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717 records · Page 40

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗

A GPS-Based Pitot-Static Calibration Method Using Global Output-Error Optimization

Pressure-based airspeed and altitude measurements for aircraft typically require calibration of the installed system to account for pressure sensing errors such as those due to local flow field effects. In some cases, calibration is used to meet requirements such as those specified in Federal Aviation Regulation Part 25. Several methods are used for in-flight pitot-static calibration including tower fly-by, pacer aircraft, and trailing cone methods. In the 1990 s, the introduction of satellite-based positioning systems to the civilian market enabled new inflight calibration methods based on accurate ground speed measurements provided by Global Positioning Systems (GPS). Use of GPS for airspeed calibration has many advantages such as accuracy, ease of portability (e.g. hand-held) and the flexibility of operating in airspace without the limitations of test range boundaries or ground telemetry support. The current research was motivated by the need for a rapid and statistically accurate method for in-flight calibration of pitot-static systems for remotely piloted, dynamically-scaled research aircraft. Current calibration methods were deemed not practical for this application because of confined test range size and limited flight time available for each sortie. A method was developed that uses high data rate measurements of static and total pressure, and GPSbased ground speed measurements to compute the pressure errors over a range of airspeed. The novel application of this approach is the use of system identification methods that rapidly compute optimal pressure error models with defined confidence intervals in nearreal time. This method has been demonstrated in flight tests and has shown 2- bounds of approximately 0.2 kts with an order of magnitude reduction in test time over other methods. As part of this experiment, a unique database of wind measurements was acquired concurrently with the flight experiments, for the purpose of experimental validation of the optimization method. This paper describes the GPS-based pitot-static calibration method developed for the AirSTAR research test-bed operated as part of the Integrated Resilient Aircraft Controls (IRAC) project in the NASA Aviation Safety Program (AvSP). A description of the method will be provided and results from recent flight tests will be shown to illustrate the performance and advantages of this approach. Discussion of maneuver requirements and data reduction will be included as well as potential applications.

Foster, John V.↗

Space Suit Portable Life Support System Thermal Control Valve Ball Design

A Thermal Control Valve (TCV) has been in development for the Exploration Extravehicular Mobility Unit Portable Life Support System (xEMU PLSS). The xEMU PLSS TCV controls flow going to the liquid cooling and ventilation garment that the crew member wears during extra-vehicular activity to expel waste heat. A pervious TCV version with a linear actuator and diverter valve has been tested extensively to attempt to control the flow accurately. The previous TCV diverter valve has a non-linear flow response relative to valve position and has struggled to accurately meet the setpoints desired for precision thermal control. While many diverter valve design variations have been attempted, previous designs have all had difficulty in meeting set points. Additionally, high precision machining is required for these diverter valves to create a metal-on-metal seal which has its own drawbacks and doesn’t always meet requirements for internal leakage. This metal compression seal also requires stalling the linear actuator to load the seal in compression or tension which has demonstrated valve sticking failures when stalled. The xEMU PLSS TCV implements a new approach and design for a TCV which uses a rotational ball to control flow and has demonstrated a much more precise and linear flow control. The design functions like a two-way ball valve with two Teflon seats that cradle and compress the ball for sealing. A new geometric design modification to the ball outlet can create a set-able orifice like hole which is more predictable at controlling flow than using an annulus with the previous diverter valve. Additionally, the Teflon seat performs much better for preventing internal leakage than the metal seal and prevents sticking by having a large range in which it is sealed without having to stall the actuator. This paper will review a new proposed xEMU PLSS TCV ball design and compare it with previous iterations of the design.

Ryan Ogilvie↗

Analytical Review of Exploration Extravehicular Mobility Unit Heat Rejection Performance

The Primary Thermal Control Loop (PTCL) in the Exploration Extravehicular Mobility Unit (xEMU) uses a Spacesuit Water Membrane Evaporator (SWME) to provide cooling for the crew member and spacesuit avionics. A secondary emergency cooling system, the Auxiliary Thermal Control Loop (ATCL), also uses a smaller version of the SWME, called the Mini-ME, in the event of a failure in the primary system. These are integral to the comfort of the crew member (through heat rejection) during an Extravehicular Activity (EVA). This paper examines the effectiveness of the heat rejection of the PTCL and the ATCL during thermal vacuum testing and the absolute limit of heat rejection to maintain an approximately 10C outlet temperature. During this thermal vacuum test, the PTCL was taken from a heat input of 0W up to 900W, far past the design point, and the ATCL was tested from 0W to 300W. Testing showed that the PTCL and the ATCL can maintain crew member outlet temperature throughout an entire 8-hour thermally controlled EVA environment (hot and cold). The results and effectiveness of the test will be detailed throughout this paper for all EVAs (whether a full mapping profile or a standard continuous heat load).

PLSS↗

Simulated convective systems using a cloud resolving model: Impact of large-scale temperature and moisture forcing using observations and GEOS-3 reanalysis

The GCE (Goddard Cumulus Ensemble) model, which has been developed and improved at NASA Goddard Space Flight Center over the past two decades, is considered as one of the finer and state-of-the-art CRMs (Cloud Resolving Models) in the research community. As the chosen CRM for a NASA Interdisciplinary Science (IDS) Project, GCE has recently been successfully upgraded into an MPI (Message Passing Interface) version with which great improvement has been achieved in computational efficiency, scalability, and portability. By basically using the large-scale temperature and moisture advective forcing, as well as the temperature, water vapor and wind fields obtained from TRMM (Tropical Rainfall Measuring Mission) field experiments such as SCSMEX (South China Sea Monsoon Experiment) and KWAJEX (Kwajalein Experiment), our recent 2-D and 3-D GCE simulations were able to capture detailed convective systems typical of the targeted (simulated) regions. The GEOS-3 [Goddard EOS (Earth Observing System) Version-3] reanalysis data have also been proposed and successfully implemented for usage in the proposed/performed GCE long-term simulations (i.e., aiming at producing massive simulated cloud data -- Cloud Library) in compensating the scarcity of real field experimental data in both time and space (location). Preliminary 2-D or 3-D pilot results using GEOS-3 data have generally showed good qualitative agreement (yet some quantitative difference) with the respective numerical results using the SCSMEX observations. The first objective of this paper is to ensure the GEOS-3 data quality by comparing the model results obtained from several pairs of simulations using the real observations and GEOS-3 reanalysis data. The different large-scale advective forcing obtained from these two kinds of resources (i.e., sounding observations and GEOS-3 reanalysis) has been considered as a major critical factor in producing various model results. The second objective of this paper is therefore to investigate and present such an impact of large-scale forcing on various modeled quantities (such as hydrometeors, rainfall, and etc.). A third objective is to validate the overall GCE 3-D model performance by comparing the numerical results with sounding observations, as well as available satellite retrievals.

Shie, C.-L.↗

Large-Scale Hybrid Motor Testing

Hybrid rocket motors can be successfully demonstrated at a small scale virtually anywhere. There have been many suitcase sized portable test stands assembled for demonstration of hybrids. They show the safety of hybrid rockets to the audiences. These small show motors and small laboratory scale motors can give comparative burn rate data for development of different fuel/oxidizer combinations, however questions that are always asked when hybrids are mentioned for large scale applications are - how do they scale and has it been shown in a large motor? To answer those questions, large scale motor testing is required to verify the hybrid motor at its true size. The necessity to conduct large-scale hybrid rocket motor tests to validate the burn rate from the small motors to application size has been documented in several place^'^^.^. Comparison of small scale hybrid data to that of larger scale data indicates that the fuel burn rate goes down with increasing port size, even with the same oxidizer flux. This trend holds for conventional hybrid motors with forward oxidizer injection and HTPB based fuels. While the reason this is occurring would make a great paper or study or thesis, it is not thoroughly understood at this time. Potential causes include the fact that since hybrid combustion is boundary layer driven, the larger port sizes reduce the interaction (radiation, mixing and heat transfer) from the core region of the port. This chapter focuses on some of the large, prototype sized testing of hybrid motors. The largest motors tested have been AMROC s 250K-lbf thrust motor at Edwards Air Force Base and the Hybrid Propulsion Demonstration Program s 250K-lbf thrust motor at Stennis Space Center. Numerous smaller tests were performed to support the burn rate, stability and scaling concepts that went into the development of those large motors.

Story, George↗

Harmonized Emissions Component (HEMCO) 3.0 as a Versatile Emissions Component for Atmospheric Models: Application in the GEOS-Chem, NASA GEOS, WRF-GC, CESM2, NOAA GEFS-Aerosol, and NOAA UFS Models

Emissions are a central component of atmospheric chemistry models. The Harmonized Emissions Component (HEMCO) is a software component for computing emissions from a user-selected ensemble of emission inventories and algorithms. It allows users to re-grid, combine, overwrite, subset, and scale emissions from different inventories through a configuration file and with no change to the model source code. The configuration file also maps emissions to model species with appropriate units. HEMCO can operate in offline stand-alone mode, but more importantly it provides an online facility for models to compute emissions at runtime. HEMCO complies with the Earth System Modeling Framework (ESMF) for portability across models. We present a new version here, HEMCO 3.0, that features an improved three-layer architecture to facilitate implementation into any atmospheric model and improved capability for calculating emissions at any model resolution including multiscale and unstructured grids. The three-layer architecture of HEMCO 3.0 includes (1) the Data Input Layer that reads the configuration file and accesses the HEMCO library of emission inventories and other environmental data, (2) the HEMCO Core that computes emissions on the user-selected HEMCO grid, and (3) the Model Interface Layer that re-grids (if needed) and serves the data to the atmospheric model and also serves model data to the HEMCO Core for computing emissions dependent on model state (such as from dust or vegetation). The HEMCO Core is common to the implementation in all models, while the Data Input Layer and the Model Interface Layer are adaptable to the model environment. Default versions of the Data Input Layer and Model Interface Layer enable straightforward implementation of HEMCO in any simple model architecture, and options are available to disable features such as re-gridding that may be done by independent couplers in more complex architectures. The HEMCO library of emission inventories and algorithms is continuously enriched through user contributions so that new inventories can be immediately shared across models. HEMCO can also serve as a general data broker for models to process input data not only for emissions but for any gridded environmental datasets. We describe existing implementations of HEMCO 3.0 in (1) the GEOS-Chem “Classic” chemical transport model with shared-memory infrastructure, (2) the high-performance GEOS-Chem (GCHP) model with distributed-memory architecture, (3) the NASA GEOS Earth System Model (GEOS ESM), (4) the Weather Research and Forecasting model with GEOS-Chem (WRF-GC), (5) the Community Earth System Model Version 2 (CESM2), and (6) the NOAA Global Ensemble Forecast System – Aerosols (GEFS-Aerosols), as well as the planned implementation in the NOAA Unified Forecast System (UFS). Implementation of HEMCO in CESM2 contributes to the Multi-Scale Infrastructure for Chemistry and Aerosols (MUSICA) by providing a common emissions infrastructure to support different simulations of atmospheric chemistry across scales.

Haipeng Lin↗

System for Testing Thermal Insulation of Pipes

An apparatus and method have been developed for measuring the rates of leakage of heat into pipes carrying liquids, the purpose of the measurements being to quantify the thermal performance of the insulation system. The apparatus is designed primarily for testing pipes used to carry cryogenic liquids, but can also be used for measuring the thermal performance of other insulated pipes or piping systems. The basic measurement principle is straightforward: The outer surface of the pipe insulation is maintained at a fixed warmer temperature. The interior of the pipe is maintained in a narrow fixed lower-temperature range by means of a regular liquid (e.g., water) that is pumped through the pipe at a known flow rate or a cryogenic liquid (e.g., nitrogen) that is saturated at atmospheric pressure and replenished until steady-state conditions are achieved. In the case of water or another liquid pumped through, the inlet and outlet temperatures are measured and heat-leak power is calculated as the mass flow rate of the liquid multiplied by the specific heat of the liquid multiplied by the inlet-to-outlet temperature rise of the liquid. In the case of liquid nitrogen or another low-temperature boiling liquid, the heat-leak power is calculated as the rate of boil-off multiplied by the latent heat of vaporization of the liquid. Then the thermal-insulation performance of the pipe system can be calculated as a function of the measured heat-leak power, the inner and outer boundary temperatures, and the dimensions of the pipe. The apparatus can test as many as three pipes simultaneously. The pipes can have inner diameters up to .15 cm and outer diameters up to .20 cm. The lengths of the pipes may vary; typical lengths are of the order of 18 m. Two thermal guard boxes . one for each end of the pipe(s) under test . are used to make the inlet and outlet fluid connections to the pipe(s) (see figure). The connections include bellows that accommodate thermal expansion and contraction of the pipes. The guard boxes and pipe(s) are positioned so that the pipe(s) slope upward from the upstream to the downstream end at an angle of at least 2 . The upward slope allows vapor bubbles to accumulate at the downstream end. The thermal guard boxes keep the ends of the pipes at the lower interior temperature to prevent spurious lengthwise leakage of heat into the pipes. It is important to prevent this spurious heat leakage because, if it were allowed to occur, it could contribute a large error in the measured heat-leak power. The upstream thermal guard box includes a heat exchanger through which liquid flowing into the pipe(s) is subcooled to the saturation temperature corresponding to the ambient pressure. Conversely, this heat exchanger can also be used to warm the flowing liquid to a desired fixed temperature. The apparatus includes a temperature control device that is placed around each pipe under test. Each device is operated under thermostatic control to maintain the outer surface of the pipe insulation at the specified test temperature. All measurements are recorded on a portable data-acquisition system.

Fesmire, James E.↗

Design, Development and Test Challenges: Separation Mechanisms for the Orion Pad Abort-1 Flight Test

On May 6, 2010, NASA launched the first successful integrated flight test, Pad Abort-1, of the Orion Project from the White Sands Missile Range in Las Cruces, New Mexico. This test demonstrated the ability to perform an emergency pad abort of a full-scale 4.8 m diameter, 8200 kg crew capsule. During development of the critical separation mechanisms for this flight test, various challenges were overcome related to environments definition, installation complications, separation joint retraction speed, thruster ordnance development issues, load path validation and significant design loads increases. The Launch Abort System retention and release (LAS R&R) mechanism consisted of 6 discrete structural connections between the LAS and the crew module (CM) simulator, each of which had a preloaded tension tie, Superbolt torque-nut and frangible nut. During the flight test, the frangible nuts were pyrotechnically split, permitting the CM to separate from the LAS. The LAS separation event was the driving case in the shock environment for many co-located hardware items. During development testing, it was necessary to measure the source shock during the separation event so the predicted shock environment could be validated and used for certification testing of multiple hardware items. The Lockheed Martin test team measured the source separation shock due to the LAS R&R function, which dramatically decreased the predicted environment by 90% at 100 Hz. During development testing a hydraulic tensioner was used to preload the joint; however, the joint relaxation with the tensioner proved unsatisfactory so the design was modified to include a Superbolt torque-nut. The observed preload creep during lab testing was 4% after 30 days, with 2.5% occurring in the first 24 hours. The conversion of strain energy (preload) to kinetic energy (retraction) was measured to be 50-75%. Design features and careful monitoring of multiple strain gauges on each tension tie allowed a pure tensile load to be applied after stacking at the launch pad. Following installation, preload in each joint was monitored for 24 hours. Due to unforeseen complications and the influence of temperature on the portable data acquisition system, the team encountered difficulty in tracking the joint relaxation. In some cases, bond-line failure of the strain gauges occurred.

Dinsel, Alison↗

Laser Brazing of High Temperature Braze Alloy

The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.

Gao, Y. P.↗

Oxygen Production from Lunar Regolith using Ionic Liquids

The objective of this work and future follow-on work is to develop a safe, efficient, and recyclable method for oxygen and/or metals extraction from lunar regolith, in support of establishing a manned lunar outpost. The approach is to solubilize the oxides that comprise lunar regolith in media consisting of ionic liquids (ILs) and/or their mixtures at temperatures at or below 300 C. Once in solution, electrolysis can either be performed in-situ to generate oxygen at the anode and hydrogen and/or metals (silicon, iron, aluminum, titanium, etc.) at the cathode. Alternatively, the water that is generated during the solubilization process can be distilled out and condensed into a separate IL and then electrolysized to produce hydrogen and oxygen. In the case of lunar regolith, this method could theoretically produce 44g oxygen per 100g of regolith. The oxygen can be used for human life support and/or as an oxidizer for rocket fuels, and the metals can be used as raw materials for construction and/or device fabrication. Moreover, the hydrogen produced can be used to re-generate the acidic medium, which can then be used to process additional regolith, thereby making the materials recyclable and limiting upmass requirements. An important advantage of IL acid systems is that they are much "greener" and safer than conventional materials used for regolith processing such as sulfuric or hydrochloric acids. They have very low vapor pressures, which means that they contain virtually no toxic and/or flammable volatile content, they are relatively non-corrosive, and they can exhibit good stability in harsh environments (extreme temperatures, hard vacuum, etc.). Furthermore, regolith processing can be achieved at lower temperatures than other processes such as molten oxide electrolysis or hydrogen reduction, thereby reducing initial power requirements. Six ILs have been synthesized and tested for their capability to dissolve lunar simulant, and for electrochemical and thermal stability. The results showed that ILs can be very efficient electrolytes; in particular IL/phosphoric-acid mixtures appear extremely promising for solubilizing lunar simulant. Results from preliminary experiments for distillation of water produced from the oxygen within the metal oxides of the simulant and the hydrogen from the acid indicates that over 75% of the oxygen from the simulant can be harvested as water at a temperature of 150 C. A method for collection of oxygen from electrolysis of the water derived from solubilizing simulant was developed by using a liquid nitrogen trap to liquefy and collect the oxygen. Although precise quantification of the liquid oxygen trapped is difficult to obtain, the amount of hydrogen and oxygen collected from electrolysis of water in this system was greater than 98%. This set-up also included a portable mass spectrometer for the identification of gases released from electrolysis cells. Regeneration of ILs through re-protonation was also demonstrated. Four sequential re-generations of an IL following solubilization of simulant showed no significant differences in amounts of simulant dissolved. Follow-on work for this project should include more studies of IL/phosphoric acid systems. Also, much more work is necessary for defining methods for electrolysis and purification of metals from regolith solubilized in ILs, and for developing a system to use the produced hydrogen to regenerate the spent IL. Finally, design and development of flight breadboard and prototype hardware is required.

Paley, Mark Steven↗

Emergency Flight Control of a Twin-Jet Commercial Aircraft using Manual Throttle Manipulation

The Department of Homeland Security (DHS) created the PCAR (Propulsion-Controlled Aircraft Recovery) project in 2005 to mitigate the ManPADS (man-portable air defense systems) threat to the commercial aircraft fleet with near-term, low-cost proven technology. Such an attack could potentially cause a major FCS (flight control system) malfunction or other critical system failure onboard the aircraft, despite the extreme reliability of current systems. For the situations in which nominal flight controls are lost or degraded, engine thrust may be the only remaining means for emergency flight control [ref 1]. A computer-controlled thrust system, known as propulsion-controlled aircraft (PCA), was developed in the mid 1990s with NASA, McDonnell Douglas and Honeywell. PCA's major accomplishment was a demonstration of an automatic landing capability using only engine thrust [ref 11. Despite these promising results, no production aircraft have been equipped with a PCA system, due primarily to the modifications required for implementation. A minimally invasive option is TOC (throttles-only control), which uses the same control principles as PCA, but requires absolutely no hardware, software or other aircraft modifications. TOC is pure piloting technique, and has historically been utilized several times by flight crews, both military and civilian, in emergency situations stemming from a loss of conventional control. Since the 1990s, engineers at NASA Dryden Flight Research Center (DFRC) have studied TOC, in both simulation and flight, for emergency flight control with test pilots in numerous configurations. In general, it was shown that TOC was effective on certain aircraft for making a survivable landing. DHS sponsored both NASA Dryden Flight Research Center (Edwards, CA) and United Airlines (Denver, Colorado) to conduct a flight and simulation study of the TOC characteristics of a twin-jet commercial transport, and assess the ability of a crew to control an aircraft down to a survivable runway landing using TOC. The PCAR project objective was a set of pilot procedures for operation of a specific aircraft without hydraulics that (a) have been validated in both simulation and flight by relevant personnel, and (b) mesh well with existing commercial operations, maintenance, and training at a minimum cost. As a result of this study, a procedure has been developed to assist a crew in making a survivable landing using TOC. In a simulation environment, line pilots with little or no previous TOC experience performed survivable runway landings after a few practice TOC approaches. In-flight evaluations put line pilots in a simulated emergency situation where TOC was used to recover the aircraft, maneuver to a landing site, and perform an approach down to 200 feet AGL. The results of this research, including pilot observations, procedure comments, recommendations, future work and lessons learned, will he discussed. Flight data and video footage of TOC approaches may also be shown.

Cole, Jennifer H.↗

Custom Unit Pump Design and Testing for the EVA PLSS

This paper describes the effort by the Texas Engineering Experiment Station (TEES) and Honeywell for NASA to design and test a pre-flight prototype pump for use in the Extra-vehicular activity (EVA) portable life support subsystem (PLSS). Major design decisions were driven by the need to reduce the pump s mass, power, and volume compared to the existing PLSS pump. In addition, the pump must accommodate a much wider range of abnormal conditions than the existing pump, including vapor/gas bubbles and increased pressure drop when employed to cool two suits simultaneously. A positive displacement, external gear type pump was selected because it offers the most compact and highest efficiency solution over the required range of flow rates and pressure drops. An additional benefit of selecting a gear pump design is that it is self priming and capable of ingesting non-condensable gas without becoming air locked. The chosen pump design consists of a 28 V DC, brushless, sealless, permanent magnet motor driven, external gear pump that utilizes a Honeywell development that eliminates the need for magnetic coupling. Although the planned flight unit will use a sensorless motor with custom designed controller, the pre-flight prototype to be provided for this project incorporates Hall effect sensors, allowing an interface with a readily available commercial motor controller. This design approach reduced the cost of this project and gives NASA more flexibility in future PLSS laboratory testing. The pump design was based on existing Honeywell designs, but incorporated features specifically for the PLSS application, including all of the key features of the flight pump. Testing at TEES verified that the pump meets the design requirements for range of flow rates, pressure drop, power consumption, working fluid temperature, operating time, gas ingestion , and restart capability under both ambient and vacuum conditions. The pump operated between 40 and 240 lbm/hr flowrate, 35 to 100 F pump temperature range, and 5 to 10 psid pressure rise. Power consumption of the pump controller at the nominal operating point in both ambient and vacuum conditions was 9.5 W, which was less than the 12 W predicted. Gas ingestion capabilities were tested by injecting 100 cc of air into the fluid line; the pump operated normally throughout this test. The test results contained a number of anomalies, specifically power increases and a few flow stoppages, that prompted TEES and Honeywell to disassemble and inspect the pump. Inspection indicated contamination in the pump and fit issues may have played roles in the observed anomalies. Testing following reassembly indicated that the performance of the pump 1) matched both the predicted performance values, 2) the performance values measured prior to disassembly, and 3) was free of the anomalies noted in the pre-disassembly testing.

Schuller, Michael↗

EMU Ventilation Loop Simulation and Assessment of Contamination of the EMU Sublimator Hydrophilic Coating

Controlling moisture is a critical function performed in the space suit during extra vehicular activity (EVA) missions. Currently, this function is carried out by a sublimator, which is coated with a hydrophilic material. Tests have shown that siloxane compounds can off gas from the helmet absorption pad extension (HAP-E) and helmet absorption band (HAB) when they are at elevated temperatures and initial testing indicated that siloxanes could damage the hydrophilic coating. Therefore, more representative testing was needed. Important test considerations were source and destination kinetics, system geometries, scrubbing efficacy by the activated charcoal from the Metox canister, and other benefits that derive from active condensation occurring on the hydrophilic coating during exposure. A ventilation loop that was originally constructed to test hardware for control of CO2 and trace contaminants under EVA conditions was modified to conduct the siloxane off gassing tests. A vacuum compatible acrylic chamber was installed to simulate the suit volume. A steel beaker located in the chamber contained the HAP-E and HAB materials and was heated with two band heaters. The flow exiting the chamber passed through a LiOH cannister, which contained carbon beds to simulate their function in the Metox. The flow then was directed into a smaller volume that contained a coupon, which was coated with the hydrophilic material and was maintained at 10°C (50°F). Moisture was injected upstream of the suit volume simulator to maintain the dew point between 12.7°C (55°F) and 18.3°C (65°F). The pressure was controlled to between 3.8 and 4.4 psia, and the flow was held at 6 acfm. The system was run for an equivalent of 25 ten-hour EVAs, where the HAP-E/HAB materials were changed out after each EVA. The effect of the potential off gassing on the coupon was measured after each EVA period.

PLSS↗

Pre-Mission Input Requirements to Enable Successful Sample Collection by a Remote Field/EVA Team

This paper is intended to evaluate the sample collection process with respect to sample characterization and decision making. In some cases, it may be sufficient to know whether a given outcrop or hand sample is the same as or different from previous sampling localities or samples. In other cases, it may be important to have more in-depth characterization of the sample, such as basic composition, mineralogy, and petrology, in order to effectively identify the best sample. Contextual field observations, in situ/handheld analysis, and backroom evaluation may all play a role in understanding field lithologies and their importance for return. For example, whether a rock is a breccia or a clast-laden impact melt may be difficult based on a single sample, but becomes clear as exploration of a field site puts it into context. The FINESSE (Field Investigations to Enable Solar System Science and Exploration) team is a new activity focused on a science and exploration field based research program aimed at generating strategic knowledge in preparation for the human and robotic exploration of the Moon, near-Earth asteroids (NEAs) and Phobos and Deimos. We used the FINESSE field excursion to the West Clearwater Lake Impact structure (WCIS) as an opportunity to test factors related to sampling decisions. In contract to other technology-driven NASA analog studies, The FINESSE WCIS activity is science-focused, and moreover, is sampling-focused, with the explicit intent to return the best samples for geochronology studies in the laboratory. This specific objective effectively reduces the number of variables in the goals of the field test and enables a more controlled investigation of the role of the crewmember in selecting samples. We formulated one hypothesis to test: that providing details regarding the analytical fate of the samples (e.g. geochronology, XRF/XRD, etc.) to the crew prior to their traverse will result in samples that are more likely to meet specific analytical objectives than samples collected in the absence of this premission information. We conducted three tests of this hypothesis. Our investigation was designed to document processes, tools and procedures for crew sampling of planetary targets. This is not meant to be a blind, controlled test of crew efficacy, but rather an effort to recognize the relevant variables that enter into sampling protocol and to develop recommendations for crew and backroom training in future endeavors. Methods: One of the primary FINESSE field deployment objectives was to collect impact melt rocks and impact melt-bearing breccias from a number of locations around the WCIS structure to enable high precision geochronology of the crater to be performed [1]. We conducted three tests at WCIS after two full days of team participation in field site activities, including using remote sensing data and geologic maps, hiking overland to become familiar with the terrain, and examining previously-collected samples from other islands. In addition, the team members shared their projects and techniques with the entire team. We chose our "crew members" as volunteers from the team, all of whom had had moderate training in geologic fieldwork and became familiar with the general field setting. The first two tests were short, focused tests of our hypothesis. Test A was to obtain hydrothermal vugs; Test B was to obtain impact melt and intrusive rock as well as the contact between the two to check for contact metamorphism and age differences. In both cases, the test director had prior knowledge of the site geology and had developed a study-specific objective for sampling prior to deployment. Prior to the field deployment, the crewmember was briefed on the sampling objective and the laboratory techniques that would be used on the samples. At the field sites (Fig. 2), the crewmember was given 30 minutes to survey a small section of outcrop (10-15 m) and acquire a suite of three samples. The crewmember talked through his process and the test director kept track of the timeline in verbal cues to the crewmember. At the conclusion, the team member conducting the scientific study appraised the samples and train of thought. Test C was a 90-minute EVA simulation using two crewmembers working out of line-of-sight in communication with a science backroom. The science objectives were determined by the science backroom team in advance using a Gigapan image of the outcrop (Fig. 1). The science team formulated hypotheses for the outcrop units and created sampling objectives for impact-melt lithologies; the science team turned these into a science plan, which they communicated to the crew in camp prior to crew deployment. As part of the science plan, the science team also discussed their sample needs in depth with the crewmembers, including laboratory methods, objectives, and samples sizes needed. During the deployment, the two crewmembers relayed real-time information to the science backroom by radio with no time delay. Both the crew and science team re-evaluated their hypotheses and science plans in real-time. Discussion: Upon evaluation, we found that the focused tests (Tests A and B) were successful in meeting their scientific objectives. The crewmember used their knowledge of how the samples were to be used in further study (technique, sample size, and scientific need) to focus on the sampling task. The crewmember was comfortable spending minimal time describing and mapping the outcrop. The crewmember used all available time to get a good sample. The larger test was unsuccessful in meeting the sampling objectives. When the crewmembers began describing the lithologies, it was quickly apparent that the lithologies were not as the backroom expected and had communicated to the crew. When the outcrop wasn't as expected, the crew members instinctively switched to field characterization mode, taking significant time to characterize and map the outcrop. One crew member admitted that he "kind of lost track" of the sampling strategy as he focused on the basic outcrop characterization. This is the logical first step in a field geology campaign, that a significant amount of time must be spent by the crew and backroom to understand the outcrop and its significance. Basic field characterization of an outcrop is a focused activity that takes significant time and training [2, 3]. Sampling of representational lithologies can be added to this activity for little cost [4]. However, we have shown that identification of unusual or specific samples for laboratory study also takes significant time and knowledge. We suggest that sampling of this type be considered a separate activity from field characterization, and that crewmembers be trained in sampling needs for different kinds of studies (representative lithologies vs. specialized samples) to acquire a mindset for sampling similar to field mapping. Sampling activities should be given a significant amount of specifically allocated time in scheduling EVA activities; and in the better case, that sampling be done as a second activity to a previously studied outcrop where both crew and backroom are comfortable with its context and characteristics. Our hypothesis posited that crewmember knowledge of how the samples would be used upon return would aid them in choosing relevant samples. Our testing bore this hypothesis out to some extent. We therefore recommend that crewmember training should include exposure to the laboratory techniques and analyses that will be used on the samples to foster this knowledge. There is also the potential for increasing crewmember contextual knowledge real-time in the field through the introduction of in situ geochemical technologies such as field portable XRF. The presence of field portable geochemical technology could enable the astronauts to interrogate the samples for K abundance real-time, ensuring they could collect valuable and dateable samples [5]. Though simulations such as these can teach us a fair bit about decision making processes and timeline building, one EVA participant noted that when he wasn't collecting "real" samples, he wasn't at his best. This effect suggests that higher-fidelity studies involving truly remote participants conducting actual scientific studies merit further attention to capture lessons for application to future crew situations.

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