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NASA NTRS2014

Additive Manufacturing and 3D Printing in NASA: An Overview of Current Projects and Future Initiatives for Space Exploration

NASA, including each Mission Directorate, is investing in, experimenting with, and/or utilizing AM across a broad spectrum of applications and projects; Centers have created and are continuing to create partnerships with industry, other Government Agencies, other Centers, and Universities; In-house additive manufacturing capability enables rapid iteration of the entire design, development and testing process, increasing innovation and reducing risk and cost to projects; For deep space exploration, AM offers significant reduction to logistics costs and risk by providing ability to create on demand; There are challenges: Overwhelming message from recent JANNAF AM for Propulsion Applications TIM was "certification."; NASA will continue to work with our partners to address this and other challenges to advance the state of the art in AM and incorporate these capabilities into an array of applications from aerospace to science missions to deep space exploration.

Clinton, R. G., Jr.↗

NASA NTRS2019

Optimal Control within the Context of Multidisciplinary Design, Analysis, and Optimization

Multidisciplinary design, analysis and optimization involves modeling the interactions of complex systems across a variety of disciplines. The optimization of such systems can be a computationally expensive exercise with multiple levels of nested nonlinear solvers running under an optimizer.The application of optimal control in project development often involves performing trajectory optimization for fixed vehicle designs or parametric sweeps across some key vehicle properties.This information is then relayed to the subsystem design teams who update their designs and relay some bulk characteristics back to the trajectory optimization procedure.This iteration is then repeated until the design closes.However, with increasing interest in more tightly coupled systems, such as electric and hybrid-electric aircraft propulsion and boundary layer ingestion, this process is prone to ignore subtle coupling between vehicle subsystem designs and vehicle operation on a given mission.Integrating trajectory optimization into a tightly coupled multidisciplinary design procedure can be computationally prohibitive, depending on the complexity of the subsystem analyses and the optimal control technique applied.To address these issues a new optimal control software tool, Dymos, has been developed.Dymos is built upon NASA's OpenMDAO software and can leverage its capabilities to efficiently compute gradients for the optimization and optimize complex models in parallel on distributed memory systems.This report provides some explanation into the numerical methods employed in Dymos and provides several use cases that demonstrate its performance on traditional optimal control problems and improvements ino techniques have been used extensively in recent decades to solve a variety of optimal control problems, typically in the form of aerospace vehicle trajectory optimization.

pseudospectral↗

NASA NTRS2017

Mars 2020 Sampling and Caching Subsystem Environmental Development Testing and Preliminary Results

The Environmental Development Testing program supported the development test efforts of the Mars 2020 Sampling and Caching Subsystem from May to November 2015. The engineering prototype Brassboard Corer was attached to a five degree-of-freedom robotic arm to execute a 96-test matrix of ambient and low pressure tests in the 10 ft. thermal vacuum chamber at the NASA Jet Propulsion Laboratory, California Institute of Technology. The Pretest, Test, and Post Test procedures are described, and some preliminary results are discussed. Data and observations from this test campaign inform the future development of the software and hardware toward the Mars 2020 flight design, including the next iteration of the rock coring drill, the Engineering Development Unit Corer.

Kriechbaum, Kristo↗

NASA NTRS2017

Design and Development of the Heat Redistribution System for the Mission to Europa Spacecraft:

This paper details the conceptual design of the Heat Redistribution System (HRS) used for thermal control of the Europa Clipper spacecraft. The solar powered spacecraft will launch in the early 2020s and will study Jupiter’s Icy moon, Europa, where previous investigations have indicated the possibility of a liquid water ocean underneath its ice-encrusted surface. The spacecraft will execute multiple flybys of Europa while relying on the HRS for thermal control of the spacecraft bus. The HRS utilizes a Mechanically Pumped Fluid Loop (MPFL) to reclaim waste heat from an avionics and payload electronics compartment and redistribute it to other parts of the spacecraft, such as the propulsion module structure and the louver-radiator assembly. A “replacement heater block” provides supplemental heat when needed to maintain the spacecraft hardware above its allowable flight temperatures. Additionally, a set of thermal control valves autonomously actuate to reduce the fluid flow through the radiator during cold environment cases. The HRS was used in previous flight projects at JPL such as Mars Science Laboratory, but the uniqueness of the Europa Clipper mission has mandated changes to previous HRS designs; the most significant design drivers and design changes for this iteration of the HRS are discussed.

Bertagne, Christopher↗

NASA NTRSDate not supplied

Human-in-the-Loop Evaluations: Process and Mockup Fidelity

Human-in-the-loop (HITL) evaluations are iterative events used during design and development to identify issues with the implementation of human systems integration. HITL evaluations involve human test subjects who are user-representative participants performing activities with representative hardware, software, and procedures. The paper will describe the process by which HITL evaluations can be implemented in a program or project. This will include definitions for developmental and verification HITL evaluations, levels of mockup fidelity, and certification of HITL articles. The proposed process can be tailored depending on the type of HITL evaluation being conducted. It is highly recommended that findings are timely reported and incorporated in the hardware and/or software design.

Jackelynne Silva-Martinez↗

NASA NTRSDate not supplied

Operational Workflow in a Sample Receiving Facility: Input from the MSR Operation Definition Team

The return of scientifically selected samples from Mars would provide a rare opportunity for investigation with the full range of the latest technology available. To take full advantage of this opportunity, it is important to plan ahead to ensure the pristine nature of the samples upon arrival within the Earth environment until scientific investigations can begin. The NASA/ESA science community-driven MSR Science Planning Group – Phase 2 (MSPG2) delivered recommendations and guidance regarding curation (1) and science (2,3) activities to be performed on the samples under containment. High-level requirements for the infrastructure were also developed by MSPG2 (4). In order to prepare infrastructure-targeted input for the ESA and NASA facility studies planned in the 2022-2023 timeframe, the MSR agency-led Operational Scenarios Definition Team (MOSDT) was assembled to conceptualize the sample operations that will inform future architecture teams. Emphasis was placed on the responsibility of MOSDT to use community-defined requirements and to represent the view of the international scientific community. The main deliverable of MOSDT was an operational workflow for a Sample Receiving Facility (SRF). Two other deliverables were produced: a report to narrate the workflow, and a list of instruments (see Hutzler et al., this conference). Activities described in the main sequence of the workflow range from engineering operations to curation to science, with the latter term being used here as the science to be done within a SRF. Side sequences (e.g. engineering inspection of hardware, head gas extraction) were also identified, and detailed when they would have a significant impact on the infrastructure of a SRF. It was necessary for the MOSDT to rely on assumptions for some steps and activities, and though these were kept to a minimum (and are described in both the report supporting the workflow and in the full presentation), in general, the assumptions and overall work were very conservative, as the impact of underestimating the scope of the SRF infrastructure was considered more detrimental than overestimating it. It is expected that future work will be able to confirm or inform these assumptions. The community was consulted during the course of the MOSDT work. This abstract’s aim is two-fold: on one hand, inform the scientific community and overall MSR stakeholders, to make the infrastructure studies and trade-off more understandable; on the other hand, to solicit feedback from a larger community audience for the next iterations planning for SRF design and activities.

Mars Sample Return↗

NASA NTRSDate not supplied

Computational Fluid Dynamics Simulation of A Hazardous Gas Purge System in an EUS Aft Adapter Umbilical Plate Concept

The Fluid Dynamics Branch at the NASA Marshall Space Flight Center actively supports flight programs through a variety of in-line analyses. One area of expertise is the mitigation of hazardous gas mixtures that may form during nominal vehicle fueling operation. After the successful Artemis I launch, design cycles for future iterations of the vehicle are in progress. The subject of this work concerns the analysis of a hazardous gas mitigation system concept for a future upper stage.

Riley D Bridges↗

NASA NTRSDate not supplied

Computational Fluid Dynamics Simulation of A Hazardous Gas Purge System in an EUS Aft Adapter Umbilical Plate Concept

Riley Bridges↗

DOE OSTI2020

Data Collection and Analysis Challenges and Mitigation Strategies for Quantitative Human Factors Research Studies in Nuclear Power Plant Modernization

The United States (U.S.) Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) program Plant Modernization Pathway is conducting targeted research and development (R&D) to address aging and reliability concerns with the legacy instrumentation and control and related information systems of the U.S. LWR fleet. In this effort, the application of human factors engineering (HFE) provides an important role in ensuring new digital plant technologies enable broad innovation and business improvement with continued operational safety. Evaluation is a key activity in HFE, which often occurs iteratively through the system design lifecycle. While qualitative methods are important in collecting information of how users perform tasks through observations, quantitative methods are equally important in assessing system design based on performance. In collecting and analyzing this quantitative data, there are notable challenges in the nuclear HFE domain that may threaten the validity and reliability of the inferences made in these studies. Notable challenges include small sample size and limited resources, large error variance and small effect size, an “adding test features to losing degrees of freedom” dilemma, non-normal distribution, and heterogeneity of variance. The results in control room usability studies are often statistically non-significant, which makes it hard to interpret. This work discusses these challenges across different scientific viewpoints and provides real-world examples of these challenges in practice. Collectively, the objective of this work is to position these challenges to the larger data science community as a means of identifying future opportunities to address these issues.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2009

Human Factors Interface with Systems Engineering for NASA Human Spaceflights

This paper summarizes the past and present successes of the Habitability and Human Factors Branch (HHFB) at NASA Johnson Space Center s Space Life Sciences Directorate (SLSD) in including the Human-As-A-System (HAAS) model in many NASA programs and what steps to be taken to integrate the Human-Centered Design Philosophy (HCDP) into NASA s Systems Engineering (SE) process. The HAAS model stresses systems are ultimately designed for the humans; the humans should therefore be considered as a system within the systems. Therefore, the model places strong emphasis on human factors engineering. Since 1987, the HHFB has been engaging with many major NASA programs with much success. The HHFB helped create the NASA Standard 3000 (a human factors engineering practice guide) and the Human Systems Integration Requirements document. These efforts resulted in the HAAS model being included in many NASA programs. As an example, the HAAS model has been successfully introduced into the programmatic and systems engineering structures of the International Space Station Program (ISSP). Success in the ISSP caused other NASA programs to recognize the importance of the HAAS concept. Also due to this success, the HHFB helped update NASA s Systems Engineering Handbook in December 2007 to include HAAS as a recommended practice. Nonetheless, the HAAS model has yet to become an integral part of the NASA SE process. Besides continuing in integrating HAAS into current and future NASA programs, the HHFB will investigate incorporating the Human-Centered Design Philosophy (HCDP) into the NASA SE Handbook. The HCDP goes further than the HAAS model by emphasizing a holistic and iterative human-centered systems design concept.

Wong, Douglas T.↗

NASA NTRS2010

Altair Descent and Ascent Reference Trajectory Design and Initial Dispersion Analyses

The Altair Lunar Lander is the linchpin in the Constellation Program (CxP) for human return to the Moon. Altair is delivered to low Earth orbit (LEO) by the Ares V heavy lift launch vehicle, and after subsequent docking with Orion in LEO, the Altair/Orion stack is delivered through translunar injection (TLI). The Altair/Orion stack separating from the Earth departure stage (EDS) shortly after TLI and continues the flight to the Moon as a single stack. Altair performs the lunar orbit insertion (LOI) maneuver, targeting a 100-km circular orbit. This orbit will be a polar orbit for missions landing near the lunar South Pole. After spending nearly 24 hours in low lunar orbit (LLO), the lander undocks from Orion and performs a series of small maneuvers to set up for descending to the lunar surface. This descent begins with a small deorbit insertion (DOI) maneuver, putting the lander on an orbit that has a perilune of 15.24 km (50,000 ft), the altitude where the actual powered descent initiation (PDI) commences. At liftoff from Earth, Altair has a mass of 45 metric tons (mt). However after LOI (without Orion attached), the lander mass is slightly less than 33 mt at PDI. The lander currently has a single descent module main engine, with TBD lb(sub f) thrust (TBD N), providing a thrust-to-weight ratio of approximately TBD Earth g's at PDI. LDAC-3 (Lander design and analysis cycle #3) is the most recently closed design sizing and mass properties iteration. Upgrades for loss of crew (LDAC-2) and loss of mission (LDAC-3) have been incorporated into the lander baseline design (and its Master Equipment List). Also, recently, Altair has been working requirements analyses (LRAC-1). All nominal data here are from the LDAC-3 analysis cycle. All dispersions results here are from LRAC-1 analyses.

Kos, Larry D.↗

DOE OSTI2021

Integrated model predictions on the impact of substrate damage on gas dynamics during ITER burning-plasma operations

Divertor design and choice of plasma-facing materials (PFM) will be essential to the success of next-generation fusion reactors as they operate under more powerful scenarios. Understanding and controlling interactions between the plasma and PFM is essential to making these choices. Within these plasma–material interactions and especially in tungsten (W), the interplay between the most abundant plasma species (hydrogen isotopes and helium, He) with the wall material alters fuel retention. However, this interplay is yet to be sufficiently understood to confidently project fuel retention levels to future fusion devices. The paper presents a series of integrated simulations of fusion plasmas and their interaction with tungsten. Specifically, this study assesses the impact of He plasma pre-exposure on hydrogenic species retention during 100 s of burning plasma operations (BPO) in ITER. Multiple pre-exposure scenarios are considered, including sub-surface damage resulting from exposures in the linear device PISCES and from early ITER He-operation. The predictions from these consecutive He-BPO exposures show that fuel content and spatial distribution in the material are largely determined by the He-induced damage, as manifest in: (i) changes in surface temperature expected during BPO have little effect on fuel retention in the presence of He-induced damage; (ii) gas content stabilizes quickly in substrates pre-exposed in PISCES, at levels set by the concentration of pre-existing vacancies, while it continues to increase in substrates initially pristine or pre-exposed to ITER He plasmas; (iii) the presence of He and He–V clusters in the near-surface region locally increases hydrogenic retention, but decreases its permeation; this results in hydrogenic species that remain closer to the surface in pre-damaged substrates, while the bulk content is higher for initially pristine cases. In summary, the interaction and binding of D and T with the pre-existing He–V clusters modifies retention and permeation of hydrogen species during ITER BPO.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2013

Hidden Connections between Regression Models of Strain-Gage Balance Calibration Data

Hidden connections between regression models of wind tunnel strain-gage balance calibration data are investigated. These connections become visible whenever balance calibration data is supplied in its design format and both the Iterative and Non-Iterative Method are used to process the data. First, it is shown how the regression coefficients of the fitted balance loads of a force balance can be approximated by using the corresponding regression coefficients of the fitted strain-gage outputs. Then, data from the manual calibration of the Ames MK40 six-component force balance is chosen to illustrate how estimates of the regression coefficients of the fitted balance loads can be obtained from the regression coefficients of the fitted strain-gage outputs. The study illustrates that load predictions obtained by applying the Iterative or the Non-Iterative Method originate from two related regression solutions of the balance calibration data as long as balance loads are given in the design format of the balance, gage outputs behave highly linear, strict statistical quality metrics are used to assess regression models of the data, and regression model term combinations of the fitted loads and gage outputs can be obtained by a simple variable exchange.

Ulbrich, Norbert↗

NASA NTRS1996

Methodology for Sensitivity Analysis, Approximate Analysis, and Design Optimization in CFD for Multidisciplinary Applications

An incremental iterative formulation together with the well-known spatially split approximate-factorization algorithm, is presented for solving the large, sparse systems of linear equations that are associated with aerodynamic sensitivity analysis. This formulation is also known as the 'delta' or 'correction' form. For the smaller two dimensional problems, a direct method can be applied to solve these linear equations in either the standard or the incremental form, in which case the two are equivalent. However, iterative methods are needed for larger two-dimensional and three dimensional applications because direct methods require more computer memory than is currently available. Iterative methods for solving these equations in the standard form are generally unsatisfactory due to an ill-conditioned coefficient matrix; this problem is overcome when these equations are cast in the incremental form. The methodology is successfully implemented and tested using an upwind cell-centered finite-volume formulation applied in two dimensions to the thin-layer Navier-Stokes equations for external flow over an airfoil. In three dimensions this methodology is demonstrated with a marching-solution algorithm for the Euler equations to calculate supersonic flow over the High-Speed Civil Transport configuration (HSCT 24E). The sensitivity derivatives obtained with the incremental iterative method from a marching Euler code are used in a design-improvement study of the HSCT configuration that involves thickness. camber, and planform design variables.

Taylor, Arthur C., III↗

DOE OSTI2020

Characterization of Transition Edge Sensors for the Simons Observatory

The Simons Observatory is building both large (6 m) and small (0.5 m) aperture telescopes in the Atacama Desert in Chile to observe the cosmic microwave background CMB radiation with unprecedented sensitivity. Simons Observatory telescopes in total will use over 60,000 transition edge sensor (TES) detectors spanning center frequencies between 27 and 285 GHz and operating near 100 mK. TES devices have been fabricated for the Simons Observatory by NIST, Berkeley, and HYPRES/SeeQC corporation. Iterations of these devices have been tested cryogenically in order to inform the fabrication of further devices, which will culminate in the final TES designs to be deployed in the field. The detailed design specifications have been independently iterated at each fabrication facility for particular detector frequencies. We present test results for prototype devices, with emphasis on NIST high frequency detectors. A dilution refrigerator was used to achieve the required temperatures. Measurements were taken both with 4-lead resistance measurements and with a time-domain Superconducting Quantum Interference Device (SQUID) multiplexer system. The SQUID readout measurements include analysis of current versus voltage (IV) curves at various temperatures, square wave bias step measurements, and detector noise measurements. Lastly, normal resistance, superconducting critical temperature, saturation power, thermal and natural time constants, and thermal properties of the devices are extracted from these measurements.

47 OTHER INSTRUMENTATION↗

NASA NTRS1993

An application of the IMC software to controller design for the JPL LSCL Experiment Facility

A software package which Integrates Model reduction and Controller design (The IMC software) is applied to design controllers for the JPL Large Spacecraft Control Laboratory Experiment Facility. Modal Cost Analysis is used for the model reduction, and various Output Covariance Constraints are guaranteed by the controller design. The main motivation is to find the controller with the 'best' performance with respect to output variances. Indeed it is shown that by iterating on the reduced order design model, the controller designed does have better performance than that obtained with the first model reduction.

Zhu, Guoming↗

NASA NTRS2005

Two-Photon Fluorescence Microscope for Microgravity Research

A two-photon fluorescence microscope has been developed for the study of biophysical phenomena. Two-photon microscopy is a novel form of laser-based scanning microscopy that enables three-dimensional imaging without many of the problems inherent in confocal microscopy. Unlike one-photon optical microscopy, two-photon microscopy utilizes the simultaneous nonlinear absorption of two near-infrared photons. However, the efficiency of two-photon absorption is much lower than that of one-photon absorption, so an ultra-fast pulsed laser source is typically employed. On the other hand, the critical energy threshold for two-photon absorption leads to fluorophore excitation that is intrinsically localized to the focal volume. Consequently, two-photon microscopy enables optical sectioning and confocal performance without the need for a signal-limiting pinhole. In addition, there is a reduction (relative to one-photon optical microscopy) in photon-induced damage because of the longer excitation wavelength. This reduction is especially advantageous for in vivo studies. Relative to confocal microscopy, there is also a reduction in background fluorescence, and, because of a reduction in Rayleigh scattering, there is a 4 increase of penetration depth. The prohibitive cost of a commercial two-photon fluorescence-microscope system, as well as a need for modularity, has led to the construction of a custom-built system (see Figure 1). This system includes a coherent mode-locked titanium: sapphire laser emitting 120-fs-duration pulses at a repetition rate of 80 MHz. The pulsed laser has an average output power of 800 mW and a wavelength tuning range of 700 to 980 nm, enabling the excitation of a variety of targeted fluorophores. The output from the laser is attenuated, spatially filtered, and then directed into a confocal scanning head that has been modified to provide for side entry of the laser beam. The laser output coupler has been replaced with a dichroic filter that reflects the longer-wavelength excitation light and passes the shorter-wavelength fluorescence light. Also, the confocal pinhole has been removed to increase the signal strength. The laser beam is scanned by a twoperpendicular- axis pair of galvanometer mirrors through a pupil transfer lens into the side port of an inverted microscope. Finally, the beam is focused by a 63-magnification, 1.3-numerical- aperture oil-immersion objective lens onto a specimen. The pupil transfer lens serves to match the intermediate image planes of the scanning head and the microscope, and its location is critical. In order to maximize the quality of the image, (that is, the point spread function of the objective lens for all scan positions), the entire system was modeled in optical-design software, and the various free design parameters (the parameters of the spatial-filter components as well as the separations of all of the system components) were determined through an iterative optimization process. A modular design was chosen to facilitate access to the optical train for future fluorescence correlation spectroscopy and fluorescence-lifetime experiments.

Fischer, David G.↗

DOE OSTI2025

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects (Final Technical Report)

The number of commercial coal, gas, and nuclear projects built over the past 100 years number in the thousands. As such, there is a large database, available to a wide range of commercial engineering contractors, on proven designs. In essence, unsuccessful designs have, through generations of iterations, been identified and then deleted from further consideration. In contrast, the number of commercial parabolic trough projects using nitrate salt for the thermal storage media is perhaps 60. Further, the number of commercial central receiver projects using nitrate salt as the working fluid is on the order of 20, including estimates for China. Given the relative immaturity of salt technology, and commercial pressures to successfully bid new solar projects into a mature electricity market, solar projects often promise more than has been delivered. The Design Basis Document / Owner’s Technical Specification is a first step in the iteration process. The report describes the successful features of commercial projects, outlines a range equipment and system failures in projects that didn’t operate as intended, and provides a draft set of design changes intended to correct the known problems. The product of the study is 3 volumes of technical material; one volume is on parabolic trough technologies; a second is on central receiver technologies, and the third is on potential design changes to parabolic trough and central receiver projects. The 3 volumes, which total some 590 pages, can be found at https://www.solardynllc.com/csp-plant-technologies. One of the principal topics in the report is the use of functional or prescriptive specifications. Functional specifications describe what the equipment needs to do, consistent with the minimum legal requirements of the local jurisdictions. The details of how this is to be accomplished is developed by the engineering contractor. Prescriptive specifications, which are developed by the Owner, prescribe to the engineering contractor how the functional requirements are to be met. This arrangement ensures that the favorable experience from a previous project is repeated. One example is the design code for the hot salt tank in central receiver projects. The closest design basis is API Standard 650 Welded Steel Tanks for Oil Storage. However, the maximum design temperature in API 650 is 260 °C. As such, solar projects have typically adopted a hybrid Code approach, in which allowable material stresses are taken from ASME Section II Materials. Further, since the tanks experience daily changes in temperature and in (static) pressure, and since portions of the tank can operate at stresses beyond the elastic range, the low cycle fatigue life of the tank is conducted using the rules of Section VIII Division 2. However, in a recent study by NREL, the principal damage mechanism was identified as creep rather than fatigue. Further, design stresses permitted under Section VIII Division 2, corresponding to a fatigue life of 30 years, result in projected creep lifetimes of only 2 to 5 years. An alternate design approach, prescribed by the Owner, would be based on Code sections intended for high temperature service in the creep regime. A candidate is Section III Division 5. Granted, this is a nuclear code section, and it’s use would not likely be mandated by local jurisdictions. However, the effects of creep have been deemed to be of sufficient importance that one nuclear project developer, and one central receiver project developer, have stipulated in the tank design specification that the equipment be designed to the requirements of Section III Division 5.

14 SOLAR ENERGY↗