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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗
NASA NTRS2017

Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails

State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.

Fernandez, Juan M.↗
NASA NTRS2017

Development and Testing of the Europa Mission's Venturi Flow Meter

NASA's Marshall Space Flight Center (MSFC), in collaboration with NASA's Goddard Space Flight Center (GSFC), Fox Valve Development Corp. and Oxford Lasers, is developing a set of venturi flow meters for use on the Europa Mission's propulsion subsystem. The requirement for the venturi flow meters' throat diameters is approximately 0.040". An early risk reduction activity conducted by MSFC revealed that a venturi flow meter produced by FOX with a throat diameter near 0.040" had much higher pressure loss than venturi flow meters with larger throat diameters and venturis of similar throat diameter size but with no pressure taps (i.e. venturis with a throat length to diameter ratio of zero). In response, a series of venturi flow meters was fabricated and flow tested to gain insight into pressure recovery as it is affected by pressure port diameter, throat length and diffuser angle in an effort to improve the performance of a venturi flow meter. This presentation provides a summary of the venturi flow meter development activity including: a description of the test's objectives, a detailed description of each venturi configuration, a description of the manufacturing processes of the venturis, and observations from the test data. A summary of the current development activities will also be given, as well as the current development path forward. Ultimately, the knowledge gained through the fabrication and testing of these venturis provides guidance to design a flight venturi flow meters with pressure recoveries that is acceptable for the Europa flight application.

Diaz, C. E.↗
NASA NTRS2016

Progress on the Fabrication of High Resolution and Lightweight Monocrystalline Silicon X-ray Mirrors

Monocrystalline silicon is an excellent X-ray mirror substrate material due to its high stiffness, low density, high thermal conductivity, zero internal stress, and commercial availability. Our work at NASA Goddard Space Flight Center focuses on identifying and developing a manufacturing process to produce high resolution and lightweight X-ray mirror segments in a cost and time effective manner. Previous efforts focused on demonstrating the feasibility of cylindrical silicon mirror polishing and lightweighting. Present efforts are aimed towards producing true paraboloidal and hyperboloidal mirror surfaces on the lightweight silicon segments. This paper presents results from these recent investigations, including a mirror which features a surface quality sufficient for a 3 arcsecond telescope.

X-ray optics↗
NASA NTRS2017

Relationship of Powder Feedstock Variability to Microstructure and Defects in Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer by layer. For selective laser melted (SLM) Alloy 718, the powders that are available off-the-shelf are in the 10-45 or 15-45 micron size range. A comprehensive investigation of sixteen powders from these typical ranges and two off-nominal-sized powders is underway to gain insight into the impact of feedstock on processing, durability and performance of 718 SLM space-flight hardware. This talk emphasizes an aspect of this work: the impact of powder variability on the microstructure and defects observed in the as-fabricated and full heated material, where lab-scale components were built using vendor recommended parameters. These typical powders exhibit variation in composition, percentage of fines, roughness, morphology and particle size distribution. How these differences relate to the melt-pool size, porosity, grain structure, precipitate distributions, and inclusion content will be presented and discussed in context of build quality and powder acceptance.

Characterization↗
NASA NTRS2018

Corrosion Failure in Electronic Devices for Aerospace Application

Corrosion of complex electronic systems is a growing and expensive concern. New materials and technology are constantly being introduced to increase performance of devices. There are many factors that can induce a corrosive environment during the various stages of manufacturing, processing, transport, and storage of these devices. The scope of this paper was to identify potential causes for the corrosion failure of optocoupler batches being used in launch applications. Optical microscope with surface profile measurements, scanning electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDS), and X-ray photoelectron spectroscopy (XPS) were used to identify and analyze the source of these failure. These studies revealed that the loss of adhesion between the electrolytic plated gold and nickel layers is the critical area that traps impurity ions into the chip allowing for blisters to form along the pins of the optocoupler.

Corrosion↗
NASA NTRS2018

Test and Analysis of Full-Scale 27.5-Foot-Diameter Stiffened Metallic Launch Vehicle Cylinders

The Shell Buckling Knockdown Factor Project (SBKF) was established with the goal of developing improved (i.e., less-conservative, more robust) shell buckling knockdown factors (KDFs) for modern launch-vehicle structures. To this end, SBKF has engaged in several activities to support the development, validation, and implementation of the new design factors, including subscale and full-scale structural testing. Tests on eight different subscale, 8-foot-diameter, integrally stiffened aluminum-lithium 2195 (Al-Li 2195) cylinders were conducted in order to obtain the majority of the required validation data. In addition, two full-scale, 27.5-foot-diameter, Al-Li 2195, integrally stiffened cylinders were tested to provide additional validation data and to determine structural scaling trends. Presented herein are the details of a recent analysis model development and test and analysis correlation effort on the full-scale test articles. The effects of selected modeling assumptions and approaches are discussed, and results from a modeling sensitivity study are presented. It was found that simplified finite element models, that assume nominal test article geometry and material properties, can predict the overall response characteristics well. However, several discrepancies in the test and analysis results were observed. A sensitivity study was performed to determine the effects of several modeling assumptions and address the observed discrepancies. The results from the study indicated that the evolution of local skin pocket buckling and the presence of residual stresses due to the manufacturing process can have a significant influence on the predicted buckling response of the cylinders considered.

Lovejoy, Andrew E.↗
NASA NTRS2018

On the Development of Shell Buckling Knockdown Factors for Stiffened Metallic Launch Vehicle Cylinders

From the 1920s to the early 1970s, many shell buckling experiments were conducted in an effort to understand the complex buckling behavior exhibited by thin-walled cylindrical shells, to provide data to correlate with new shell stability theories, and provide design guidelines. Typically, the experiments yielded buckling loads that were substantially lower than the corresponding analytical predictions, which were based on simplified linear bifurcation analyses of geometrically perfect shells with nominal dimensions and idealized boundary conditions. The seminal works by von Kármán and Tsien, by Donnell and Wan, and by Koiter identified small deviations from the idealized geometry of a shell, known as initial geometric imperfections, as a primary source of the discrepancy between corresponding analytical predictions and experimental results. However, the computational tools and capabilities at that time could not perform the nonlinear analyses needed to assess the effects of these imperfections on the buckling behavior of thin-walled shells. Thus, buckling design allowables were determined by establishing lower bounds to test data. Specifically, empirical design factors, that have become known as knockdown factors, were determined and were to be used in conjunction with linear bifurcation analyses for simply supported shells; that is, these empirical factors were used to "knock down" the value of the unconservative simplified analytical prediction. This approach to shell buckling design has proved satisfactory for most design purposes and remains prominent in industry practice, as evidenced by the extensive use of the NASA space vehicle design criteria and recommendations. Unfortunately, the current design guidelines have not been updated since they were first published in the late 1960s and may not be able to take full advantage of modern materials, precision manufacturing processes, and new structural concepts.

Hilburger, Mark W.↗
NASA NTRS2018

Characterization of Titanium Alloys Produced by Electron Beam Directed Energy Deposition

Functionally graded materials offer the potential to improve structural efficiency by allowing the material composition and/or microstructural features to spatially vary within a component. Additive manufacturing techniques enable the fabrication of such graded materials and structures. While examining several titanium alloys, this paper focuses on Ti-8Al-1Er as it has a unique microstructure that is only feasible when produced by rapid solidification methods like electron beam directed energy deposition, an additive manufacturing process. The results show that, when mixed, Ti-8Al-1Er and commercially-pure titanium uniformly mix at various ratios and the resultant static tensile properties of the mixed alloys behave according to rule-of-mixtures. At discontinuous interfaces between Ti-8Al-1Er and commercially-pure titanium, the crack growth behavior progresses smoothly across the discontinuity as the crack transitions from one crack growth regime into another. Studies on monolithic samples shows the mechanisms of damage in the Ti-8Al-1Er; specifically, that strain localization occurs near grain boundaries of high mis-orientation on the microscale and that twinning and dislocation density is concentrated near erbia-strengthening particles (Er2O3) on the nanoscale.

Newman, John A.↗
NASA NTRS2018

Fabrication and Characterization of a NIR-FIR Dichroic for the Infrared Interferometer BETTII

BETTII is a balloon-borne far infra-red (FIR: 30-100 µm) interferometer that also uses a near-infrared (NIR: 1-2.5 µm) channel for fine pointing sensing using stars. We have developed an inductive grid dichroic to divide the incoming beam into two components, by reflecting FIR light and transmitting NIR light. The dichroic is fabricated using focused electron beam technology to produce a 1 µm period, 100 nm width metal grid on a sapphire substrate in order to have high reflectance for FIR wavelengths. Here we discuss the design and the detailed manufacturing process for such a dichroic. The transmission and reflectance characteristics are also presented. We discuss them in context of the BETTII requirements.

Dhabal, Arnab↗
NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System (HT-SSEP) to Enable Lower Cost NASA Science Missions

Discusses progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kilograms at a minimum thruster efficiency of 50 percent was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel↗
NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗
NASA NTRS2019

Electrodynamic Dust Shield Testing on the Materials on International Space Station Experiment 11

Dust is a major concern for lunar exploration. To combat the effects of dust, NASA, academia, and industry are developingsolutions to the dust problem. One potential technology solution for this problem is the Electrodynamic DustShield (EDS). Many years of research and development have gone into this technology. The Materials on InternationalSpace Station Experiment - 11 (MISSE-11) provides a long term space exposure platform for this technology to verifycompatibility of materials and manufacturing processes to the space environment. The MISSE-11 EDS experimentconsists of 12 EDS panels. These panels are made of glass, polyimide, or prototype spacesuit fabric. Some panels arecovered with a lotus leaf coating while others are covered with thermal paint. They are flown in the wake position ofthe ISS to simulate the lunar environment. Two panels are in an active configuration and are energized with a highvoltage power supply, which generates high-voltage pulses to activate the dust shields. Current and voltage data arerecovered from each of these trials to compare to baseline data. Also, each of the EDS panels are imaged on a monthlybasis to track any changes with time that may occur with the EDS variants. In this paper, we report preliminary dataand analysis from this spaceflight experiment.

Johansen, Michael R.↗
NASA NTRS2019

Development of a High-Propellant Throughput Small Spacecraft Electric Propulsion System to Enable Lower Cost NASA Science Missions

This paper describes recent progress at the NASA Glenn Research Center (GRC) in the development and demonstration of an integrated high-propellant throughput small spacecraft electric propulsion (HT-SSEP) system based on a Hall-effect thruster. A center-mounted cathode and an innovative magnetic circuit topology were implemented in the design of the Hall-effect thruster to achieve high-propellant throughput, high performance, and efficient packaging. To minimize technical risk, the HT-SSEP development approach sought to limit design features and materials to those with a clear path-to-flight. A propellant throughput capability of greater than 100 kg at a minimum thruster efficiency of 50% was targeted. The proof-of-concept NASA-H64M laboratory model (LM) thruster was designed, fabricated, and tested at GRC in fiscal year 2018. The thruster development leveraged heritage Hall-effect thruster design and manufacturing processes wherever appropriate. Recent NASA advances in Hall-effect thruster technology were also leveraged. A scalable discharge power supply (DPS) capable of powering the H64M-LM was developed, then demonstrated as part of an integrated system test. The DPS uses commercial off-the-shelf components with spaceflight equivalents. A keeper supply with DC ignitor was breadboarded, then demonstrated with a laboratory cathode. Finally, feed system trade studies were performed to ascertain what feed system architecture might be appropriate for an HT-SSEP system. This paper details the motivations for the project, the development approach, the chosen sub-system architectures, design considerations, and test results.

Benavides, Gabriel F.↗
NASA NTRS2019

A Discussion of the Need to Sustain Mission Ready TPS and for Continued Development of Innovative Entry System Technologies

Flight proven entry system and TPS technologies are critical for the successful execution of in-situ science missions at Venus. Emerging new technologies point to new possibilities and offer innovative approaches to delivering small satellites for orbital science. Venus entry can be very demanding and there are only a few flight proven TPS, some developed by Industry and others by NASA, capable of meeting the mission needs. NASA developed TPS has predominately been transferred to Industry and it is assumed industry will maintain the fabrication capability. However, lack of mission needs may result in obsolence of TSP fabrication capability if there is no money and no motivation. Even within NASA, its' expertise could be diverted to higher priority objectives and thereby the readiness for particular material systems can be impacted or lost. Atrophy of capabilities can come about in other ways as well such as changes to raw materials. Even small manufacturing process changes can demand requalification and TRL may be degraded. Carbon-Phenolic is a text book example. After a long period of absence of US Venus missions, VEXG and the Science community is making the case for future missions. It is insufficient to assume the TSP technologies will be there in 5 or 10 years without active and continual planning and assessment. After Galileo, Carbon-Phenolic materials and fabrication skills were allowed to atrophy. Then when missions needed it, in early 2000, it was no longer possible to make the heritage Carbon-Phenolic. What do we need to do? The first step is to advocate for the establishment of TPS readiness assess-ment. The assessment will involve understanding threats and opportunities, and the development of risk mitigation strategies. VEXAG needs to advocate for such an active monitoring of the needed capabilities, assessment of emerging risks and development of risk mitigation strategies with implementation plans. Such an approach reduces the threat of material obsolence and helps maintain the availability of entry system and TPS technology capabilities, both old and new. Venus probes, landers, balloons and other variable altitude missions, and skimmer missions such as "Cu-pid's Arrow" as well as aerocapture missions to deliver small spacecraft require qualified entry systems and ablative TPS. VEXAG advocated for HEEET in 2013/2014 and the community is well versed with the need to sustain it. But, other TPS that need to be sustained may not be apparent to VEXAG community. The following figure summarizes the ablative TPS capabilities vs Venus mission needs for both primary heatshield and backshell.

Venkatapathy, Ethiraj↗
NASA NTRS2019

Analysis of Bioreduction Strategies for a Solid Rocket Motor on an Interplanetary Mission to Europa

The Europa Lander De-Orbit stage braking motor must comply with the Planetary Protection requirements established for a category IV mission. In its mission to Europa, a motor that hasn’t gone through bioreduction environments will carry microbial spores and other biosignature molecules that might jeopardize a mission of astrobiological concern as well as future missions to come. A motor with solid rocket propellant represents exclusive challenges associated to the calculation of high numbers of an encapsulated bioburden hidden behind a nozzle plug. Existing techniques for bioburden reduction are analysed in perspective to motor assembly facilities and the series of events that are involved in manufacturing a solid rocket motor. These techniques include antimicrobial effects of chemical components already present within the motor and bioreduction due to assembly and operational environments induced in the motor. Analysis of the manufacturing process, adhered bioburden and recent investigations into the effectiveness of microbiological techniques in finding inherent antimicrobial properties have generated a step by step outline of Planetary Protection for lander mission associated solid rocket motors.

Velez-Justiniano, Yo-Ann↗
NASA NTRS2019

Heat-Cleaned Nextel in MMOD Shielding

Meteoroid and orbital debris (MMOD) shielding can include NextelTM ceramic cloth in the outer layers of the shielding to enhance MMOD breakup. The Nextel fabric can contain size (or sizing) which aids in manufacture of the fabric. Sizing is a starch, oil or waxy material that is added to the rovings and yarns to protect the fibers from being cut or broken during the fabric manufacturing process and by later handling. For spacecraft applications, sizing is removed by heat-cleaning to reduce/eliminate off-gassing during vacuum operations. After the sizing is removed, the fibers in the woven fabric are prone to breakage during handling which reduces fabric strength. Because heat-cleaned Nextel tends to shed fibers that can be irritating to workers, the usual practice for hypervelocity impact tests is to use Nextel with sizing. The reduced strength of heat-cleaned Nextel does not typically effect the performance of MMOD shields with Nextel used in outer layers of the shield, because the density and areal density of the ceramic fibers in the fabric control MMOD breakup (not fabric strength). This paper provides data demonstrating that hypervelocity impact protection performance is not adversely altered for shields containing heat-cleaned Nextel compared to Nextel with sizing.

Christiansen, Eric L.↗
NASA NTRS2018

Effectiveness of Surface Treatment Techniques for Composite Bonding with Different Contamination Levels

Various surface treatment techniques have been developed to promote adhesive bond performance for composite structural components in aerospace applications. The condition of the pre-bond surface is critical to achieving desirable bond quality. Contamination on bonding surfaces is well recognized as a major threat to ultimate bond performance. Variation in contamination level has brought additional challenges into manufacturing process control. High fidelity surface treatment techniques are required for effective removal of contaminants over a wide range of contamination levels. In this study, a common contaminant, i.e. silicone mold release, was introduced to pre-bond composite surfaces with different concentrations. Plasma and laser surface treatment techniques were performed and their effectiveness in restoring and enhancing desirable bond quality was investigated. Surface characterization techniques, including water contact angle goniometry, Fourier transform infrared spectroscopy and X-ray photoelectron spectroscopy, were conducted to assess the condition of contaminated surfaces and the improvement induced by plasma and laser surface treatments. Failure modes from a customized double cantilever beam test were investigated before and after surface treatments. Fundamental mechanisms of plasma and laser surface treatments on the composite bonding surfaces were also investigated.

Fang, Xiaomei↗