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At least 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Adaptive structures - Test hardware and experimental results

The facilities and procedures used at JPL to test adaptive structures such as the large deployable reflector (LDR) are described and preliminary results are reported. The applications of adaptive structures in future NASA missions are outlined, and the techniques which are employed to modify damping, stiffness, and isolation characteristics, as well as geometric changes, are listed. The development of adaptive structures is shown to be effective as a result of new actuators and sensors, and examples are listed for categories such as fiber optics, shape-memory materials, piezoelectrics, and electrorheological fluids. Some ground test results are described for laboratory truss structures and truss test beds, which are shown to be efficient and easy to assemble in space. Adaptive structures are shown to be important for precision space structures such as the LDR, and can alleviate ground test requirements.

Wada, Ben K.↗
NASA NTRS2006

The X-43 Fin Actuation System Problem - Reliability in Shades of Gray

Following the loss of the first X-43 during launch, the mishap investigation board indicated the Fin Actuator System (FAS) needed to have a larger torque margin. To supply this added torque, a second actuator was added. The consequences of what seemed to be a simple modification would trouble the X-43 program. Because of the second actuator, a new computer board was required. This proved to be subject to electronic noise. This resulted in the actuator latch up in ground tests of the FAS for the second launch. Such a latch up would cause the Pegasus booster to fail, as the FAS was a single string system. The problem was corrected and the second flight was successful. The same modifications were added to the FAS for flight three. When the FAS underwent ground tests, it also latched up. The failure indicated that each computer board had a different tolerance to electronic noise. The problem with the FAS was corrected. Subsequently, another failure occurred, raising questions about the design, and the probability of failure for the X-43 Mach 10 flight. This was not simply a technical issue, but illuminated the difficulties facing both managers and engineers in assessing risk, design requirements, and probabilities in cutting edge aerospace projects.

Peebles, Curtis↗
NASA NTRSDate not supplied

Development Status of Powered Descent for High-Mass Mars Entry, Descent, and Landing Systems

Retropropulsion, initiated at supersonic conditions, provides both deceleration and control authority as an enabling capability for the delivery of human-scale payloads to the surface of Mars. There are no other presently viable approaches to the descent phase of flight for vehicles of such scales. NASA continues to dedicate investment in the maturation of powered descent in atmospheric environments, for the express application to large-scale entry, descent, and landing systems. Efforts focus on parametric, subscale, inert gas ground testing, rigorous validation of computational modeling approaches against these data, and the implementation of highly efficient, scalable simulation tools. This paper summarizes the current maturity of retropropulsion in a free-flight, atmospheric environment for vehicles with significant aerodynamic surface area, as well as the current status of efforts within NASA for ground testing, computational simulation, and flight testing.

Mars↗
NASA NTRSDate not supplied

Development Status of Powered Descent for High-Mass Mars Entry, Descent, and Landing Systems

Retropropulsion, initiated at supersonic conditions, provides both deceleration and control authority as an enabling capability for the delivery of human-scale payloads to the surface of Mars. There are no other presently viable approaches to the descent phase of flight for vehicles of such scales. NASA continues to dedicate investment in the maturation of powered descent in atmospheric environments, for the express application to large-scale entry, descent, and landing systems. Efforts focus on parametric, subscale, inert gas ground testing, rigorous validation of computational modeling approaches against these data, and the implementation of highly efficient, scalable simulation tools. This paper summarizes the current maturity of retropropulsion in a free-flight, atmospheric environment for vehicles with significant aerodynamic surface area, as well as the current status of efforts within NASA for ground testing, computational simulation, and flight testing.

Ashley Korzun↗
NASA NTRSDate not supplied

Reconstruction of Thermal Protection System Aeroheating using a Green’s Function Approach

Inverse heat transfer (IHT) techniques are often used to reconstruct the surface heating conditions on spacecraft thermal protection systems (TPS) during atmospheric entry. Current IHT techniques for entry spacecraft applications, however, demand substantial computational resources, and are impractical for analyses such as uncertainty quantification and real-time health monitoring. In this paper, a Green’s function sensor fusion approach is used to reconstruct the TPS surface aeroheating conditions on experimental spaceflight and ground test systems from collocated temperature and heat flux sensors embedded in the TPS. The algorithm leverages Green’s functions to model the heat conduction within the spacecraft TPS and stabilizes the recovery of the surface heating condition using the direct heat flux sensor measurement. The algorithm is validated using arc-jet ground test data and applied to the reconstruction of the Mars 2020 backshell heating during Martian atmospheric entry. The performance of the algorithm is benchmarked against a current state-of-the-art IHT framework, FIAT_Opt. The Green’s function-based reconstruction algorithm recovers the net hot-wall heat flux absorbed by the TPS and the incident heat flux from the atmospheric entry environment in close agreement with FIAT_Opt. Notably, computation of the surface heating condition is completed in three orders of magnitude less time with the Green’s function sensor fusion approach using a consumer-grade PC, versus with FIAT_Opt running on a high performance computer cluster. The efficiency of the algorithm is leveraged to compute the uncertainty contributions of input parameters to the total uncertainty in reconstructed Mars 2020 backshell heating for the full atmospheric entry heat pulse. The sensitivity analysis uncovers that, at different times throughout the entry heat pulse, uncertainties in the TPS specific heat, thermal conductivity, and emissivity are all dominant drivers of the reconstruction uncertainty. These results demonstrate Green’s functions and sensor-fusion techniques as promising IHT approaches to reconstruct atmospheric entry environments from TPS-embedded measurements, and highlight how these techniques may give access to post-flight analyses previously hindered by the prohibitive cost of current methods.

Kenneth McAfee↗
NASA NTRSDate not supplied

Reconstruction of Thermal Protection System Aeroheating using a Green’s Function Approach

Inverse heat transfer (IHT) techniques are often used to reconstruct the surface heating conditions on spacecraft thermal protection systems (TPS) during atmospheric entry. Current IHT techniques for entry spacecraft applications, however, demand substantial computational resources, and are impractical for analyses such as uncertainty quantification and real-time health monitoring. In this paper, a Green’s function sensor fusion approach is used to reconstruct the TPS surface aeroheating conditions on experimental spaceflight and ground test systems from collocated temperature and heat flux sensors embedded in the TPS. The algorithm leverages Green’s functions to model the heat conduction within the spacecraft TPS and stabilizes the recovery of the surface heating condition using the direct heat flux sensor measurement. The algorithm is validated using arc-jet ground test data and applied to the reconstruction of the Mars 2020 backshell heating during Martian atmospheric entry. The performance of the algorithm is benchmarked against a current state-of-the-art IHT framework, FIAT_Opt. The Green’s function-based reconstruction algorithm recovers the net hot-wall heat flux absorbed by the TPS and the incident heat flux from the atmospheric entry environment in close agreement with FIAT_Opt. Notably, computation of the surface heating condition is completed in three orders of magnitude less time with the Green’s function sensor fusion approach using a consumer-grade PC, versus with FIAT_Opt running on a high performance computer cluster. The efficiency of the algorithm is leveraged to compute the uncertainty contributions of input parameters to the total uncertainty in reconstructed Mars 2020 backshell heating for the full atmospheric entry heat pulse. The sensitivity analysis uncovers that, at different times throughout the entry heat pulse, uncertainties in the TPS specific heat, thermal conductivity, and emissivity are all dominant drivers of the reconstruction uncertainty. These results demonstrate Green’s functions and sensor-fusion techniques as promising IHT approaches to reconstruct atmospheric entry environments from TPS-embedded measurements, and highlight how these techniques may give access to post-flight analyses previously hindered by the prohibitive cost of current methods.

Kenneth McAfee↗
NASA NTRS1983

Influence of computational fluid dynamics on experimental aerospace facilities: A fifteen year projection

An assessment was made of the impact of developments in computational fluid dynamics (CFD) on the traditional role of aerospace ground test facilities over the next fifteen years. With improvements in CFD and more powerful scientific computers projected over this period it is expected to have the capability to compute the flow over a complete aircraft at a unit cost three orders of magnitude lower than presently possible. Over the same period improvements in ground test facilities will progress by application of computational techniques including CFD to data acquisition, facility operational efficiency, and simulation of the light envelope; however, no dramatic change in unit cost is expected as greater efficiency will be countered by higher energy and labor costs.

Source record↗
NASA NTRS1992

BIPS Turboalternator-Compressor characteristics and application to the NASA Solar Dynamic Ground Demonstration Program

The NASA-sponsored 2kW(e) Solar Dynamic Space Power System Ground Test Demonstration Program requires the physical and the thermodynamic integration of the Brayton Isotope Power System (BIPS) Turboalternator-Compressor (TAC) and recuperator with a heat receiver, solar concentrator, and radiator based on Space Station Freedom designs. The aim of the designs is to provide a cost-effective, minimal-risk, viable ground test system. This paper describes the BIPS TAC configuration and performance characteristics along with the cycle analysis of BIPS TAC.

Amundsen, Peter C.↗
NASA NTRS1993

Identification and interpretation of patterns in rocket engine data

A prototype software system was constructed to detect anomalous Space Shuttle Main Engine (SSME) behavior in the early stages of fault development significantly earlier than the indication provided by either redline detection mechanism or human expert analysis. The major task of the research project is to analyze ground test data, to identify patterns associated with the anomalous engine behavior, and to develop a pattern identification and detection system on the basis of this analysis. A prototype expert system which was developed on both PC and Symbolics 3670 lisp machine for detecting anomalies in turbopump vibration data was checked with data from ground tests 902-473, 902-501, 902-519, and 904-097 of the Space Shuttle Main Engine. The neural networks method was also applied to supplement the statistical method utilized in the prototype system to investigate the feasibility in detecting anomalies in turbopump vibration of SSME. In most cases the anomalies detected by the expert system agree with those reported by NASA. On the neural networks approach, the results are given the successful detection rate higher than 95 percent to identify either normal or abnormal running condition based on the experimental data as well as numerical simulation.

Lo, C. F.↗
NASA NTRS2006

Development Overview of the Revised NASA Ultra Long Duration Balloon

The development of the National Aeronautics and Space Administration s (NASA) Ultra Long Duration Balloon (ULDB) has made significant strides in addressing the deployment issues experienced in the scaling up of the balloon structure. This paper concentrates on the super-pressure balloon developments that have been, and are currently being planned by the NASA Balloon Program Office at Goddard Space Flight Center s Wallops Flight Facility. The goal of the NASA ULDB development project is to attempt to extend the potential flight durations for large scientific balloon payloads. A summary of the February 2005 test flight from Ft. Sumner, New Mexico will be presented. This test flight spurred a number of investigations and advancements for this project. The development path has pursued some new approaches in the design, analysis, and testing of the balloons. New issues have been ideEti6ed throu& both analysis md testing. These have been addressed in the design stage before the next balloon construction was begun. This paper will give an overview of the recent history for this effort and the development approach pursued for ULDB. A description of the balloon design, including the modifications made as a result of the lessons learned, will be presented. Areas to be presented include the design approach, deployment issues that have been encountered and the proposed solutions, ground testing, photogrammetry, and an analysis overview. Test flight planning and considerations will be presented including test flight safety. An extended duration test flight of the National Aeronautics and Space Administration s Ultra Long Duration Balloon is planned for the May/June 2006 time frame. This flight is expected to fly from Sweden to either Canada or Alaska. Preliminary results of this flight will be presented as available. Future plans for both ground testing and additional test flights will also be presented. Goals of the future test flights, which are staged in increments of increasing suspended load and altitude, will be presented. This will include the projected balloon volumes, payload capabilities, test flight locations, and proposed flight schedule.

Cathey, H. M.↗
NASA NTRS2017

Preparing for Veg-04 and Veg-05: Improving Pick-And-Eat Food Capabilities for the International Space Station

The capability to grow nutritious, palatable food for crew consumption during spaceflight has the potential to provide health-promoting, bioavailable nutrients, enhance the dietary experience, and reduce launch mass as we move toward longer-duration missions. Studies of edible produce during spaceflight have been limited, leaving a significant knowledge gap in the methods required to grow safe, acceptable, nutritious crops for consumption in space. Researchers from Kennedy Space Center, Johnson Space Center, Purdue University and ORBITEC have teamed up to explore the potential for plant growth and food production on the International Space Station (ISS) and future exploration missions. Ground testing of Chinese cabbage and dwarf tomato crops under different LED lighting and fertilizer conditions is being conducted to allow for a preliminary down selection of the two best lighting recipes and the best fertilizer treatment. Two trials of Chinese cabbage and one trial on dwarf tomato have been completed in on-going ground tests. Horticultural data on crop growth and productivity and chemical data on specific nutrients have been collected and are being analyzed to allow preliminary down selection. Taste test evaluations are planned on the preliminary down selection treatments to allow a final down selection for flight testing. Microbial assessment for hazard analysis critical control points (HACCP) evaluation is also underway to enable implementation of food consumption. Following down selection flight preparation will commence for testing these crops in the Veggie vegetable-production system on the ISS. A crew questionnaire has been developed to better understand the impact of crop growth in Veggie on crew behavioral health. A single Veggie plant growth chamber is currently installed on ISS, and preparations are underway to launch a second Veggie, allowing side-by-side testing under different lighting conditions. Veg-04 will be the first mission that will use this dual-Veggie capability, where the selected cultivar of Tokyo bekana Chinese cabbage will be grown under two different red-to-blue light ratios. ORBITEC has developed custom lighting software allowing independent selection of red and blue light levels. The VEG-05 experiment will test similar light treatments using Red Robin dwarf tomato. These tests offer an opportunity to develop a pick-and-eat fresh vegetable component to the ISS food system as a first step to regular supplemental food production. Our work will help define light colors, levels, and horticultural best practices to achieve high yields of safe, nutritious leafy greens and tomatoes to supplement a space diet of prepackaged food. With this work we will continue the synergistic research to help close gaps in the human research roadmap, and enable humans to venture to Mars and beyond. This research was co-funded by the Human Research Program and Space Biology (MTL1075) in the ILSRA 2015 NRA call.

International Space Station↗
NASA NTRS1986

Vibration of a large space beam under gravity effect

Future space structures will have a low mass density and high flexibility, with ground test dynamic behavior differing significantly from that in zero-G orbit. Attention is presently given to the vibration behavior of a beam deformed by its own weight; the results obtained by the differential equations for both the static and dynamic responses of a large, simply supported beam, which are derived and solved analytically, allow ground test experiment measurements to be used for orbital dynamic characteristics verification efforts.

Shih, C.-F.↗
NASA NTRS1983

Technology requirements for large flexible space structures

Research, test, and demonstration experiments necessary for establishing a data base that will permit construction of large, lightweight flexible space structures meeting on-orbit pointing and surface precesion criteria are discussed. Attention is focused on the wrap-rib proof-of-concept antenna structures developed from technology used on the ATS-6 satellite. The target structure will be up to 150 m in diameter or smaller, operate at RF levels, be amenable to packaging for carriage in the Shuttle bay, be capable of being ground-tested, and permit on-orbit deployment and retraction. Graphite/epoxy has been chosen as the antenna ribs material, and the antenna mesh will be gold-plated Mo wire. A 55-m diam reflector was built as proof-of-concept with ground-test capability. Tests will proceed on components, a model, the entire structure, and in-flight. An analytical model has been formulated to characterize the antenna's thermal behavior. The flight test of the 55-m prototype in-orbit offers the chance to validate the analytical model and characterize the control, mechanical, and thermal characteristics of the antenna configuration.

Wada, B. K.↗
NASA NTRS2016

Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m Class System

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. The HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to 15m-class system. Two complications in working with handmade textiles structures are the non-linearity of the materials and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the materials out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m class HIAD. In this paper, the challenges and associated mitigation plans related to scaling up the HIAD stacked-torus aeroshell to a 15m class system will be discussed. In addition, the benefits of enlarging the structure will be further explored.

Decellerators↗
NASA NTRS2016

Manufacturing Challenges and Benefits When Scaling the HIAD Stacked-Torus Aeroshell to a 15 Meter Class System

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6 meters, with cone angles of 60 and 70 degrees. To meet NASA and commercial near-term objectives, the HIAD team must scale the current technology up to 12-15 meters in diameter. Therefore, the HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6-meter to a 15-meter class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15-meter-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6-meter aeroshell (the largest HIAD built to date), a 12-meter aeroshell has four times the cross-sectional area, and a 15-meter one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15-meter HIAD. In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current manufacturing and testing that addressing these challenges.

Infatables↗
NASA NTRS2014

Technology Maturation in Preparation for the Cryogenic Propellant Storage and Transfer (CPST) Technology Demonstration Mission (TDM)

In support of its goal to find an innovative path for human space exploration, NASA embarked on the Cryogenic Propellant Storage and Transfer (CPST) Project, a Technology Demonstration Mission (TDM) to test and validate key cryogenic capabilities and technologies required for future exploration elements, opening up the architecture for large in-space cryogenic propulsion stages and propellant depots. Recognizing that key Cryogenic Fluid Management (CFM) technologies anticipated for on-orbit (flight) demonstration would benefit from additional maturation to a readiness level appropriate for infusion into the design of the flight demonstration, the NASA Headquarters Space Technology Mission Directorate (STMD) authorized funding for a one-year technology maturation phase of the CPST project. The strategy, proposed by the CPST Project Manager, focused on maturation through modeling, concept studies, and ground tests of the storage and fluid transfer of CFM technology sub-elements and components that were lower than a Technology Readiness Level (TRL) of 5. A technology maturation plan (TMP) was subsequently approved which described: the CFM technologies selected for maturation, the ground testing approach to be used, quantified success criteria of the technologies, hardware and data deliverables, and a deliverable to provide an assessment of the technology readiness after completion of the test, study or modeling activity. The specific technologies selected were grouped into five major categories: thick multilayer insulation, tank applied active thermal control, cryogenic fluid transfer, propellant gauging, and analytical tool development. Based on the success of the technology maturation efforts, the CPST project was approved to proceed to flight system development.

propellants↗
NASA NTRS2002

A Desorbed Gas Molecular Ionization Mechanism for Arcing Onset in Solar Arrays Immersed in a Low-Density Plasma

Previous experimental studies have hypothesized that the onset of Solar Array Arc (SAA) initiation in low-density space plasmas is caused by a desorbed gas molecular ionization mechanism. Indeed past investigations performed at the NASA Glenn Plasma Interaction Facility tend to not only support the desorbed gas molecular ionization mechanism, but have gone as far as identifying the crucial molecular species that must be present for molecular ion dominated process to occur. When electrical breakdown occurs at a triple junction site on a solar array panel, a quasi-neutral plasma cloud is ejected. Assuming the main component of the expelled plasma cloud by weight is due to water vapor, the fastest process available is due to HO molecules and OH(+) ions, or more succinctly, dissociative molecular-ion dominated recombination processes: H2O(+) + e(-) yields H* + OH*. Recently published spectroscopic observations of solar array arc spectra in ground tests have revealed the well-known molecular OH band (302 to 309nm), as well as the molecular SiH band (387nm peak), and the molecular CH band (432nm peak). Note that the OH band is observed in emission arcs where water vapor is present. Strong atomic lines were also observed for H(sub beta) at 486nm and H(sub alpha) at 656.3nm in prior ground testing. Independent supporting evidence of desorbed gas molecular ionization mechanisms also come from measurements of arc current pulse widths at different capacitances. We will revisit an earlier first order approximation demonstrating the dependence of arc current pulse widths on the square root of the capacitance. The simple arc current pulse width model will be then be used to estimate the temperature of the arc plasma (currently believed to be somewhere in the range of 3 to 5 eV). The current paper then seeks to extend the outlined work by including numerous vacuum chamber measurements obtained with a quadrupole mass spectrometer. A small solar array was mounted inside the vacuum chamber. A plasma source, also mounted inside the vacuum chamber, is used to simulate a low-density plasma environment. The solar array is then biased to a high negative potential and allowed to arc while a mass spectrometer is used to record the partial pressure of H2O and to track other significant changes in mass (1 to 150) AMU.

Galofaro, J.↗
NASA NTRS2016

Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m-Class System

Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. Therefore, the HIAD projects experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m-class system will introduce many new structural and logistical challenges to an already complicated manufacturing process.Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to ac-count for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs.There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m HIAD.In this presentation, a handful of the challenges and associated mitigation plans will be discussed, as well as an update on current 12m aeroshell manufacturing and testing that is addressing these challenges

Infatables↗