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The topics covered are presented in viewgraph form and include the following: problem definition and motivation; survey of current technology; focus problems; approach; progress/discussion; and future direction and anticipated results.
Three dimensional (3D) printing is a new and booming topic in many realms of research and engineering technology. When it comes to space science and aerospace engineering, it can be useful in numerous ways. As humans travel deeper into space and farther from Earth, sending large quantities of needed supplies from Earth for a mission becomes astronomically expensive and less plausible. In order to reach further to new places, In Situ Resource Utilization (ISRU), a project that pushes for technologies to use materials already present in the destination's environment, is necessary. By using materials already available in space such as regolith from the Moon, Mars, or an asteroid's surface, fewer materials need to be brought into space on a launched vehicle. This allows a vehicle to be filled with more necessary supplies for a deep space mission that may not be found in space, like food and fuel. This project's main objective was to develop a 3D printer that uses regolith to "print" large structures, such as a dome, to be used as a heat shield upon a vehicle's reentry into the atmosphere or even a habitat. 3D printing is a growing technology that uses many different methods to mix, heat, and mold a material into a specific shape. In order to heat the regolith enough to stick together into a solid shape, it must be sintered at each layer of material that is laid. Sintering is a process that heats and compresses a powdered material until it fuses into a solid, which requires a lot of energy input. As an alternative, a polymer can be mixed with the regolith before or as it is sent to the 3D printer head to be placed in the specific shape. The addition of the polymer, which melts and binds at much lower temperatures than sintering temperatures, greatly decreases the required heating temperature and energy input. The main task of the project was to identify a functional material for the printer. The first step was to find a miscible. polymer/solvent solution. This solution was added to the regolith and the solvent was evaporated essentially leaving polymer-coated regolith particles. This material would be sent through the printer head and heated layer by layer to melt the polymer and bind the regolith. This method was one of many in a large goal to utilize materials in space with a custom-made 3D printer that builds dome-shaped habitats and other essential equipment for future deep space missions.
The problems confronting the designer of models for cryogenic wind tunnel models are discussed with particular reference to the difficulties in obtaining appropriate data on the mechanical and physical properties of candidate materials and their fabrication technologies. The relationship between strength and toughness of alloys is discussed in the context of maximizing both and avoiding the problem of dimensional and microstructural instability. All major classes of materials used in model construction are considered in some detail and in the Appendix selected numerical data is given for the most relevant materials. The stepped-specimen program to investigate stress-induced dimensional changes in alloys is discussed in detail together with interpretation of the initial results. The methods used to bond model components are considered with particular reference to the selection of filler alloys and temperature cycles to avoid microstructural degradation and loss of mechanical properties.
The problems confronting the designer of models for cryogenic wind tunnel models are discussed with particular reference to the difficulties in obtaining appropriate data on the mechanical and physical properties of candidate materials and their fabrication technologies. The relationship between strength and toughness of alloys is discussed in the context of maximizing both and avoiding the problem of dimensional and microstructural instability. All major classes of materials used in model construction are considered in some detail and in the Appendix selected numerical data is given for the most relevant materials. The stepped-specimen program to investigate stress-induced dimensional changes in alloys is discussed in detail together with interpretation of the initial results. The methods used to bond model components are considered with particular reference to the selection of filler alloys and temperature cycles to avoid microstructural degradation and loss of mechanical properties.
A lunar construction shack vehicle is a critical component in most of the plans proposed for the construction of a permanent base on the moon. The Selene Engineering Company (SEC) has developed a concept for this vehicle which is both innovative and practical. The design makes use of the most advanced technology available to meet the goals for a safe, versatile and durable habitat that will serve as a starting point for the initial phase of the construction of a permanent lunar base. This document outlines SEC's proposed design for a lander vehicle which will be fully self-sufficient and will provide for all necessary life support, including consumables and radiation protection, needed by the construction crew until they can complete the assembly of a more permanent habitat. Since it is highly likely that it will take more than one crew to complete the construction of a permanent lunar base, the design emphasis is on systems which can be easily maintained and resupplied and which will take a minimum of start up preparation by succeeding crews.
Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews(NASA Apollo program).Now, the next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and theEuropean Union of nations, have all expressed interest in either collaborating or competing with NASA on theMoon. This next phase has an overarching goal of achieving a permanent human presence on theMoon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment.Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity(EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. Radiation shielding via the use of regolith can also mitigate radiation dangers.The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve.In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give ahistorical review and current status of lunar construction planning and a high level introduction to the required infrastructure and construction equipment that will be required to robotically build a lunar base using in-situ resources.It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.
Environments generated in high pressure liquid rocket engines impose severe requirements on regeneratively cooled combustor liners. Liners fabricated for use in high chamber pressures using conventional processes suffer from limitations that can impair operational cycle life and can adversely affect wall compatibility. Chamber liners fabricated using formed platelet technology provide an alternative to conventional regeneratively cooled liners (an alternative that has many attractive benefits). A formed platelet liner is made from a stacked assembly of platelets with channel features. The assembly is diffusion bonded into a flat panel and then three-dimensionally formed into a section of a chamber. Platelet technology permits the liner to have very precisely controlled and thin hot gas walls and therefore increased heat transfer efficiency. Further cooling efficiencies can be obtained through enhanced design flexibility. These advantages translate into increased cycle life and enhanced wall compatibility. The increased heat transfer efficiency can alternately be used to increase engine performance or turbopump life as a result of pressure drop reductions within the regeneratively cooled liner. Other benefits can be obtained by varying the materials of construction within the platelet liner to enhance material compatibility with operating environment or with adjoining components. Manufacturing cost savings are an additional benefit of a formed platelet liner. This is because of reduced touch labor and reduced schedule when compared to conventional methods of manufacture. The formed platelet technology is not only compatible with current state-of-the art combustion chamber structural support and manifolding schemes, it is also an enabling technology that allows the use of other high performance and potentially low cost methods of construction for the entire combustion chamber assembly. The contract under which this report is submitted contains three phases: (1) phase A - feasibility study and technology development; (2) phase B - sub-scale fabrication feasibility; and (3) phase C - large scale fabrication validation. This report covers the Phase A activities, which began in December of 1988.
Solid oxide electrolyzers, such as electrolysis cells utilizing yttria-stabilized zirconia, can produce oxygen from Mars atmospheric carbon dioxide and reject carbon monoxide and unreacted carbon dioxide in a separate stream. The oxygen-production process has been shown to be far more efficient if the high-pressure, unreacted carbon dioxide can be separated and recycled back into the feed stream. Additionally, the mass of the adsorption compressor can be reduced. Also, the carbon monoxide by-product is a valuable fuel for space exploration and habitation, with applications from fuel cells to production of hydrocarbons and plastics. In our research, we will design, construct, and test an innovative, robust, low mass, low power separation device that can recover carbon dioxide and carbon monoxide for Mars ISRU. Such fundamental process technology, involving gas-solid phase separation in a reduced gravitational environment, will help to enable Human Exploration and Development of Space. The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, respectively. In our research, we will design, construct, and test an innovative, robust, low mass, low power separation device that can recover carbon dioxide and carbon monoxide for Mars ISRU, Such fundamental process technology, involving gas-solid phase separation in a reduced gravitational environment, will help to enable Human Exploration and Development of Space. The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, Research needs for the design shown are as follows: (1) The best adsorbent for the process must be determined. (2) Adsorption isotherms must be measured, both for pure components and mixtures. (3) Mathematical modeling must be performed to provide a solid framework for design. (4) The separation system must be constructed and tested. (5) System integration must be studied.
This final project report covers the design, development, construction, testing and qualification of the NIMBUS D BUV (Backscatter Ultraviolet) instrument. The instrument was designed and constructed in accordance with GSFC specification S-623-P-l and amendments. The design phase consisted of activity in three areas of technology: (1) Optical, (2) Mechanical, and (3) Electrical. Beckman Instruments, Inc. performed the tasks concerned with optical and mechanical design while Analog Technology Corporation was the electronics subcontractor. Initial studies resulted in the development of a breadboard model of the BUV instrument. Following extensive testing, additional mathematical analyses, and required modifications, preliminary and critical design reviews were performed. The results of these activities were the construction of an engineering model, used for extensive testing and demonstration of the final design features. Final design data resulted in the construction of two flight-rated instruments, serial numbers P103 and Fl04. On April 8, 1970, the P103 instrument was successfully launched into orbit on NIMBUS D and is presently fully operational.
It is proposed that a stratospheric photochemistry simulator could be created in sun-synchronous orbit, so that diffusion and photochemistry could be decoupled and uncertainties in photochemical reaction rates could be substantially reduced. The proposed test chamber is described, and it is suggested that the technology of superpressure balloons seems to be the best short-term solution to the construction of the proposed facility. Both unreinforced polyester films and gelatin films are considered as candidate chamber coatings. It is noted that the experiments can be performed early in the space-manufacturing era and that at least three dedicated Shuttle launches will be required to establish the proposed facility.
Flight article and associated design concepts are evaluated to meet fundamental requirements of a universal crew cabin to be used as a construction cherrypicker, a space crane turret, a railed work station, or a free flyer. Key technology developments are embodied into a simulation program. A schedule and simulation test plan matrix is given for the open cabin cherry picker.
A methodology is presented for predicting coal prices in regional markets for the target time frames 1985 and 2000 that could subsequently be used to guide the development of an advanced coal extraction system. The model constructed is a supply and demand model that focuses on underground mining since the advanced technology is expected to be developed for these reserves by the target years. Coal reserve data and the cost of operating a mine are used to obtain the minimum acceptable selling price that would induce the producer to bring the mine into production. Based on this information, market supply curves can be generated. Demand by region is calculated based on an EEA methodology that emphasizes demand by electric utilities and demand by industry. The demand and supply curves are then used to obtain the price targets. The results show a growth in the size of the markets for compliance and low sulphur coal regions. A significant rise in the real price of coal is not expected even by the year 2000. The model predicts heavy reliance on mines with thick seams, larger block size and deep overburden.
An engine test facility was constructed at the NASA Langley Research Center in support of a supersonic combustion ramjet (scramjet) technology development program. Hydrogen combustion in air with oxygen replenishment provides simulated air at Mach 4 flight velocity, pressure, and true total temperature for an altitude range from 57,000 to 86,000 feet. A facility nozzle with a 13 in square exit produces a Mach 3.5 free jet flow for engine propulsion tests. The facility is described and calibration results are presented which demonstrate the suitability of the test flow for conducting scramjet engine research.
It was recognized that the traditional hot rod type deposition process for decomposing silane is energy intensive, and a different approach for converting silane to silicon was chosen. A 1200 metric tons/year capacity commercial plant was constructed in Moses Lake, Washington. A fluidized bed processor was chosen as the most promising technology and several encouraging test runs were conducted. This technology continues to be very promising in producing low cost polysilicon. The Union Carbide silane process and the research development on the fluidized bed silane decomposition are discussed.
This article explores a potential scenario for the further development of space infrastructure resources and operations management. It is a scenario that transitions from the current ground-based system to an architecture that is predominantly space-based by exploiting key mission systems in an operational support role. If this view is accurate, an examination of the range of potential infrastructure elements and how they might interact in a maximally productive space-based operations complex is needed, innovative technologies beyond the current Shuttle and Space Station legacy need to be identified, and research programs pursued. Development of technologies within the areas of telerobotics, machine autonomy, human autonomy, in-space manufacturing and construction, propulsion and energy is discussed.
The current state of development of the NASA/GSFC (Goddard Space Flight Center) Split-Rail Parallel Gripper (SRPG) is described. The SPRG has been shown to be a high performance gripper for industrial robots. It has a precise wide throw and at the same time, it is light, simple, compact, rugged, and jam-proof against side loads. Originated at the National Bureau of Standards (NBS), this gripper is undergoing further development at NASA/GSFC in pursuit of two goals: as a potential gripper for robots in space and as the basis for sensory-interactive industrial gripper as part of NASA's technology utilization program. The gripper design features, its principles of operation and how it is constructed are described. Test results are included.
Experimental robotic system semiautomatically grasps rotating object, stops rotation, and pulls object to rest in fixture. Based on combination of advanced techniques for sensing and control, constructed to test concepts for robotic recapture of spinning artificial satellites. Potential terrestrial applications for technology developed with help of system includes tracking and grasping of industrial parts on conveyor belts, tracking of vehicles and animals, and soft grasping of moving objects in general.
The XV-15, N703NA Tiltrotor Research Aircraft located at the NASA Ames Research Center, Moffett Field, California, currently uses a set of composite rotor blades of complex shape known as the advanced technology blades (ATBs). The main structural element of the blades is a D-spar constructed of unidirectional, angled fiberglass/graphite, with the aft fairing portion of the blades constructed of a fiberglass cross-ply skin bonded to a Nomex honeycomb core. The blade tip is a removable laminate shell that fits over the outboard section of the spar structure, which contains a cavity to retain balance weights. Two types of tip shells are used for research. One is highly twisted (more than a conventional helicopter blade) and has a hollow core constructed of a thin Nomex-honeycomb-and-fiberglass-skin sandwich; the other is untwisted with a solid Nomex honeycomb core and a fiberglass cross-ply skin. During initial flight testing of the blades, a number of problems in the composite structure were encountered. These problems included debonding between the fiberglass skin and the honeycomb core, failure of the honeycomb core, failures in fiberglass splices, cracks in fiberglass blocks, misalignment of mated composite parts, and failures of retention of metal fasteners. Substantial time was spent in identifying and repairing these problems. Discussed here are the types of problems encountered, the inspection procedures used to identify each problem, the repairs performed on the damaged or flawed areas, the level of criticality of the problems, and the monitoring of repaired areas. It is hoped that this discussion will help designers, analysts, and experimenters in the future as the use of composites becomes more prevalent.