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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

In-Space Modular Assembly: An Approach for Reliable, Affordable, Precision Space Apertures

In-space assembly will revolutionize the creation, upgrade, and evolution of future space systems. In-space assembly represents an alternative deployment strategy that is not constrained by the requirement of using a single launch vehicle and enables a greater freedom of design for the initial emplacement of assets and their evolution over time. In-space assembly enables assets, such as observatories and science platforms, to become persistent, evolving over time like their terrestrial counterparts. Also, in-space assembly provides a direct path for utilization of in-space manufactured components designed exclusively for the operational environment. To highlight the advantages of an in-space assembly approach, the modular assembly of a 3 m to 4 m precision optical aperture based on thin meniscus technology coupled with structurally efficient TriTruss modules is presented. The 3 m to 4 m aperture stows compactly within two standard ride share slots (0.61 m by 0.71 m by 0.97 m). Placing instruments and the robotic system used for assembly in an adjacent ride share slot enables a capable observatory to be placed into service via modest ride share opportunities. Further, recent hardware assembly tests of similar modules and progress toward hardware tests to validate the overall architecture via diffraction limited testing will be summarized.

Design↗
DOE OSTI2016

Broadly Applicable Dose Model for Radiotherapy Beams from 6-25 MV

The goal of modern external beam radiotherapy is to deliver a highly targeted radiation dose to a specified treatment volume while sparing the healthy surrounding tissue as much as possible. However, some healthy tissue radiation exposure is unavoidable. Healthy tissue in the margin of the treatment field will receive absorbed doses on the order of the prescribed dose, and tissue far out of field will receive stray dose from scattered and leakage radiation. These doses can lead to late effects such as secondary cancers both near the treatment field and far out of field in tissues only receiving stray radiation dose. Many researchers have investigated algorithms to model absorbed dose from external beam photon radiation therapy; however, none of these works have fully addressed the stray dose far from the treatment field. The AAPM Task Group Report No. 36 described three main sources of stray radiation from external beam radiation therapy delivered with electron linear accelerators. Radiation scattered from the treatment head, known as head scatter, is primarily important within about 10 cm from the field edge. Patient scatter is an important source up to around 30 cm from the field edge. Finally, leakage radiation emanates from the treatment enclosure and predominates the stray radiation dose beyond about 30 cm. Monte Carlo simulations have been a useful research tool for modeling stray dose, but these methods have not found use in clinical settings due to their complexity and long computational times. The feasibility of analytical models to predict stray dose from radiation therapy has been supported by several works, but few attempts have been made at developing models accurate for both in-field and out-of-field doses. Jagetic and Newhauser reported on one such model that predicts absorbed dose from therapeutic, scatter, and leakage radiation with promising results. This model was validated at 6 MV for Conformal Radiation Therapy (CRT) beams from an Elekta linac. Intensity Modulated Radiation Therapy (IMRT) was not considered, and the model has not been tested at beam energies greater than 6 MV. Additionally, this model relies on proprietary, machine specific parameters, and so adapting the model for use on treatment units from other manufacturers is not straightforward. In this study we aim to test whether a physics-based analytical modeling approach is broadly applicable and if sufficient accuracy can be achieved without the need for proprietary, machine specific parameters. In order to accomplish this, a new analytical model was developed that does not rely on machine specific parameters, so that it can easily be trained on measurements from whatever treatment machine is available at a given clinic. This model was tested using measured data from a variety of treatment machines and techniques in the 6 MV to 25 MV energy interval. (authors)

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2024

Large area projection micro stereolithography

A large area projection micro stereolithography (LAPuSL) system uses an addressable spatial light modulator (SLM) in coordination with an optical scanning system to make very large stereolithographically produced objects. The SLM is imaged onto a photosensitive material with an optical system that has the ability to scan the image over a large area and speedily manufacture large scale complex three dimensional components with micro scale features.

Moran, Bryan D.↗
NASA NTRS2000

Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗
DOE OSTI2021

Proton switching molecular magnetoelectricity

Abstract The convergence of proton conduction and multiferroics is generating a compelling opportunity to achieve strong magnetoelectric coupling and magneto-ionics, offering a versatile platform to realize molecular magnetoelectrics. Here we describe machine learning coupled with additive manufacturing to accelerate the design strategy for hydrogen-bonded multiferroic macromolecules accompanied by strong proton dependence of magnetic properties. The proton switching magnetoelectricity occurs in three-dimensional molecular heterogeneous solids. It consists of a molecular magnet network as proton reservoir to modulate ferroelectric polarization, while molecular ferroelectrics charging proton transfer to reversibly manipulate magnetism. The magnetoelectric coupling induces a reversible 29% magnetization control at ferroelectric phase transition with a broad thermal hysteresis width of 160 K (192 K to 352 K), while a room-temperature reversible magnetic modulation is realized at a low electric field stimulus of 1 kV cm −1 . The findings of electrostatic proton transfer provide a pathway of proton mediated magnetization control in hierarchical molecular multiferroics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗
NASA NTRS1995

T/BEST: Technology Benefit Estimator Select Features and Applications

A Technology Benefit Estimator (T/BEST) system has been developed to provide a formal method to assess advanced aerospace technologies and quantify the benefit contributions for prioritization. An open-ended, modular approach is used to allow for upgrade and insertion of advanced technology modules. T/BEST's software framework, beginner-to-expert operation, interface architecture, and key analysis modules are discussed. In this paper, selected features and applications of T/BEST are demonstrated. Sample cases pertaining to structural analysis of titanium and composite blades are presented. The performance of hot and cold composite fan blades is also discussed. The cost required to manufacture titanium and composite fan blades is estimated.

Generazio, Edward R.↗
NASA NTRS2002

Submillimeter Laboratory Investigations: Spectroscopy and Collisions

Currently, millimeter-wave and submillimeter-wave spectroscopy is conducted in our laboratory on several different types of spectrometers. Our standard spectrometer utilizes the output of a phase-locked klystron operating in the 40-60 GHz region, which is sent into a crossed-waveguide harmonic generator, or "multiplier". The high frequency millimeter-and submillimeter-wave radiation is transmitted via quasi-optical techniques through an absorption cell and then onto a detector, which is either an InSb hot electron bolometer cooled to 1.4 K or a Si bolometer cooled to 0.3 K. The detector response is sent to a computer for measurement and analysis. The frequency range produced and detected in this manner goes from 80 GHz to upwards of 1 THz. Spectra are normally taken with source modulation, with line frequencies typically measured to an accuracy of 50-100 kHz. Higher accuracy is available when needed. Recently, we developed a new, broad-band spectrometer in our laboratory based on a free-running backward wave oscillator (BWO) of Russian manufacture as the primary source of radiation. The so-called FASSST (fast-scan submillimeter spectroscopic technique) system uses fast-scan and optical calibration methods rather than the traditional locking techniques. The output power from the BWO is split such that 90% goes into the absorption cell while 10% is coupled to a 40-meter Fabry-Perot cavity, which yields fringe? for frequency measurement. Results from this spectrometer on the spectrum of nitric acid (HNO3) show that 100 GHz of spectral data can be obtained in 5 seconds with a measurement accuracy of 50 kHz. Currently, the frequency range of the FASSST system in our laboratory is roughly 100-700 GHz.

Herbst, Eric↗
NASA NTRSDate not supplied

Design and Analysis of Battery Thermal Management Systems

Thermal management of battery cell packs is a critically needed technology. The purpose of this work is to design new and improved Battery Thermal Management Systems (BTMS) for use in electric airplanes. The BTMS should be 3D printable and hold twelve to sixteen 18650 batteries. To minimize aircraft’s weight, an actively air-cooled battery pack was chosen to avoid the excess weight of water-cooled and phase change material (PCM) cooled packs. As a result, significant changes were made to remove all metal in the pack and replace it with lower density polymer matrix composites (PMCs) which can be additively manufactured. Two air cooled battery pack configurations (traditional propeller fans & bladeless fans) were designed, modeled, and compared. These packs were first modeled in SolidWorks 2021 3D CAD, then imported into COMSOL MultiPhysics to be studied using the “Heat Transfer in Solids and Fluids” module. The design with the bladeless fans eliminated the need to use high conductivity heavy metal to remove unwanted thermal energy. These bladeless fans were designed entirely out of PMCs. This thermal pack design weighs 0.04 kg less than that of the traditional propeller fans design and has increased the battery pack energy density by 8.25 Wh/kg.

Thermal Management System for Battery Packs↗
NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗
NASA NTRS1986

Pulse Code Modulation (PCM) encoder handbook for Aydin Vector MMP-600 series system

The hardware and software characteristics of a time division multiplex system are described. The system is used to sample analog and digital data. The data is merged with synchronization information to produce a serial pulse coded modulation (PCM) bit stream. Information presented herein is required by users to design compatible interfaces and assure effective utilization of this encoder system. GSFC/Wallops Flight Facility has flown approximately 50 of these systems through 1984 on sounding rockets with no inflight failures. Aydin Vector manufactures all of the components for these systems.

Currier, S. F.↗
DOE OSTI2023

System and method for simulation-assisted additive manufacturing involving estimating anisotropic deformation

A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.

Kim, Seokpum↗
DOE OSTI2017

RatCAP Time to Digital Converter and Signal Processing module (TSPM)

The TSPM receives and processes ASIC signals and transmits processed data over to the PC using an Ethernet cable. The data is given a location and a time stamp. This is the heart of the device as it gathers and stamps the timing and location of events on each of the ASICs. The five files for the TSPM are needed to manufacture Pet scanners that are based on the RatCAP (Rat Conscious Animal PET). They include a TSPM schematic, a raw data file to build the RatCAP TSPM, an output file that along with the assay file is used by an assembly house to build the RatCAP TSPM, an assay file that provides the part list and XY location for the components that go on the RatCAP TSPM, firmware that includes the source code to program the FPGA, and a realized program on the TSPM based on the firmware.

Fried, Jack↗
NASA NTRSDate not supplied

In-Situ Surface Construction of Infrastructure

In situ resources offer an opportunity to reduce the amount of items brought from Earth when exploring moons and planets. Utilizing those resources requires energy that comes with a cost. In the case of human missions to Mars, trading surface power for launch mass is beneficial for propellant and consumables required to sustain human pioneering and settlement on the planet’s surface. However, In Situ Resource Utilization (ISRU) can mean far more than propellant production and consumables replacement for missions beyond Low Earth Orbit. NASA’s Systems Capability Leader-ship Team (SCLT) for ISRU created a work break-down structure based on functions identified in roadmaps pertaining to human exploration. That WBS includes Prospecting, Extraction, Processing, Construction, Manufacturing, and Energy. Over the years, NASA has developed some capabilities and technologies for prospecting, extraction, and processing carbon dioxide and water on Mars into propellants and life support consumables. However, that is a small subset of the ISRU needs that are coming to light with NASA’s push to return to the Moon for extended periods of time. For instance, astronauts require shielding from Ga-lactic Cosmic Rays and nuclear radiation and protection from the low temperatures and pressures in Space. Surface assets including crew, landers, and ascent modules can be damaged by surface ejecta during landing and launch operations on the Moon and Mars. Creating shielding, berms, and pads requires movement of large volumes and stabilization of regolith in the context of a civil engineering construction project. Because of the multi-disciplinary nature of the aerospace systems needed for human exploration, SCLT on ISRU created an ISRU Construction Integrated Steering Group that combines expertise among several NASA Principal Technologists and Capabilities Leaders for exploring options, assessing opportunities, and developing requirements for construction and manufacturing on the Moon and Mars NASA’s new program to develop Lunar landers for small, mid, and large payload deliveries to the Lunar surface leading to human missions by 2025 spawned an investigation into plume surface interactions caused by the lander during descent and ascent. The trade space to resolve this issue includes regolith stabilization via landing pad construction techniques and lander nozzles characteristics due to vehicle systems design. Some data exists from the Apollo missions but more is required for the missions ahead. The purpose of this paper [1] is to outline an approach for developing requirements that can guide systems designs while taking advantage of flight opportunities in NASA’s plans to return to the Moon.

In-Situ↗
NASA NTRS2016

Space to Space Advanced EMU Radio

The main task for this project was the development of a prototype for the Space to Space Advanced EMU Radio (SSAER). The SSAER is an updated version of the Space to Space EMU Radio (SSER), which is the current radio used by EMUs (Extravehicular Mobility Unit) for communication between suits and with the ISS. The SSER was developed in 1999, and it was desired to update the design used in the system. Importantly, besides replacing out-of-production parts it was necessary to decrease the size of the radio due to increased volume constraints with the updated Portable Life Support System (PLSS) 2.5, which will be attached on future space suits. In particular, it was desired to fabricate a PCB for the front-end of the prototype SSAER system. Once this board was manufactured and all parts assembled, it could then be tested for quality of operation as well as compliancy with the SSER required specifications. Upon arrival, a small outline of the target system was provided, and it was my responsibility to take that outline to a finished, testable board. This board would include several stages, including frequency mixing, amplification, modulation, demodulation, and handled both the transmit and receive lines of the radio. I developed a new design based on the old SSER system and the outline provided to me, and found parts to fit the tasks in my design. It was also important to consider the specifications of the SSER, which included the system noise figure, gain, and power consumption. Further, all parts needed to be impedance matched, and spurious signals needed to be avoided. In order to fulfill these two requirements, it was necessary to perform some calculations using a Smith Chart and excel analysis. Once all parts were selected, I drew the schematics for the system in Altium Designer. This included developing schematic symbols, as well as layout. Once the schematic was finished, it was then necessary to lay the parts out onto a PCB using Altium. Similar to the schematic design, in order to accomplish this it was necessary to develop component land patterns and add component 3D models. All of this was achieved, and the PCB is currently in review. After it is finished being reviewed, this board will be sent out for manufacture. All electronic components used in the PCB have been acquired, and once the board arrives they will be soldered onto the board using a machine in building 44. Finally, the board will be tested for performance on-site. This will likely be accomplished by the end of the internship.

Maicke, Andrew↗
NASA NTRSDate not supplied

Development of Acoustic Mufflers for Cabin Noise Reduction in Orion Spacecraft

Controlling cabin acoustic noise levels in the Crew Module (CM) of the Orion spacecraft is critical to ensure adequate speech intelligibility, to avoid fatigue, and prevent any possibility of temporary and permanent hearing loss to the crew. The primary source of cabin noise for the on-orbit phase of the mission is from the Environmental Control and Life Support System (ECLSS) which recycles and conditions breathing air and maintains cabin pressurization through its duct network and components. Unfortunately, as a side effect, noise from the ECLSS fans propagates through theses ducts and emanate into the cabin habitable volume via the ECLSS inlet and outlets. To mitigate excessive duct-borne noise, two ECLSS mufflers have been designed to provide significant acoustic transmission loss (TL) so that the cabin noise requirements can be met. Each muffler is meant to be installed in the ducting of the ECLSS air inlet and outlet sides, respectively. Packaging constraints and tight volume requirements necessitated the mufflers to be of complex geometry and compatible with the bends of the ECLSS duct layout. To design and characterize the acoustic performance of the inlet and outlet mufflers, computational acoustic models were developed using the Finite Element Method (FEM) with 𝑤𝑎𝑣𝑒଺ vibroacoustic software. Characterization of the acoustic material and perforations in the mufflers were addressed with poroelastic theory. Once the mufflers were designed on paper and its TL predicted, prototypes of these mufflers were created using additive manufacturing. The muffler prototypes were subsequently tested for acoustic TL in the laboratory with various con-figurations of acoustic materials. Comparing the analytical predictions to the test performance yielded excellent correlation for acoustic TL and demonstrated significant broadband noise attenuation. The ECLSS mufflers are currently scheduled to be installed on the Artemis II Crew Module (CM) of the Orion spacecraft and will provide significant cabin comfort to crew during the mission.

Indranil Dandaroy↗
DOE OSTI2016

SU-F-T-171: Manufacturing Cost Effective Heterogeneous Phantoms for Use in Proton Therapy

Purpose: To study the feasibility of 3D printing cost effective heterogeneous phantoms for use in proton therapy treatment planning quality assurance. Methods: A desktop 3D printer was utilized to create a series of 2 cm × 2 cm × 4 cm PLA plastic blocks of varying fill materials and hexagonal fill pattern. The blocks were than tested when filled with air, polyurethane foam, paraffin, silicone, and caulk of calcium carbonate – acrylic polymer blend. The blocks were evaluated with a “GE Lightspeed” 16 slice CT scanner and average CT# of the materials’ centers evaluated. Blocks were then placed into a custom aperture fitted to a Mevion Proton system to determine the relative stopping power of each. Scans were performed in water tank with Marcus type parallel plate chamber under a beam with a range of 15 cm and modulation of 2 cm. Shifts in range occurring relative to the 80% distal edge of the open SOBP were evaluated. Results: The CT#s of the blocks were plotted against their measured relative stopping power. This curve was compared to that which is in clinical use. While the trend agrees generally, specific differences between the relative stopping powers were as great as 10%. Conclusion: We have demonstrated that it is possible to utilize different cost effective materials in the manufacturing of phantoms for use in proton therapy. While different materials may provide better agreement to established calibration curves, a custom curve specific to the materials used may be utilized to accurately predict proton treatment dose distributions.

60 APPLIED LIFE SCIENCES↗