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All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Moon-to-Mars Planetary Autonomous Construction Technology: MMPACT Material Screening

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. MMPACT must screen for the most feasible technologies with the earliest potential technology insertions given the ambitious goals of the Artemis campaign. This poster summarizes recent efforts to discover and document mechanical and thermal capabilities of various technologies: a laser-based vitreous material transformation from Texas-based ICON, a molten extrusion process from ICON, a mortar from MSFC, a mortar from an MSFC-Louisiana State University partnership, and a geopolymer from a MSFC-Pennsylvania State University partnership. Other testing and development activities are documented as well. [1] https://www.nasa.gov/directorates/spacetech/Lunar_Surface_Innovation_Initiative

In-situ Resource Utilization↗
NASA NTRSDate not supplied

Overview of Lightning Science at NASA Marshall Space Flight Center

NASA Marshall Space Flight Center (MSFC) is a recognized world leader in the science of lightning. To date, MSFC has led three space-based global lightning observing missions and has helped lead multiple suborbital field campaigns involving lightning observations. Recently, the MSFC Lightning Team is closing out the recently completed International Space Station Lightning Imaging Sensor (ISS LIS) mission, including developing a nearly three-decade global climatology of lightning from space. This work also includes integrating lightning observations with data from NASA precipitation missions. The Team is also busy analyzing data from a recent airborne field campaign that observed dozens of terrestrial gamma-ray flashes (TGFs) from intense tropical thunderstorms. Lightning Team members are also leaders in validation of the Geostationary Lightning Mapper (GLM) operated by NOAA, and in developing lightning safety applications and studying the relationship between lightning and wildfires. The Lightning Team also studies chemical production by lightning and contributes to the National Climate Assessment (NCA). Finally, the Lightning Team is busy developing the next generation of spaceborne lightning sensors to broaden our understanding of the relationships between lightning, weather, climate, and atmospheric composition.

Timothy Lang↗
NASA NTRSDate not supplied

Design and Applications of Tethered Spacecraft Simulators

Small, tethered spacecraft, or space tugs, are a promising space capability. They can be deployed on tethers and used for a wide variety of in-space activities; a large portion of which fall under in-space servicing, assembly, manufacturing (ISAM) functions. This includes functions such as structural mating and assembly, servicing, proximity operations, capture, docking, mating, and relocation. However, there is a great deal of work to be done to raise the Technology Readiness Level (TRL) of the capabilities needed to fully realize these capabilities. The Flat Floor Robotics Lab (FFRL) at NASA’s Marshall Spaceflight Center (MSFC) has been working on space tug development for several years. The eponymous floor is 44 by 86 feet, made from a self-leveling epoxy. This creates an extremely smooth surface that air bearings can float on with very little friction, creating a simulation of zero gravity in a two-dimensional plane. The lab has several platforms of various sizes that act as vehicle simulators for testing sensors, control algorithms, mechanisms, etc. One of these platforms is a small spacecraft simulator, which can be tethered to simulate a space tug. In the last several months, the FFRL team has been working with MSFC’s welding group to conduct a laser beam welding demonstration on air bearing platforms. This demo is utilizing a space tug simulator to fly up to a floating weld platform, where two parts are clamped together and laser welded. The space tug simulator has an air bearing to provide float, as well as several actuated air thrusters to provide propulsion and make the simulator maneuverable. Currently, flights of this simulator are completed by a human operator. An RF hand controller sends signals to both actuate and fire three sets of thrusters on the simulator. This makes any maneuvers of the space tug highly subject to human error, and operators must have dedicated practice time before being able to perform maneuvers with any sufficient reliability. For the current laser welding demonstration, human operated performance is sufficient, but future implementations of in-space welding and other ISAM efforts will require higher precision, reliability, and autonomy. MSFC has funded a project that will allow a small team in the FFRL to develop the next generation of space tug simulator, which will be automated. Closed loop control will allow a user to command a position, or set of positions, that the simulator will be able to “fly” to on its own. This Maneuverable Automated Tethered Spacecraft (MATS) simulator will have configurable design, to allow a variety of payloads and mission configurations to be demonstrated on the air bearing floor. This will be an invaluable test bed for low and mid TRL advancement for space tether mission subsystems, such as more advanced demonstrations of in-space welding. Once one MATSS is constructed and demonstrated effectively, several more can be built, enabling more advanced tether missions; Electric Sail test beds, sensor arrays, and other science-enabling missions. This paper will detail the design and test of the FFRL’s MATS simulator, including efforts to establish closed loop control and autonomous capabilities. It will also detail use cases for this technology, and how it will further develop both develop science and exploration missions.

Space Tethers↗
NASA NTRSDate not supplied

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗
DOE OSTI2020

Further Support of the Development of Advanced Multilayer Optics Coatings for X-Ray Imaging

SAO is working with LLNL to develop Wolter-I optics for x-ray imaging applications at energies of 15-50 keV and above at NNSA facilities. Our work includes R&D on advanced multilayer coatings as well as fabrication and testing of Wolter-I multilayer coated optics. It also includes delivery of custom 3.05-meter focal length Wolter optics with response at energies of interest to Sandia National Laboratories and LLNL. The mandrels for the custom optics are fabricated at MSFC. In previous contracts, SAO delivered several optics to LLNL with response at various energies. During this present contract period two tasks were carried out. Task1: the coating, replication and characterization of a custom optic with peak response at 22.8 keV, using the custom-designed SANZ mandrels. Task2: carrying out modifications to the coating chamber at SAO to accommodate new, longer, custom-designed mandrels (SANZlong) that will be fabricated at NASA MSFC in FY2020. The longer mandrels are necessary to mitigate end effects observed in the replication process for the small optics currently being fabricated.

36 MATERIALS SCIENCE↗
NASA NTRS1962

Studies in the Fields of Space Flight and Guidance Theory: Progress Report - No. 2

Compiled in this paper are 11 progress papers from 7 of the agencies working under contract to MSFC in the areas of guidance theory and space flight theory. This is the second paper of the "Progress Reports" and covers the period from December 1, 1961 to June 15, 1962. Extensive references are made to "Progress Report No. 1." This second progress report is referred to as "report" and "Progress Report No. 1" will be referred to as the "first report" in this introduction. Information given in the first report is not repeated herein. The reports of the various contractors will be referred to by index number as papers. There are two parallel series of publications covering the over-all activities at MSFC in the areas of guidance theory and space flight theory. One is the series of progress reports of which this paper is the second in the series. The other is the series of "Status Reports on Theory of Space Flight and Adaptive Guidance." These series along with a few other special reports, give a complete picture of the immediate objectives, accomplishments, and final goals of Aeroballistics Division and associated contr

FLIGHT OPTIMIZATION↗
NASA NTRS1966

Orbital tube flare for tubing connectors

Marshall engineering personnel have developed and are now refining a new and unique method of mechanically flaring tubing. The system eliminates the use of the conventional split backing die which is used with most tube-flaring equipment. The Marshall-developed tool is adapted for use on standard Leonard 3-CP-HD flaring machines. The stationary split backing die is replaced in function with a die ring, whose i.d.-surface rolls or orbits around the o.d. of the tube flare zone. An i.d.-flaring cone moves axially and forces the metal against the rolling die to form the flare. Major advantages of this system are the elimination of flash, or split die marks, on the back angle of the flare, and improved flare-surface finishes, permitting more uniform sealing characteristics and improvements of the total geometric configuration of the flare as required by the MSFC specification MC-146. The Orbital Adapter system of tooling is currently being used to manufacture flared tube hardware for the Saturn V S-IO space launch vehicle at MSFC, for the Agena space launch vehicle (used for the Gemini project) at Lockheed, Sunnyvale, for LEM checkout equipment for Grumman, and for the Saturn S-IV-B space launch vehicle by Douglas Aircraft Company. Several other aerospace firms are evaluating the system for possible incorporation on their tube flaring requirements. Marshall engineers are now concentrating their efforts on refining and reducing the total cost of the overall system.

Tubing↗
NASA NTRS1966

Tooling concepts for assembly of large structures

Manufacture of the S-IC stage of the Saturn V space vehicle has resulted in new. concepts and innovations in the field of tooling. The structure size (35-ft diameter), the high reliability and accuracy requirements, and the low density or production quantity lead to a greater degree of simplicity, economy, and versatility in fabrication and assembly tooling. There are three specific concepts which should be applicable in industry, local jigging for welding, rotation of structures in vertical assemblies, and the assembly of two structures. The usual weld jigging serves a two-fold purpose: (a) to support the molten weld puddle and (b) to force and maintain alinement of the parts being welded. The extension of this method to large-diameter tanks is expensive and difficult. An alternate procedure used at MSFC is to perform free-state welding and use local jigging (stra1rclamps) and intermittent tack welding. Cylindrical structures can be accurately rotated for routing or welding on a simplified ring turntable. The tool consists of a ring of the structure diameter resting on rollers. Torque is nearly zero since the ring is rotated by friction rollers with the force being applied at the ring perimeter. Two such turntables are used at MSFC. The horizontal mating of two large components, where controlled motions of small magnitude are necessary, can be easily done by positioning units equipped with air-bearings. Such bearings are usable on concrete of minimum surface preparation and require no special air pressure source. This concept is used in assembly of the two S-IC containers.

Saturn S-IC stage↗
NASA NTRS1971

Multilayer Insulation Thermal Protection Systems Technology

A summary is presented of the work performed by Marshall Space Flight Center (MSFC) and industry toward the development of flight-type multilayer insulation(MLI) systems. The MSFC MLI program is divided into three large categories: (1) the generation and compilation of MLI composite test data; (2) the analysis, design, and testing of heat flow through MLI applied to ducting, seams, electrical feedthroughs, structural supports, and the tank sidewall; and (3) the development, modification, and utilization of new testing procedures, tanks, and the test facilities. Numerous data have been generated, analyzed, and documented on different MLI composites.

E H Hyde↗
NASA NTRS1972

ZM-21 magnesium alloy corrosion properties and cryogenic to elevated temperature mechanical properties

The mechanical properties of bare ZM-21 magnesium alloy flat tensile specimens were determined for test temperatures of +400 F, +300 F, +200 F, +80 F, 0 F, -100 F, -200 F, and -320 F. The ultimate tensile and yield strengths of the material increased with decreasing temperature with a corresponding reduction in elongation values. Stress corrosion tests performed under: (1) MSFC atmospheric conditions; (2) 95% relative humidity; and (3) submerged in 100 ppm chloride solution for 8 weeks indicated that the alloy is not susceptible to stress corrosion. The corrosion tests indicated that the material is susceptible to attack by crevice corrosion in high humidity and chemical type attack by chloride solution. Atmospheric conditions at MSFC did not produce any adverse effects on the material, probably due to the rapid formation of a protective oxide coating. In both the mechanical properties and the stress corrosion evaluations the test specimens which were cut transverse to the rolling direction had superior properties when compared to the longitudinal properties.

Montana, J. W.↗
NASA NTRS1972

Space shuttle: Aerodynamic characteristics of cone-cylinder-flare-fin configurations at Mach numbers of 1.96, 2.74, and 4.96 and angles of attack from 50 to 90 degrees

A 0.00227-scale parametric model of an LMSC/MSFC water recoverable booster was tested in the MSFC 14 x 14-inch trisonic wind tunnel. The purpose of the test was to obtain high angle of attack force and static stability data which could be used by MSFC in preliminary design and aerodynamic trade studies. These data were obtained using six-component internal strain gauge balances. One hundred forty-four different geometrical combinations were possible as all model parts were interchangeable (three nose cones, three cylinder lengths, four flare sections and three sets of fins, plus a no-fin case in combination with the other components). However, due to tunnel occupancy limitations, only the most representative combinations were tested. All configurations investigated were tested at Mach 1.96, 2.74 and 4.96 with data obtained at angles of attack from 50 degrees to 90 degrees and at angles of sideslip from -10 degrees to +10 degrees (at an angle of attack of 60 degrees).

Bradley, D.↗
NASA NTRS1972

ERISTAR: Earth Resources Information Storage, Transformation, Analysis, and Retrieval

The National Aeronautics and Space Administration (NASA) and the American Society for Engineering Education (ASEE) have sponsored faculty fellowship programs in systems engineering design for the past several years. During the summer of 1972 four such programs were conducted by NASA, with Auburn University cooperating with Marshall Space Flight Center (MSFC). The subject for the Auburn-MSFC design group was ERISTAR, an acronym for Earth Resources Information Storage, Transformation, Analysis and Retrieval, which represents an earth resources information management network of state information centers administered by the respective states and linked to federally administered regional centers and a national center. The considerations for serving the users and the considerations that must be given to processing data from a variety of sources are described. The combination of these elements into a national network is discussed and an implementation plan is proposed for a prototype state information center. The compatibility of the proposed plan with the Department of Interior plan, RALI, is indicated.

Source record↗
NASA NTRS1972

Termination of flat conductor cable to NASA/MSFC plugs

Data, supplemented with artwork, are presented on the major steps involved with terminating flat conductor cable (FCC) to MSFC's FCC plugs. Cable and shield preparation steps include material cutting, insulation stripping, and plating of exposed conductors. Methods and equipment required to terminate FCC to each of four MSFC plugs are described.

Angele, W.↗
NASA NTRS1973

Computer enhancement of radiographs

Examination of three relevant noise processes and the image degradation associated with Marshall Space Flight Center's (MSFC) X-ray/scanning system was conducted for application to computer enhancement of radiographs using MSFC's digital filtering techniques. Graininess of type M, R single coat and R double coat X-ray films was quantified as a function of density level using root-mean-square (RMS) granularity. Quantum mottle (including film grain) was quantified as a function of the above film types, exposure level, specimen material and thickness, and film density using RMS granularity and power spectral density (PSD). For various neutral-density levels the scanning device used in digital conversion of radiographs was examined for noise characteristics which were quantified by RMS granularity and PSD. Image degradation of the entire pre-enhancement system (MG-150 X-ray device; film; and optronics scanner) was measured using edge targets to generate modulation transfer functions (MTF). The four parameters were examined as a function of scanning aperture sizes of approximately 12.5 25 and 50 microns.

Dekaney, A.↗
NASA NTRS1973

Aerodynamic investigations on a 0.004 scale model MCR 0074 baseline space shuttle launch vehicle at Mach numbers between 0.6 and 4.96

A test of a 0.004-scale MCR 0074 Baseline Launch Configuration Space Shuttle model was conducted in the NASA-MSFC 14 x 14-inch Trisonic Wind Tunnel (MSFC TWT 566). The objective of the test was to determine the effects of model parametric variations on aerodynamic static stability characteristics over a Mach number range from 0.6 to 4.96. Angles-of-attack from minus 10 deg to plus 10 deg at 0 deg sideslip and angles-of-sideslip from minus 10 deg to plus 10 deg at minus 5 deg, 0 deg, and plus 5 deg angle-of-attack were investigated. The basic configuration investigated was the integrated vehicle consisting of the orbiter, and external tank, and two solid rocket boosters. It was designated 03T9S3.

Ramsey, P.↗
NASA NTRS1976

Payload/orbiter contamination control requirement study: Computer interface

A preliminary assessment of the computer interface requirements of the Spacelab configuration contamination computer model was conducted to determine the compatibility of the program, as presently formatted, with the computer facilities at MSFC. The necessary Spacelab model modifications are pointed out. The MSFC computer facilities and their future plans are described, and characteristics of the various computers as to availability and suitability for processing the contamination program are discussed. A listing of the CDC 6000 series and UNIVAC 1108 characteristics is presented so that programming requirements can be compared directly and differences noted.

Bareiss, L. E.↗