributed energy resources into utility grids for a sustainable energy future. Virtual power plants (VPPs) aggregate DERs to enhance resource adequacy and reduce emissions. U.S. utilities are exploring various technologies to manage DERs effectively. FERC Order 2222 allows DERs to participate in both wholesale and retail markets. Enhancing observability and controllability of behind-the-meter (BTM) DERs is essential for reliable grid operations. A hierarchical control architecture can improve coordination among residential energy resources. Field tests showed nearly 20% energy savings and 30% peak power reduction during grid events. Effective management of DERs requires enhanced situational awareness to prevent grid congestion. Integrating DER management systems (DERMS) with existing planning tools can improve operational security. Near-real-time grid models can validate optimal resource set points against resource uncertainty. Traditional uninterruptible power supplies (UPS) can be upgraded to support grid services and become part of VPPs. Upgrading UPS systems can reduce costs by 75% and unlock significant battery capacity. New battery management systems and grid-aware controllers are essential for optimizing UPS performance. Continued research and development are necessary to address challenges in integrating DERs into utility grids. Encouraging customer participation in pilot programs is vital for the evolution of VPPs. Here, the shift towards price-responsive DERs and VPPs is expected to enhance energy distribution efficiency.

24 POWER TRANSMISSION AND DISTRIBUTION

Update on Waveguide-Embedded Differential MMIC Amplifiers

There is an update on the subject matter of Differential InP HEMT MMIC Amplifiers Embedded in Waveguides (NPO-42857) NASA Tech Briefs, Vol. 33, No. 9 (September 2009), page 35. To recapitulate: Monolithic microwave integrated-circuit (MMIC) amplifiers of a type now being developed for operation at frequencies of hundreds of gigahertz contain InP high-electron-mobility transistors (HEMTs) in a differential configuration. The MMICs are designed integrally with, and embedded in, waveguide packages. The instant work does not mention InP HEMTs but otherwise reiterates part of the subject matter of the cited prior article, with emphasis on the following salient points: An MMIC is mounted in the electric-field plane ("E-plane") of a waveguide and includes a finline transition to each differential-amplifier stage. The differential configuration creates a virtual ground within each pair of transistor-gate fingers, eliminating the need for external radio-frequency grounding. This work concludes by describing a single-stage differential submillimeter-wave amplifier packaged in a rectangular waveguide and summarizing results of tests of this amplifier at frequencies of 220 and 305 GHz.

Kangaslahti, Pekka

Eye height scaling of absolute size in immersive and nonimmersive displays

Eye-height (EH) scaling of absolute height was investigated in three experiments. In Experiment 1, standing observers viewed cubes in an immersive virtual environment. Observers' center of projection was placed at actual EH and at 0.7 times actual EH. Observers' size judgments revealed that the EH manipulation was 76.8% effective. In Experiment 2, seated observers viewed the same cubes on an interactive desktop display; however, no effect of EH was found in response to the simulated EH manipulation. Experiment 3 tested standing observers in the immersive environment with the field of view reduced to match that of the desktop. Comparable to Experiment 1, the effect of EH was 77%. These results suggest that EH scaling is not generally used when people view an interactive desktop display because the altitude of the center of projection is indeterminate. EH scaling is spontaneously evoked, however, in immersive environments.

NASA Discipline Space Human Factors

Acoustic modal analysis of a full-scale annular combustor

An acoustic modal decomposition of the measured pressure field in a full scale annular combustor installed in a ducted test rig is described. The modal analysis, utilizing a least squares optimization routine, is facilitated by the assumption of randomly occurring pressure disturbances which generate equal amplitude clockwise and counter-clockwise pressure waves, and the assumption of statistical independence between modes. These assumptions are fully justified by the measured cross spectral phases between the various measurement points. The resultant modal decomposition indicates that higher order modes compose the dominant portion of the combustor pressure spectrum in the range of frequencies of interest in core noise studies. A second major finding is that, over the frequency range of interest, each individual mode which is present exists in virtual isolation over significant portions of the spectrum. Finally, a comparison between the present results and a limited amount of data obtained in an operating turbofan engine with the same combustor is made. The comparison is sufficiently favorable to warrant the conclusion that the structure of the combustor pressure field is preserved between the component facility and the engine.

Karchmer, A. M.

Acoustic modal analysis of a full-scale annular combustor

An acoustic modal decomposition of the measured pressure field in a full scale annular combustor installed in a ducted test rig is described. The modal analysis, utilizing a least squares optimization routine, is facilitated by the assumption of randomly occurring pressure disturbances which generate equal amplitude clockwise and counter-clockwise pressure waves, and the assumption of statistical independence between modes. These assumptions are fully justified by the measured cross spectral phases between the various measurement points. The resultant modal decomposition indicates that higher order modes compose the dominant portion of the combustor pressure spectrum in the range of frequencies of interest in core noise studies. A second major finding is that, over the frequency range of interest, each individual mode which is present exists in virtual isolation over significant portions of the spectrum. Finally, a comparison between the present results and a limited amount of data obtained in an operating turbofan engine with the same combustor is made. The comparison is sufficiently favorable to warrant the conclusion that the structure of the combustor pressure field is preserved between the component facility and the engine. Previously announced in STAR as N83-21896

Karchmer, A. M.

Virtual and Experimental Visualization of Flows in Packed Beds of Spheres Simulating Porous Media Flows

A videotape presentation of flow in a packed bed of spheres is provided. The flow experiment consisted of three principal elements: (1) an oil tunnel 76.2 mm by 76.2 mm in cross section, (2) a packed bed of spheres in regular and irregular arrays, and (3) a flow characterization methodology, either (a) full flow field tracking (FFFT) or (b) computational fluid dynamic (CFD) simulation. The refraction indices of the oil and the test array of spheres were closely matched, and the flow was seeded with aluminum oxide particles. Planar laser light provided a two-dimensional projection of the flow field, and a traverse simulated a three-dimensional image of the entire flow field. Light focusing and reflection rendered the spheres black, permitting visualization of the planar circular interfaces in both the axial and transverse directions. Flows were observed near the wall-sphere interface and within the set of spheres. The CFD model required that a representative section of a packed bed be formed and gridded, enclosing and cutting six spheres so that symmetry conditions could be imposed at all cross-boundaries. Simulations had to be made with the flow direction at right angles to that used in the experiments, however, to take advantage of flow symmetry. Careful attention to detail was required for proper gridding. The flow field was three-dimensional and complex to describe, yet the most prominent finding was flow threads, as computed in the representative 'cube' of spheres with face symmetry and conclusively demonstrated experimentally herein. Random packing and bed voids tended to disrupt the laminar flow, creating vortices.

Hendricks, R. C.

A comparative study of calibration techniques for finite strain elastoplasticity: Numerically-exact sensitivities for FEMU and VFM

Accurate identification of material parameters is crucial for predictive modeling in computational mechanics. Here, the two primary approaches in the experimental mechanics community for calibration from full-field digital image correlation data are known as finite element model updating (FEMU) and the virtual fields method (VFM). In VFM, the objective function is a squared mismatch between internal and external virtual work or power. In FEMU, the objective function quantifies the weighted mismatch between model predictions and corresponding experimentally measured quantities of interest. It is minimized by iteratively updating the parameters of an FE model. While FEMU is seen as more flexible, VFM is commonly used instead of FEMU due to its considerably greater computational expense. However, comparisons between the two methods usually involve approximations of gradients or sensitivities with finite difference schemes, thereby making direct assessments difficult. Hence, in this study, we compare VFM and FEMU in the context of numerically-exact sensitivities obtained through local sensitivity analyses and the application of automatic differentiation software. To this end, we conduct a series of test cases to assess both methods under practical challenges using a finite strain elastoplasticity model.

Automatic differentiation

SoLID Program at JLab

An overview of the Solenoidal Large Intensity Device (SoLID) and its scientific program will be given in this talk. SoLID is a spectrometer/detector system proposed to exploit the full potential of the Jefferson Lab (JLab) 12 GeV energy upgrade. SoLID will push the limit of luminosity frontier in hadronic physics with its unique capability to handle very high rates with large acceptance under high luminosity (1037-39/cm2/s). A rich and vibrant scientific program has been developed for SoLID, including but not limited to the precision study of the 3d nucleon structure in both momentum space using Semi-Inclusive Deep Inelastic Scattering (SIDIS) and coordinate space using Deep Virtual Exclusive Reactions (DVER), probing physics beyond the Standard Model with Parity Violating Deep Inelastic Scattering (PVDIS), and investigating the gluonic field contribution to the proton structure and proton mass via J/¿ threshold production. The SoLID collaboration has developed a robust, low risk and flexible conceptual design, with a base line design capable of accomplishing its scientific goals and flexibility to adopt the cutting-edge technology. Detector subsystems have been tested with prototypes in realistic high luminosity conditions and are demonstrated to function well under extremely challenging environment to satisfy the requirements of planned experiments.

Chen, Jian-Ping [Thomas Jefferson National Acceler

Computation of Coupled Thermal-Fluid Problems in Distributed Memory Environment

The thermal-fluid coupling problems are very important to aerospace and engineering applications. Instead of analyzing heat transfer and fluid flow separately, this study merged two well-accepted engineering solution methods, SINDA for thermal analysis and FDNS for fluid flow simulation, into a unified multi-disciplinary thermal fluid prediction method. A fully conservative patched grid interface algorithm for arbitrary two-dimensional and three-dimensional geometry has been developed. The state-of-the-art parallel computing concept was used to couple SINDA and FDNS for the communication of boundary conditions through PVM (Parallel Virtual Machine) libraries. Therefore, the thermal analysis performed by SINDA and the fluid flow calculated by FDNS are fully coupled to obtain steady state or transient solutions. The natural convection between two thick-walled eccentric tubes was calculated and the predicted results match the experiment data perfectly. A 3-D rocket engine model and a real 3-D SSME geometry were used to test the current model, and the reasonable temperature field was obtained.

Wei, H.

Study of exothermic processes in shock ignited gases by the use of laser shear interferometry

Report on measurements of maximum exothermic power pulses attainable from a given chemical system. Experimental tests involved the use of a shock tube technique whereby the exothermic process of combustion was controlled by reflected shock, so that it occurred under virtually inviscid flow conditions, while the measurements were performed at a resolution commensurate with the actual rate of chemical reaction. Experimental observations were made by means of a novel method of laser shear interferometry - a cross-breed between holography and the conventional means for measuring refractive index fields, in that, on one hand, it was based on the exploitation of the phase coherence of the laser light beam, recording first a diffraction image of the wave fronts which, for the desired final result, had to be optically reconstructed, and, on the other, it yielded eventually either two-dimensional interferograms or schlieren photographs of the observed phenomena.

Meyer, J. W.