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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5

Conceptual Design of In-Space Vehicles for Human Exploration of the Outer Planets

During FY-2002, a team of engineers from TD30/Advanced Concepts and TD40/Propulsion Research Center embarked on a study of potential crewed missions to the outer solar system. The study was conducted under the auspices of the Revolutionary Aerospace Systems Concepts activity administered by Langley Research Center (LaRC). The Marshall Space Flight Center (MSFC) team interacted heavily with teams from other Centers including Glenn Research Center, LaRC, Jet Propulsion Laboratory, and Johnson Space Center. The MSFC team generated five concept missions for this project. The concept missions use a variety of technologies, including magnetized target fusion (MTF), magnetoplasmadynamic thrusters, solid core reactors, and molten salt reactors in various combinations. The Technical Publication (TP) reviews these five concepts and the methods used to generate them. The analytical methods used are described for all significant disciplines and subsystems. The propulsion and power technologies selected for each vehicle are reviewed in detail. The MSFC team also expended considerable effort refining the MTF concept for use with this mission. The results from this effort are also contained within this TP. Finally, the lessons learned from this activity are summarized in the conclusions section.

Adams, R. B.↗

A space station Structures and Assembly Verification Experiment, SAVE

The Space Station structure has been baselined to be a 5 M (16.4 ft) erectable truss. This structure will provide the overall framework to attach laboratory modules and other systems, subsystems and utilities. The assembly of this structure represents a formidable EVA challenge. To validate this capability the Space Station Structures/Dynamics Technical Integration Panel (TIP) met to develop the necessary data for an integrated STS structures flight experiment. As a result of this meeting, the Langley Research Center initiated a joint Langley/Boeing Aerospace Company study which supported the structures/dynamics TIP in developing the preliminary definition and design of a 5 M erectable space station truss and the resources required for a proposed flight experiment. The purpose of the study was to: (1) devise methods of truss assembly by astronauts; (2) define a specific test matrix for dynamic characterization; (3) identify instrumentation and data system requirements; (4) determine the power, propulsion and control requirements for the truss on-orbit for 3 years; (5) study the packaging of the experiment in the orbiter cargo bay; (6) prepare a preliminary cost estimate and schedule for the experiment; and (7) provide a list of potential follow-on experiments using the structure as a free flyer. The results of this three month study are presented.

Russell, R. A.↗

Research papers and publications (1981-1987): Workload research program

An annotated bibliography of the research reports written by participants in NASA's Workload Research Program since 1981 is presented, representing the results of theoretical and applied research conducted at Ames Research Center and at universities and industrial laboratories funded by the program. The major program elements included: 1) developing an understanding of the workload concept; 2) providing valid, reliable, and practical measures of workload; and 3) creating a computer model to predict workload. The goal is to provide workload-related design principles, measures, guidelines, and computational models. The research results are transferred to user groups by establishing close ties with manufacturers, civil and military operators of aerospace systems, and regulatory agencies; publishing scientific articles; participating in and sponsoring workshops and symposia; providing information, guidelines, and computer models; and contributing to the formulation of standards. In addition, the methods and theories developed have been applied to specific operational and design problems at the request of a number of industry and government agencies.

Hart, Sandra G.↗

The 2004 NASA Aerospace Battery Workshop

Topics covered include: Super NiCd(TradeMark) Energy Storage for Gravity Probe-B Relativity Mission; Hubble Space Telescope 2004 Battery Update; The Development of Hermetically Sealed Aerospace Nickel-Metal Hydride Cell; Serial Charging Test on High Capacity Li-Ion Cells for the Orbiter Advanced Hydraulic Power System; Cell Equalization of Lithium-Ion Cells; The Long-Term Performance of Small-Cell Batteries Without Cell-Balancing Electronics; Identification and Treatment of Lithium Battery Cell Imbalance under Flight Conditions; Battery Control Boards for Li-Ion Batteries on Mars Exploration Rovers; Cell Over Voltage Protection and Balancing Circuit of the Lithium-Ion Battery; Lithium-Ion Battery Electronics for Aerospace Applications; Lithium-Ion Cell Charge Control Unit; Lithium Ion Battery Cell Bypass Circuit Test Results at the U.S. Naval Research Laboratory; High Capacity Battery Cell By-Pass Switches: High Current Pulse Testing of Lithium-Ion; Battery By-Pass Switches to Verify Their Ability to Withstand Short-Circuits; Incorporation of Physics-Based, Spatially-Resolved Battery Models into System Simulations; A Monte Carlo Model for Li-Ion Battery Life Projections; Thermal Behavior of Large Lithium-Ion Cells; Thermal Imaging of Aerospace Battery Cells; High Rate Designed 50 Ah Li-Ion Cell for LEO Applications; Evaluation of Corrosion Behavior in Aerospace Lithium-Ion Cells; Performance of AEA 80 Ah Battery Under GEO Profile; LEO Li-Ion Battery Testing; A Review of the Feasibility Investigation of Commercial Laminated Lithium-Ion Polymer Cells for Space Applications; Lithium-Ion Verification Test Program; Panasonic Small Cell Testing for AHPS; Lithium-Ion Small Cell Battery Shorting Study; Low-Earth-Orbit and Geosynchronous-Earth-Orbit Testing of 80 Ah Batteries under Real-Time Profiles; Update on Development of Lithium-Ion Cells for Space Applications at JAXA; Foreign Comparative Technology: Launch Vehicle Battery Cell Testing; 20V, 40 Ah Lithium Ion Polymer Battery for the Spacesuit; Low Temperature Life-Cycle Testing of a Lithium-Ion Battery for Low-Earth-Orbiting Spacecraft; and Evaluation of the Effects of DoD and Charge Rate on a LEO Optimized 50 Ah Li-Ion Aerospace Cell.

Source record↗

SHOOT performance testing

The Superfluid Helium On-Orbit Transfer (SHOOT) Flight Demonstration is a shuttle attached payload designed to demonstrate the technology necessary to resupply liquid helium dewars in space. Many SHOOT components will also have use in other aerospace cryogenic systems. The first of two SHOOT dewar systems has been fabricated. The ground performance testing of this dewar is described. The performance tests include measurements of heat leak, impedances of the two vent lines, heat pulse mass gauging accuracy, and superfluid transfer parameters such as flow rate and efficiency. A laboratory dewar was substituted for the second flight dewar for the transfer tests. These tests enable a precise analytical model of the transfer process to be verified. SHOOT performance is thus quantified, except for components such as the liquid acquisition devices and a phase separator which cannot be verified in one gravity.

Dipirro, M. J.↗

Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.

14 SOLAR ENERGY↗

Testing For EM Upsets In Aircraft Control Computers

Effects of transient electrical signals evaluated in laboratory tests. Method of evaluating nominally fault-tolerant, aircraft-type digital-computer-based control system devised. Provides for evaluation of susceptibility of system to upset and evaluation of integrity of control when system subjected to transient electrical signals like those induced by electromagnetic (EM) source, in this case lightning. Beyond aerospace applications, fault-tolerant control systems becoming more wide-spread in industry; such as in automobiles. Method supports practical, systematic tests for evaluation of designs of fault-tolerant control systems.

Belcastro, Celeste M.↗

Development of a Battery-Free Solar Refrigerator

Recent technology developments and a systems engineering design approach have led to the development of a practical battery-free solar refrigerator as a spin-off of NASA's aerospace refrigeration research. Off-grid refrigeration is a good application of solar photovoltaic (PV) power if thermal storage is incorporated and a direct connection is made between the cooling system and the PV panel. This was accomplished by integrating water as a phase-change material into a well insulated refrigerator cabinet and by developing a microprocessor based control system that allows direct connection of a PV panel to a variable speed compressor. This second innovation also allowed peak power-point tracking from the PV panel and elimination of batteries from the system. First a laboratory unit was developed to prove the concept and then a commercial unit was produced and deployed in a field test. The laboratory unit was used to test many different configurations including thermoelectric, Stirling and vapor compression cooling systems. The final configuration used a vapor compression cooling cycle, vacuum insulation, a passive condenser, an integral evaporator/ thermal storage tank, two 77 watt PV panels and the novel controller mentioned above. The system's only moving part was the variable speed BD35 compressor made by Danfoss. The 365 liter cabinet stayed cold with as little as 274 watt-hours per day average PV power. Battery-free testing was conducted for several months with very good results. The amount of thermal storage, size of compressor and power of PV panels connected can all be adjusted to optimize the design for a given application and climate. In the commercial unit, the high cost of the vacuum insulated refrigerator cabinet and the stainless steel thermal storage tank were addressed in an effort to make the technology commercially viable. This unit started with a 142 liter, mass-produced chest freezer cabinet that had the evaporator integrated into its inner walls. Its compressor was replaced with a Danfoss DC compressor slightly larger than the one used in the laboratory unit. The control system was integrated onto a single electronics card and packaged with its starting capacitors. The water for thermal storage was placed behind a liner that was made to fit inside the original factory liner. The original condenser was also augmented with additional surface area to improve performance. PV panels with a total rated power of 180 watts were used. The unit was tested with very successful results in an outside ambient environment, demonstrating its potential for widespread use in many off-grid applications for solar refrigeration.

Ewert, Michael K.↗

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

A SIMULINK environment for flight dynamics and control analysis: Application to the DHC-2 Beaver. Part 1: Implementation of a model library in SIMULINK. Part 2: Nonlinear analysis of the Beaver autopilot

The design of advanced Automatic Aircraft Control Systems (AACS's) can be improved upon considerably if the designer can access all models and tools required for control system design and analysis through a graphical user-interface, from within one software environment. This MSc-thesis presents the first step in the development of such an environment, which is currently being done at the Section for Stability and Control of Delft University of Technology, Faculty of Aerospace Engineering. The environment is implemented within the commercially available software package MATLAB/SIMULINK. The report consists of two parts. Part I gives a detailed description of the AACS design environment. The heart of this environment is formed by the SIMULINK implementation of a nonlinear aircraft model in block-diagram format. The model has been worked out for the old laboratory aircraft of the Faculty, the De Havilland DHC-2 'Beaver', but due to its modular structure, it can easily be adapted for other aircraft. Part I also describes MATLAB programs which can be applied for finding steady-state trimmed-flight conditions and for linearization of the aircraft model, and it shows how the built-in simulation routines of SIMULINK have been used for open-loop analysis of the aircraft dynamics. Apart from the implementation of the models and tools, a thorough treatment of the theoretical backgrounds is presented. Part II of this report presents a part of an autopilot design process for the 'Beaver' aircraft, which clearly demonstrates the power and flexibility of the AACS design environment from part I. Evaluations of all longitudinal and lateral control laws by means of nonlinear simulations are treated in detail. The AACS design environment from part I proved to be a very useful tool for designing the control laws of the 'Beaver' autopilot within a very tight time-schedule. The autopilot design process itself will be used as a guideline for future AACS research at the Faculty of Aerospace Engineering. Flight tests of the 'Beaver' autopilot, done after evaluating the control laws in the SIMULINK package, proved to be quite successful. In the future, the AACS design package will evolve into a standardized, integrated design environment which can be applied to virtually any type of aircraft. The AACS design cycle will be shortened further by developing tools for automatically porting control laws from the MATLAB/SIMULINK environment to a piloted real-time flight simulator and the Flight Control Computers of the aircraft.

Flight Control System Design↗

Status of magnetic suspension technology

The reasons for the continuing interest in the Magnetic Suspension and Balance System (MSBS) are highlighted. Typical problems that can arise because of model-support interference in a transonic wind tunnel are shown to illustrate the need for MSBS. The two magnetic suspension systems in operation at Langley are the only ones active in the U.S. One of these systems is the 13 inch MSBS which was borrowed from the Air Force Arnold Engineering Development Center. The other system is the 6 inch MSBS which was developed by MIT Aerophysics Laboratory with NASA and DOD funding. Each of these systems is combined with a subsonic wind tunnel. Ongoing research in both of these systems is covered. Last year, Madison Magnetics, Inc., completed a contractual design and cost study utilizing some advance concepts for a large MSBS which would be compatible with an 8 foot transonic wind tunnel and the highlights of the study are presented. Sverdrup Technology, Inc., recently performed a study under contract for Langley on the potential usefulness to the aerospace industry of a proposed large MSBS combined with a suitable transonic wind tunnel. The results of that study are discussed. Langley has partially funded the MSBS work at the University of Southampton for about 6 years under a grant arrangement and the major results are summarized.

Boyden, Richmond P.↗

An overview of aeroelasticity studies for the National Aerospace Plane

The National Aero-Space Plane (NASP), or X-30, is a single-stage-to-orbit vehicle that is designed to takeoff and land on conventional runways. Research in aeroelasticity was conducted by NASA and the Wright Laboratory to support the design of a flight vehicle by the national contractor team. This research includes the development of new computational codes for predicting unsteady aerodynamic pressures. In addition, studies were conducted to determine the aerodynamic heating effects on vehicle aeroelasticity and to determine the effects of fuselage flexibility on the stability of the control systems. It also includes the testing of scale models to better understand the aeroelastic behavior of the X-30 and to obtain data for code validation and correlation. This paper presents an overview of the aeroelastic research which has been conducted to support the airframe design.

Ricketts, Rodney H.↗

Final Mission and Navigation Design for the 2016 Mars InSight Mission

Project Overview: NASA’s 12th Discovery Program mission that will place a single geophysical lander on Mars to study its deep interior using seismic (tidal, marsquake, and impact), rotational, and thermal measurements -First mission to unveil the composition, structure and thermal state of martian crust, mantle and core; Rebuild of the Phoenix flight system, upgraded with Juno/GRAIL avionics -Phoenix cruise stage: 3-axis stabilized, 3.2 square meter UTJ (Ultra Triple-Junction) solar array, X-band telecom -Phoenix aeroshell (heat shield, backshell, parachute) -Phoenix lander: radar, pulsed thrusters, legs, payload deck, 5.1 square meter UTJ solar arrays, two redundant Li-ion batteries, UHF (Ultra High Frequency)/X-band telecom -Dual string: Internally or functionally-redundant equipment; Science Payload -SEIS (Seismic Experiment for Interior Structure) / CNES (Centre National d’Etudes Spatiales); Three-axis seismometry, to measure seismic waves traveling through the interior -HP3 (Heat Flow and Physical Properties Probe) / DLR (German Aerospace Center) -Subsurface heat probe, to measure the heat flux from the interior - RISE (Rotation and Interior Structure Experiment) / JPL (Jet Propulsion Laboratory) -Radiometric geodesy, to determine precession & nutation of the planet’s rotation axis. 2016 Disclaimer: The InSight launch in 2016 was suspended due to critical issues with the Seismic Experiment for Interior Structure (SEIS) instrument that could not be fixed prior to the planned launch period. This presentation and its corresponding paper represent the state of the design for the 2016 mission. No attempt has been made to reflect the latest developments. [2018 Note: InSight (Mars Lander) was later launched and arrived on Mars on Nov. 26, 2018.]

Abilleira, F.↗

The impact of active controls technology on the structural integrity of aeronautical vehicles

The findings of an investigation conducted under the auspices of The Technical Cooperation Program (TTCP) to assess the impact of active controls technology on the structural integrity of aeronautical vehicles and to evaluate the present state-of-the-art for predicting loads caused by a flight-control system modification and the resulting change in the fatigue life of the flight vehicle are summarized. Important points concerning structural technology considerations implicit in applying active controls technology in new aircraft are summarized. These points are well founded and based upon information received from within the aerospace industry and government laboratories, acquired by sponsoring workshops which brought together experts from contributing and interacting technical disciplines, and obtained by conducting a case study to independently assess the state of the technology. The paper concludes that communication between technical disciplines is absolutely essential in the design of future high performance aircraft.

Noll, Thomas E.↗

Protein structural changes on a CubeSat under rocket acceleration profile

Catalyzing life-sustaining reactions, proteins are composed by 20 different amino acids that fold into a compact yet flexible three-dimensional architecture, which dictates what their function(s) might be. Determining the spatial arrangement of the atoms, the protein’s 3D structure, enables key advances in fundamental and applied research. Protein crystallization is a powerful technique to achieve this. Unlike Earth’s crystallization experiments, biomolecular crystallization in space in the absence of gravitational force is actively sought to improve crystal growth techniques. However, the effects of changing gravitational vectors on a protein solution reaching supersaturation remain largely unknown. Here, we have developed a low-cost crystallization cell within a CubeSat payload module to exploit the unique experimental conditions set aboard a sounding rocket. We designed a biaxial gimbal to house the crystallization experiments and take measurements on the protein solution in-flight with a spectrophotometry system. After flight, we used X-ray diffraction analysis to determine that flown protein has a structural rearrangement marked by loss of the protein’s water and sodium in a manner that differs from crystals grown on the ground. We finally show that our gimbal payload module design is a portable experimental setup to take laboratory research investigations into exploratory space flights.

42 ENGINEERING↗

Investigation of a Helicopter Individual Blade Control (IBC) System in Two Full-Scale Wind Tunnel Tests: Volume I

This report presents the data acquired during the testing of an individual blade control (IBC) system on a full-scale helicopter rotor in two test entries in the NASA Ames 40- by 80-Foot Wind Tunnel. The objective of these investigations was to evaluate the potential benefits of using IBC to improve rotor performance, reduce blade vortex interaction (BVI) noise, and alleviate helicopter vibrations. The wind tunnel tests were an international, collaborative effort between NASA, the U.S. Army Aeroflightdynamics Directorate, ZF Luftfahrttechnik GmbH, Eurocopter Deutschland GmbH, and the German Aerospace Laboratory (DLR). They were conducted as a task of the U.S./German Memorandum of Understanding (MOU) on Helicopter Aeromechanics. The IBC tests were performed using a full-scale BO-105 helicopter rotor mounted to the NASA/U.S. Army Rotor Test Apparatus (RTA). The first test, performed in 1993, was the first full-scale wind tunnel test to explore the effects of an IBC system on rotor vibration, noise, and performance. In this test, the pitch links of the rotor were replaced by servo-actuators. The servo-actuators and IBC control system were designed and manufactured by ZF Luftfahrttechnik GmbH. This control system allowed the pitch of each rotor blade to be changed independently of the other blades. The IBC inputs had large effects on the hub vibrations and BVI noise. However, the rotor hub moments were not retrimmed with each new IBC input. This resulted in an out-of-trim rotor configuration. The same IBC system was used in the second IBC test performed in 1994. This test more carefully investigated the potential of IBC to simultaneously reduce noise and vibration and also investigated the effect of IBC on rotor performance in high-speed-cruise flight. In the 1994 test, the hub moment and rotor thrust were readjusted to maintain rotor trim as the IBC inputs were applied. For this reason, the data taken from the second test are considered to be more accurate, except for some unique IBC input combinations not repeated in the second test. IBC controls that were evaluated were single-frequency inputs from 2/rev to 6/rev and multi-harmonic combinations of these frequencies to form pulses, wavelets, and doublets. Extensive data were acquired for each IBC data point. These data included rotor performance, average and time-varying hub loads, rotor blade bending loads, control system loads, inboard and outboard blade pitch motions, and BVI noise data. The rotor balance hub force and moment data included the mean values, half-peak-to-peak values, and sine/cosine harmonics up to the 20th rotor harmonic. The time history and averaged Fourier spectrum for each measurement are available electronically from NASA Ames Research Center. The data indicate that significant reduction in both BVI noise and hub vibration can be obtained using IBC. The 2/rev input produced the best single-frequency results. At a typical descent flight condition, 2/rev IBC combined with other IBC harmonics reduced the BVI noise up to 12 dB (85 percent) at some microphone locations. At the same time, this input could also reduce the dominant 4/rev vibratory hub loads by up to 75 percent. The data also show that performance improvements of up to 7 percent were obtained using 2/rev IBC at high-speed forward flight conditions. An analysis of the hydraulic power requirements for BVI noise suppression, vibration reduction, and rotor performance improvement is included in this report. This analysis shows that the power required by the IBC system is negligible at low-speed flight conditions, and that a net gain of 3 percent of rotor horsepower can be achieved at high-speed flight conditions.

Investigation↗

Passive Thermal Design Approach for the Space Communications and Navigation (SCaN) Testbed Experiment on the International Space Station (ISS)

The Space Communications and Navigation (SCaN) Program Office at NASA Headquarters oversees all of NASAs space communications activities. SCaN manages and directs the ground-based facilities and services provided by the Deep Space Network (DSN), Near Earth Network (NEN), and the Space Network (SN). Through the SCaN Program Office, NASA GRC developed a Software Defined Radio (SDR) testbed experiment (SCaN testbed experiment) for use on the International Space Station (ISS). It is comprised of three different SDR radios, the Jet Propulsion Laboratory (JPL) radio, Harris Corporation radio, and the General Dynamics Corporation radio. The SCaN testbed experiment provides an on-orbit, adaptable, SDR Space Telecommunications Radio System (STRS) - based facility to conduct a suite of experiments to advance the Software Defined Radio, Space Telecommunications Radio Systems (STRS) standards, reduce risk (Technology Readiness Level (TRL) advancement) for candidate Constellation future space flight hardware software, and demonstrate space communication links critical to future NASA exploration missions. The SCaN testbed project provides NASA, industry, other Government agencies, and academic partners the opportunity to develop and field communications, navigation, and networking technologies in the laboratory and space environment based on reconfigurable, software defined radio platforms and the STRS Architecture.The SCaN testbed is resident on the P3 Express Logistics Carrier (ELC) on the exterior truss of the International Space Station (ISS). The SCaN testbed payload launched on the Japanese Aerospace Exploration Agency (JAXA) H-II Transfer Vehicle (HTV) and was installed on the ISS P3 ELC located on the inboard RAM P3 site. The daily operations and testing are managed out of NASA GRC in the Telescience Support Center (TSC).

Passive Thermal Design↗

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗