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At least 739 records · Page 41

Modeling, Analyzing, and Mitigating Dissonance Between Alerting Systems

Alerting systems are becoming pervasive in process operations, which may result in the potential for dissonance or conflict in information from different alerting systems that suggests different threat levels and/or actions to resolve hazards. Little is currently available to help in predicting or solving the dissonance problem. This thesis presents a methodology to model and analyze dissonance between alerting systems, providing both a theoretical foundation for understanding dissonance and a practical basis from which specific problems can be addressed. A state-space representation of multiple alerting system operation is generalized that can be tailored across a variety of applications. Based on the representation, two major causes of dissonance are identified: logic differences and sensor error. Additionally, several possible types of dissonance are identified. A mathematical analysis method is developed to identify the conditions for dissonance originating from logic differences. A probabilistic analysis methodology is developed to estimate the probability of dissonance originating from sensor error, and to compare the relative contribution to dissonance of sensor error against the contribution from logic differences. A hybrid model, which describes the dynamic behavior of the process with multiple alerting systems, is developed to identify dangerous dissonance space, from which the process can lead to disaster. Methodologies to avoid or mitigate dissonance are outlined. Two examples are used to demonstrate the application of the methodology. First, a conceptual In-Trail Spacing example is presented. The methodology is applied to identify the conditions for possible dissonance, to identify relative contribution of logic difference and sensor error, and to identify dangerous dissonance space. Several proposed mitigation methods are demonstrated in this example. In the second example, the methodology is applied to address the dissonance problem between two air traffic alert and avoidance systems: the existing Traffic Alert and Collision Avoidance System (TCAS) vs. the proposed Airborne Conflict Management system (ACM). Conditions on ACM resolution maneuvers are identified to avoid dynamic dissonance between TCAS and ACM. Also included in this report is an Appendix written by Lee Winder about recent and continuing work on alerting systems design. The application of Markov Decision Process (MDP) theory to complex alerting problems is discussed and illustrated with an abstract example system.

Song, Lixia↗

The Development of Real-Time Physiological Monitoring and Training Software for Remote Applications

Autogenic Feedback Training Exercise (AFTE) is an protocol and technology developed by Dr. Patricia Cowings and her associates at NASA Ames Research Center as a means to facilitate astronaut adaptation to space and exposure to the microgravity. AFTE is a training method which involves teaching subjects to voluntarily control several of their own physiological responses to environmental stressors. As the procedures matured, the training program was expanded to determine if technology developed to facilitate astronaut adaptation to space would be valuable in treating patients suffering from autonomic and vestibular pathologies and symptomatic relief from nausea and/or blood pressure control anomalies such as hypo- or hypertension. The present study, performed in conjunction with Morehouse School of Medicine, Biomedical Engineering at The University of Akron and NASA Ames Research Center has demonstrated that this technology can be successfully applied over vast distances. The specific purpose of this research was to develop a PC based system which could handle processing of twenty channels of acquired physiological data in addition to the necessary duplex communication protocols that would, for example, permit a patient in Atlanta, GA to be trained by a clinician stationed in San Jose, CA. Sixteen channels of physiological data and 20 channels of processed data are included.

Source record↗

Plenoptic Imager for Automated Surface Navigation

An electro-optical imaging device is capable of autonomously determining the range to objects in a scene without the use of active emitters or multiple apertures. The novel, automated, low-power imaging system is based on a plenoptic camera design that was constructed as a breadboard system. Nanohmics proved feasibility of the concept by designing an optical system for a prototype plenoptic camera, developing simulated plenoptic images and range-calculation algorithms, constructing a breadboard prototype plenoptic camera, and processing images (including range calculations) from the prototype system. The breadboard demonstration included an optical subsystem comprised of a main aperture lens, a mechanical structure that holds an array of micro lenses at the focal distance from the main lens, and a structure that mates a CMOS imaging sensor the correct distance from the micro lenses. The demonstrator also featured embedded electronics for camera readout, and a post-processor executing image-processing algorithms to provide ranging information.

Zollar, Byron↗

Selection and Manufacturing of Membrane Materials for Solar Sails

Commercial metallized polyimide or polyester films and hand-assembly techniques are acceptable for small solar sail technology demonstrations, although scaling this approach to large sail areas is impractical. Opportunities now exist to use new polymeric materials specifically designed for solar sailing applications, and take advantage of integrated sail manufacturing to enable large-scale solar sail construction. This approach has, in part, been demonstrated on the JAXA IKAROS solar sail demonstrator, and NASA Langley Research Center is now developing capabilities to produce ultrathin membranes for solar sails by integrating resin synthesis with film forming and sail manufacturing processes. This paper will discuss the selection and development of polymer material systems for space, and these new processes for producing ultrathin high-performance solar sail membrane films.

Bryant, Robert G.↗

Enabling Technologies for Entrepreneurial Opportunities in 3D printing of SmallSats

A consortium of innovative experts in additive manufacturing (AM) comprising Northrup Grumman Technical Services, University of Texas at El Paso (UTEP), Configurable Space Microsystems Innovations & Applications Center (COSMIAC), NASA Glenn Research Center (GRC), and Youngstown State University, have made significant breakthroughs in the goal of creating the first complete 3D printed small satellite. Since AM machines are relatively inexpensive, this should lead to many entrepreneurial opportunities for the small satellite community. Our technology advancements are focused on the challenges of embedding key components within the structure of the article. We have demonstrated, using advanced fused deposition modeling techniques, complex geometric shapes which optimize the spacecraft design. The UTEP Keck Center has developed a method that interrupts the printing process to insert components into specific cavities, resulting in a spacecraft that has minimal internal space allocated for what traditionally were functional purposes. This allows us to increase experiment and instrument capability by provided added volume in a confined small satellite space. Leveraging initial progress made on a NASA contract, the team investigated the potential of new materials that exploit the AM process, producing candidate compositions that exceed the capabilities of traditional materials. These "new materials" being produced and tested include some that have improved radiation shielding, increased permeability, enhanced thermal properties, better conductive properties, and increased structural performance. The team also investigated materials that were previously not possible to be made. Our testing included standard mechanical tests such as vibration, tensile, thermal cycling, and impact resistance as well as radiation and electromagnetic tests. The initial results of these products and their performance will be presented and compared with standard properties. The new materials with the highest probability to disrupt the future of small satellite systems by driving down costs will be highlighted, in conjunction with the electronic embedding process.

Communications↗

Development of High-Performance Solar Cells for the Jupiter and Saturn Environments

Many of the mission targets that NASA and the planetary-science community are interested in are located in deep space, in the 5-10AU range. This provides compelling motivation to develop solar cells and arrays that are highly efficient in low irradiance low temperature (LILT) environments. We give several examples of the iterative process our team has employed to develop cell designs that optimize the performance at LILT. We also provide results on advanced-architecture devices that have already demonstrated very high efficiencies in the Jupiter and Saturn LILT and radiation environments, specifically four-junction inverted metamorphic and triple-junction upright metamorphic solar cells, respectively.

Boca, Andreea↗

Seeker 1.0: Prototype Robotic Free Flying Inspector Mission Overview

Seeker 1.0 is a prototype free flying robot that will one day be capable of inspecting human-rated spacecraft. Building off previous free flyer experience, this technology will eventually improve safety of human spacecraft by offering a variety of inspection capabilities for both routine and emergency scenarios providing increased capability and safety over current inspection methods. Seeker 1.0 is capable of 6 degree of freedom flight via a cold gas propulsion system and can operate up to 1 hour via a semi-autonomous guidance, navigation, and control system. The prototype spacecraft is capable of capturing still images at a variety of resolutions up to 13 MP. The initial test flight utilizes a command and data relay box called Kenobi. Kenobi is a derivative of the Seeker design and will communicate between Cygnus and Seeker and store data for post-mission downlink. Seeker and Kenobi have launched inside a NanoRacks External CubeSat Deployer (NRCSD-E) attached to the NG-11 Cygnus ISS resupply vehicle and will operate after Cygnus departs ISS and moves to a safe altitude. Operations will last approximately 30 minutes and will consist of basic vehicle maneuvers while capturing high-resolution still images. With any remaining time and propellant, Seeker will demonstrate additional safety capabilities and maneuvers required for operations around a crewed spacecraft. The Seeker project utilized the Class IE process that allows for streamlined flight hardware development and increased mission risk tolerance.

Spacecraft Inspection↗

SWIPE: Spectral Water Inversion Processor and Emulator

Degradation of Earth’s inland water resources due to anthropogenic perturbations and climate anomalies at both local and global scales continues to place human health at substantial risk. There is now a growing necessity to develop pragmatic approaches that allow timely and effective extrapolation of local processes, to spatially resolved global products, and to promote operational and sustainable resource policy management. This presentation will be discussing the progress made developing SWIPE: Spectral Water Inversion Processor and Emulator. SWIPE is a platform for advanced modeling of coastal and inland aquatic habitats. The goal is create a comprehensive and cohesive system to leverage recent advancements in computation and machine learning to develop a synthetic training ground for sensitivity studies and algorithm development. The four principal facets of SWIPE include: 1. Advanced two-layer coated sphere bio-optical modeling and GPU radiative transfer modeling, 2. Big Data involving massive synthetic spectral libraries of optical properties of various global aquatic particles, surface reflectance, and top-of-atmosphere reflectance, all at hyperspectral resolution leveraging high-end computing systems at NASA Ames Research Center, 3. Deep Learning for algorithm development for water quality inversion of concentrations of common biogeophysical variables as well as optics, full uncertainty characterization by water type, and forward emulation, and lastly, 4. Image Processing for application of developed retrieval algorithms for both hyperspectral and multispectral sensors with experimental corrections for global adjacency, noise, sunglint, and benthic reflectance. This presentation will demonstrate the Equivalent Algal Populations (EAP) two-layer coated sphere scattering model which has been used develop spectral libraries of hyperspectral inherent optical properties of roughly 80 species of phytoplankton, covering 15 different classes and nine taxonomic functional types. The EAP model was also used to derive spectral properties of 10 different non-algal particle functional types. Examples of how the SMART-G (Speed-up Monte-carlo Advanced Radiative Transfer using GPU) radiative transfer code is used to model optically complex aquatic signals will be presented and discussed in the context of creating a massive synthetic database which can leverage the full power of next generation machine learning techniques and high end computing for water quality inversion. We will discuss our active investigation in things like appropriate model architectures, dimensionality reduction techniques such as PCA and autoencoders, uncertainty quantification and abstaining, and which variables actually benefit most from hyperspectral information versus multispectral resolution. We are also curious about questions relating to cost/benefit analysis in terms of computation resources, neural network complexity, and data volumes. Answers to these questions will hopefully elaborate on cost efficiency for potential future sensor design considerations.

SWIPE↗

Rapid Lightweight Firmware Architecture of the Mobile Metamaterial Internal Co-Integrator Robot

The Mobile Metamaterial Internal Co-Integrator (MMIC-I) is a structure assembly and servicing robot for in-space servicing, assembly, and manufacturing of primary structures and infrastructure. MMIC-I is a battery-powered crawling robot that can travel through periodic structures such as trusses and open framework mechanical metamaterials. It does this through sequences of component extension, contraction, and gripping. This paper provides a detailed discussion of MMIC-I’s lightweight and rapidly developed firmware architecture, to enable demonstration of robot locomotion, secondary operations, and communications with a central command source. The rationale for the lightweight rapid development approach is to allow for assessment of long term system requirements in parallel with the mechatronics development, including optimization of system and subsystem power densities, to inform a future choice of flight ready software frameworks. MMIC-I system computing and I/O requirements are much lower than what is provided by proven baseline computing hardware for existing flight ready software frameworks such as the core Flight System, F prime, and the Robot Operating System. Development of earth gravity ground demonstration of the robotic systems is greatly benefited by limited power and mass factors for computing hardware. Here, we implement inter-process communication, commanding, and telemetry with the Espressif ESP32 module running the Arduino OS.

Damiana Catanoso↗

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an assortment of "post-processing" methods to locally alter properties (such as coating, heat treating, work hardening, shot peening, etching, anodizing, among others). Building the final part in an additive process allows for the development of an entirely new class of metals, so-called "functionally graded metals" or "gradient alloys." By carefully blending feedstock materials with different properties in an AM process, hardware can be developed with properties that cannot be obtained using other techniques but with the added benefit of the net-shaped fabrication that AM allows.

Hofmann, Douglas C.↗

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing↗

From Earth to Space: Application of Biological Treatment for the Removal of Ammonia from Water

Managing ammonia is often a challenge in both drinking water and wastewater treatment facilities. Ammonia is unregulated in drinking water, but its presence may result in numerous water quality issues in the distribution system such as loss of residual disinfectant, nitrification, and corrosion. Ammonia concentrations need to be managed in wastewater effluent to sustain the health of receiving water bodies. Biological treatment involves the microbiological oxidation of ammonia to nitrate through a two‐step process. While nitrification is common in the environment, and nitrifying bacteria can grow rapidly on filtration media, appropriate conditions, such as the presence of dissolved oxygen and required nutrients, need to be established. This presentation will highlight results from two ongoing research programs - one at NASA's Johnson Space Center, and the other at a drinking water facility in California. Both programs are designed to demonstrate nitrification through biological treatment. The objective of NASA's research is to be able to recycle wastewater to potable water for spaceflight mission. To this end, a biological water processor (BWP) has been integrated with a forward osmosis secondary treatment system (FOST). Bacteria mineralize organic carbon to carbon dioxide as well as ammonia‐nitrogen present in the wastewater to nitrogen gas, through a combination of nitrification and denitrification. The effluent from the BWP system is low in organic contaminants, but high in total dissolved solids. The FOST system, integrated downstream of the BWP, removes dissolved solids through a combination of concentration‐driven forward osmosis and pressure driven reverse osmosis. The integrated system testing planned for this year is expected to produce water that requires only a polishing step to meet potable water requirements for spaceflight. The pilot study in California is being conducted on Golden State Water Company's Yukon wellsthat have hydrogen sulfide odor, color, total organic carbon, bromide, iron and manganese in addition to ammonia. A treatment evaluation, conducted in 2011, recommended the testing of biological oxidation filtration for the removal of ammonia and production of biologically stable water. A 8‐month pilot testing program was conducted to develop and optimize key design and operational variables. Steadystate operational data was collected to demonstrate long‐term performance and inform California Department of Public Health permitting of the full‐scale process. As ammonia continues to present challenges to water and wastewater systems, innovative strategies such as biological treatment can be applied to successfully manage it. This presentation will discuss application of cutting‐age research being conducted by NASA that will bridge existing information gaps, and benefit municipal utilities.

Ghosh, Amlan↗

From Earth to Space: Application of Biological Treatment for the Removal of Ammonia from Water

Managing ammonia is often a challenge in both drinking water and wastewater treatment facilities. Ammonia is unregulated in drinking water, but its presence may result in numerous water quality issues in the distribution system such as loss of residual disinfectant, nitrification, and corrosion. Ammonia concentrations need to be managed in wastewater effluent to sustain the health of receiving water bodies. Biological treatment involves the microbiological oxidation of ammonia to nitrate through a two‐step process. While nitrification is common in the environment, and nitrifying bacteria can grow rapidly on filtration media, appropriate conditions, such as the presence of dissolved oxygen and required nutrients, need to be established. This presentation will highlight results from two ongoing research programs - one at NASA's Johnson Space Center, and the other at a drinking water facility in California. Both programs are designed to demonstrate nitrification through biological treatment. The objective of NASA's research is to be able to recycle wastewater to potable water for spaceflight missions. To this end, a biological water processor (BWP) has been integrated with a forward osmosis secondary treatment system (FOST). Bacteria mineralize organic carbon to carbon dioxide as well as ammonia‐nitrogen present in the wastewater to nitrogen gas, through a combination of nitrification and denitrification. The effluent from the BWP system is low in organic contaminants, but high in total dissolved solids. The FOST system, integrated downstream of the BWP, removes dissolved solids through a combination of concentration‐driven forward osmosis and pressure driven reverse osmosis. The integrated system testing planned for this year is expected to produce water that requires only a polishing step to meet potable water requirements for spaceflight. The pilot study in California is being conducted on Golden State Water Company's Yukon wells that have hydrogen sulfide odor, color, total organic carbon, bromide, iron and manganese in addition to ammonia. A treatment evaluation, conducted in 2011, recommended the testing of biological oxidation filtration for the removal of ammonia and production of biologically stable water. An 8‐month pilot testing program was conducted to develop and optimize key design and operational variables. Steadystate operational data was collected to demonstrate long‐term performance and inform California Department of Public Health permitting of the full‐scale process. As ammonia continues to present challenges to water and wastewater systems, innovative strategies such as biological treatment can be applied to successfully manage it. This presentation will discuss application of cutting‐age research being conducted by NASA that will bridge existing information gaps, and benefit municipal utilities.

Pickering, Karen↗

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High↗

Commercial Implementation of Ultrasonic Velocity Imaging Methods via Cooperative Agreement Between NASA Lewis Research Center and Sonix, Inc.

This article describes the commercial implementation of ultrasonic velocity imaging methods developed and refined at NASA Lewis Research Center on the Sonix c-scan inspection system. Two velocity imaging methods were implemented: thickness-based and non-thickness-based reflector plate methods. The article demonstrates capabilities of the commercial implementation and gives the detailed operating procedures required for Sonix customers to achieve optimum velocity imaging results. This commercial implementation of velocity imaging provides a 100x speed increase in scanning and processing over the lab-based methods developed at LeRC. The significance of this cooperative effort is that the aerospace and other materials development-intensive industries which use extensive ultrasonic inspection for process control and failure analysis will now have an alternative, highly accurate imaging method commercially available.

Roth, Don J.↗

Hydra Rendezvous and Docking Sensor

The U.S. technology to support a CEV AR&D activity is mature and was developed by NASA and supporting industry during an extensive research and development program conducted during the 1990's and early 2000 time frame at the Marshall Space Flight Center. Development and demonstration of a rendezvous/docking sensor was identified early in the AR&D Program as the critical enabling technology that allows automated proxin~ity operations and docking. A first generation rendezvous/docking sensor, the Video Guidance Sensor (VGS) was developed and successfully flown on STS 87 and again on STS 95, proving the concept of a video-based sensor. Advances in both video and signal processing technologies and the lessons learned from the two successful flight experiments provided a baseline for the development of a new generation of video based rendezvous/docking sensor. The Advanced Video Guidance Sensor (AVGS) has greatly increased performance and additional capability for longer-range operation. A Demonstration Automatic Rendezvous Technology (DART) flight experiment was flown in April 2005 using AVGS as the primary proximity operations sensor. Because of the absence of a docking mechanism on the target satellite, this mission did not demonstrate the ability of the sensor to co~ltrold ocking. Mission results indicate that the rendezvous sensor operated successfully in "spot mode" (2 km acquisition of the target, bearing data only) but was never commanded to "acquire and track" the docking target. Parts obsolescence issues prevent the construction of current design AVGS units to support the NASA Exploration initiative. This flight proven AR&D technology is being modularized and upgraded with additional capabilities through the Hydra project at the Marshall Space Flight Center. Hydra brings a unique engineering approach and sensor architecture to the table, to solve the continuing issues of parts obsolescence and multiple sensor integration. This paper presents an approach to sensor hardware trades, to address the needs of future vehicles that may rendezvous and dock with the International Space Station (ISS). It will also discuss approaches for upgrading AVGS to address parts obsolescence, and concepts for modularizing the sensor to provide configuration flexibility for multiple vehicle applications. Options for complementary sensors to be integrated into the multi-head Hydra system will also be presented. Complementary sensor options include ULTOR, a digital image correlator system that could provide relative six-degree-of-freedom information independently from AVGS, and time-of-flight sensors, which determine the range between vehicles by timing pulses that travel from the sensor to the target and back. Common targets and integrated targets, suitable for use with the multi-sensor options in Hydra, will also be addressed.

Roe, Fred↗

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

High Temperature Boost (HTB) Anode Power Supply for a Modular and Scalable Power Processing Unit

A concept of a modular and scalable 10kW to 80kW High Temperature Boost (HTB) Power Processing Unit (PPU) capable of operating at temperatures beyond the standard military temperature range was proposed for solar electric in-space propulsion. Within the PPU, the Anode Power Supply (APS) module is a 10kW modular power stage and is the key to the HTB PPU. This paper is to present the design, development, fabrication, testing and thermal demonstration of the 10kW HTB APS. The system architecture and the paradigm shift of the HTB PPU is also to be described. In addition, the extreme environments electronic and packaging technologies are addressed as the fundamental technology path. The HTB PPU is intended for power processing in the area of space solar electric propulsion, where reduction of in-space mass and volume are desired, and sometimes even critical, to achieve the goals of future space flight missions. The concept of the HTB PPU can also be applied to other extreme environment applications, such as geothermal and petroleum deep-well drilling, where higher temperature operation is required.

Carr, Gregory A.↗