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Demonstration of a Large-Scale Tank Assembly via Circumferential Friction Stir Welds

A collaborative effort between NASA/Marshall Space Flight Center and the Michoud Unit of Lockheed Martin Space Systems Company was undertaken to demonstrate assembly of a large-scale aluminum tank using circumferential friction stir welds. The hardware used to complete this demonstration was fabricated as a study of near-net- shape technologies. The tooling used to complete this demonstration was originally designed for assembly of a tank using fusion weld processes. This presentation describes the modifications and additions that were made to the existing fusion welding tools required to accommodate circumferential friction stir welding, as well as the process used to assemble the tank. The tooling modifications include design, fabrication and installation of several components. The most significant components include a friction stir weld unit with adjustable pin length capabilities, a continuous internal anvil for 'open' circumferential welds, a continuous closeout anvil, clamping systems, an external reaction system and the control system required to conduct the friction stir welds and integrate the operation of the tool. The demonstration was intended as a development task. The experience gained during each circumferential weld was applied to improve subsequent welds. Both constant and tapered thickness 14-foot diameter circumferential welds were successfully demonstrated.

Jones, Clyde S.

Space Solar Power Concepts: Demonstrations to Pilot Plants

The availability of abundant, affordable power where needed is a key to the future exploration and development of space as well as future sources of clean terrestrial power. One innovative approach to providing such power is the use of wireless power transmission (WPT). There are at least two possible WPT methods that appear feasible; microwave and laser. Microwave concepts have been generated, analyzed and demonstrated. Technologies required to provide an end-to-end system have been identified and roadmaps generated to guide technology development requirements. Recently, laser W T approaches have gained an increased interest. These approaches appear to be very promising and will possibly solve some of the major challenges that exist with the microwave option. Therefore, emphasis is currently being placed on the laser WPT activity. This paper will discuss the technology requirements, technology roadmaps and technology flight experiments demonstrations required to lead toward a pilot plant demonstration. Concepts will be discussed along with the modeling techniques that are used in developing them. Feasibility will be addressed along with the technology needs, issues and capabilities for particular concepts. Flight experiments and demonstrations will be identified that will pave the road from demonstrations to pilot plants and beyond.

Carrington, Connie K.

Affordable Flight Demonstration of the GTX Air-Breathing SSTO Vehicle Concept

The rocket based combined cycle (RBCC) powered single-stage-to-orbit (SSTO) reusable launch vehicle has the potential to significantly reduce the total cost per pound for orbital payload missions. To validate overall system performance, a flight demonstration must be performed. This paper presents an overview of the first phase of a flight demonstration program for the GTX SSTO vehicle concept. Phase 1 will validate the propulsion performance of the vehicle configuration over the supersonic and hypersonic air- breathing portions of the trajectory. The focus and goal of Phase 1 is to demonstrate the integration and performance of the propulsion system flowpath with the vehicle aerodynamics over the air-breathing trajectory. This demonstrator vehicle will have dual mode ramjetkcramjets, which include the inlet, combustor, and nozzle with geometrically scaled aerodynamic surface outer mold lines (OML) defining the forebody, boundary layer diverter, wings, and tail. The primary objective of this study is to demon- strate propulsion system performance and operability including the ram to scram transition, as well as to validate vehicle aerodynamics and propulsion airframe integration. To minimize overall risk and develop ment cost the effort will incorporate proven materials, use existing turbomachinery in the propellant delivery systems, launch from an existing unmanned remote launch facility, and use basic vehicle recovery techniques to minimize control and landing requirements. A second phase would demonstrate propulsion performance across all critical portions of a space launch trajectory (lift off through transition to all-rocket) integrated with flight-like vehicle systems.

Krivanek, Thomas M.

Orbital Space Plane Program Flight Demonstrators Status

Under the Orbital Space Plane Program, NASA is currently pursuing the maturation of technologies via three flight demonstrators - DART (Demonstration of Autonomous Rendezvous Technology), X-37, and PAD (Pad Abort Demonstrator). Flight demonstrators provide the opportunity to test key technologies in their actual working environment. These flight demonstrators are required at this stage to mature technologies needed to support full-scale development design of a future competitively selected Orbital Space.

Turner, Susan G.

Technology Development and Demonstration Concepts for the Space Elevator

During the 1990s several discoveries and advances in the development of carbon nano-tube (CNT) materials indicated that material strengths many times greater than common high-strength composite materials might be possible. Progress in the development of this material led to renewed interest in the space elevator concept for construction of a tether structure from the surface of the Earth through a geostationary orbit (GEO) and thus creating a new approach to Earth-to-orbit transportation infrastructures. To investigate this possibility the author, in 1999, managed for NASA a space elevator work:hop at the Marshall Space Flight Center to explore the potential feasibility of space elevators in the 21 century, and to identify the critical technologies and demonstration missions needed to make development of space elevators feasible. Since that time, a NASA Institute for Advanced Concepts (NIAC) funded study of the Space Elevator proposed a concept for a simpler first space elevator system using more near-term technologies. This paper will review some of the latest ideas for space elevator development, the critical technologies required, and some of the ideas proposed for demonstrating the feasibility for full-scale development of an Earth to GEO space elevator. Critical technologies include CNT composite materials, wireless power transmission, orbital object avoidance, and large-scale tether deployment and control systems. Numerous paths for technology demonstrations have been proposed utilizing ground experiments, air structures. LEO missions, the space shuttle, the international Space Station, GEO demonstration missions, demonstrations at the lunar L1 or L2 points, and other locations. In conclusion, this paper finds that the most critical technologies for an Earth to GEO space elevator include CNT composite materials development and object avoidance technologies; that lack of successful development of these technologies need not preclude continued development of space elevator systems in general; and that the critical technologies required for the Earth to GEO space elevator are not required for similar systems at the Moon, Mars, Europa, or for orbital tether systems at GEO, Luna, and other locations.

Smitherman, David V., Jr.

Traveling Wave Tube (TVT) RF Power Combining Demonstration for use in the Jupiter Icy Moons Orbiter (JIMO)

The Jupiter Icy Moons Orbiter (JIMO) is set to launch between the years 2012 and 2015. It will possibly utilize a nuclear reactor power source and ion engines as it travels to the moons of Jupiter. The nuclear reactor will produce hundreds of kilowatts of power for propulsion, communication and various scientific instruments. Hence, the RF amplification devices aboard will be able to operate at a higher power level and data rate. The initial plan for the communications system is for an output of 1000 watts of RF power, a data rate of at least 10 megabits a second, and a frequency of 32 GHz. A higher data rate would be ideal to fully utilize the instruments aboard JIMO. At NASA Glenn, one of our roles in the JIMO project is to demonstrate RF power combining using multiple traveling wave tubes (TWT). In order for the power of separate TWT s to be combined, the RF output waves from each must be in-phase and have the same amplitude. Since different tubes act differently, we had to characterize each tube using a Network Analyzer. We took frequency sweeps and power sweeps to characterize each tube to ensure that they will behave similarly under the same conditions. The 200 watt Dornier tubes had been optimized to run at a lower power level (120 watts) for their extensive use in the ACTS program, so we also had to experiment with adjusting the voltage settings on several internal components (helix, anode, collector) of the tubes to reach the full 200 watt potential. from the ACTS program. Phase shifters and power attenuators were placed in the waveguide circuit at the inputs to the tubes so that adjustments could be made individually to match them exactly. A magic tee was used to route and combine the amplified electromagnetic RF waves on the tube output side. The demonstration of 200 watts of combined power was successful with efficiencies greater than 90% over a 500 MHz bandwidth. The next step will be to demonstrate the use of three amplifiers using two magic tees by adding a 200 watt Dornier tube to the Varian and Logimetrics combined setup for a total of 400 watts. After that we will use two 200 watt Dorniers for 400 watts and eventually four 200 watt Dornier tubes to demonstrate 800 watts. After demonstrating the success of power combining, we will need to verify the integrity of a modulated signal sent through the combined tubes. The purpose will be to see what effects separating and recombining will have on the modulated signal and also what effect it will have on combining efficiency. A Bit Error Rate (BER) will be determined by a Bit Error Rate Tester (BERT) by comparing the random information it transmits to what it receives back. The process began with two 100 watt tubes, a Varian and a Logimetrics, salvaged

Downey, Joseph A.

Integrated Components Technology Demonstrations Overview

Integrated Components Technology Demonstrations (ICTD) is a project under the Ultra-Efficient Engine Technology Program (UEET) as designated in the UEET Program Commitment Agreement. The ICTD Project will provide the opportunity to conduct technology demonstration tests of advanced turbine engine components (e.g., combustor, compressor, turbine, and materials) as part of an integrated system (TRL 6). Initially, the major objectives of the Integrated Components Technology Demonstrations project are to Conduct component technology evaluation and system studies to determine, and prioritize, the most promising propulsion concepts, cycle, and architecture for a propulsion system with a Technology Availability Date of approximately 2010 and Entry Into Service of 2015. Determine the most attractive, cost-effective approaches for conducting the needed demonstration tests. Conduct demonstration tests of selected component technologies (i.e.,2200 F CMC combustor liner and aspirating seal) in partnership with industry.

Long-Davis, Mary Jo

Aerospace Communications Security Technologies Demonstrated

In light of the events of September 11, 2001, NASA senior management requested an investigation of technologies and concepts to enhance aviation security. The investigation was to focus on near-term technologies that could be demonstrated within 90 days and implemented in less than 2 years. In response to this request, an internal NASA Glenn Research Center Communications, Navigation, and Surveillance Aviation Security Tiger Team was assembled. The 2-year plan developed by the team included an investigation of multiple aviation security concepts, multiple aircraft platforms, and extensively leveraged datalink communications technologies. It incorporated industry partners from NASA's Graphical Weather-in-the-Cockpit research, which is within NASA's Aviation Safety Program. Two concepts from the plan were selected for demonstration: remote "black box," and cockpit/cabin surveillance. The remote "black box" concept involves real-time downlinking of aircraft parameters for remote monitoring and archiving of aircraft data, which would assure access to the data following the loss or inaccessibility of an aircraft. The cockpit/cabin surveillance concept involves remote audio and/or visual surveillance of cockpit and cabin activity, which would allow immediate response to any security breach and would serve as a possible deterrent to such breaches. The datalink selected for the demonstrations was VDL Mode 2 (VHF digital link), the first digital datalink for air-ground communications designed for aircraft use. VDL Mode 2 is beginning to be implemented through the deployment of ground stations and aircraft avionics installations, with the goal of being operational in 2 years. The first demonstration was performed December 3, 2001, onboard the LearJet 25 at Glenn. NASA worked with Honeywell, Inc., for the broadcast VDL Mode 2 datalink capability and with actual Boeing 757 aircraft data. This demonstration used a cockpitmounted camera for video surveillance and a coupling to the intercom system for audio surveillance. Audio, video, and "black box" data were simultaneously streamed to the ground, where they were displayed to a Glenn audience of senior management and aviation security team members.

Griner, James H.

Cooperative Collision Avoidance Technology Demonstration Data Analysis Report

This report details the National Aeronautics and Space Administration (NASA) Access 5 Project Office Cooperative Collision Avoidance (CCA) Technology Demonstration for unmanned aircraft systems (UAS) conducted from 21 to 28 September 2005. The test platform chosen for the demonstration was the Proteus Optionally Piloted Vehicle operated by Scaled Composites, LLC, flown out of the Mojave Airport, Mojave, CA. A single intruder aircraft, a NASA Gulf stream III, was used during the demonstration to execute a series of near-collision encounter scenarios. Both aircraft were equipped with Traffic Alert and Collision Avoidance System-II (TCAS-II) and Automatic Dependent Surveillance Broadcast (ADS-B) systems. The objective of this demonstration was to collect flight data to support validation efforts for the Access 5 CCA Work Package Performance Simulation and Systems Integration Laboratory (SIL). Correlation of the flight data with results obtained from the performance simulation serves as the basis for the simulation validation. A similar effort uses the flight data to validate the SIL architecture that contains the same sensor hardware that was used during the flight demonstration.

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Demonstration of Active Combustion Control

The primary objective of this effort was to demonstrate active control of combustion instabilities in a direct-injection gas turbine combustor that accurately simulates engine operating conditions and reproduces an engine-type instability. This report documents the second phase of a two-phase effort. The first phase involved the analysis of an instability observed in a developmental aeroengine and the design of a single-nozzle test rig to replicate that phenomenon. This was successfully completed in 2001 and is documented in the Phase I report. This second phase was directed toward demonstration of active control strategies to mitigate this instability and thereby demonstrate the viability of active control for aircraft engine combustors. This involved development of high-speed actuator technology, testing and analysis of how the actuation system was integrated with the combustion system, control algorithm development, and demonstration testing in the single-nozzle test rig. A 30 percent reduction in the amplitude of the high-frequency (570 Hz) instability was achieved using actuation systems and control algorithms developed within this effort. Even larger reductions were shown with a low-frequency (270 Hz) instability. This represents a unique achievement in the development and practical demonstration of active combustion control systems for gas turbine applications.

Lovett, Jeffrey A.

NASA Technology Demonstrations Missions Program Overview

The National Aeronautics and Space Administration (NASA) Fiscal Year 2010 (FY10) budget introduced a new strategic plan that placed renewed emphasis on advanced missions beyond Earth orbit. This supports NASA s 2011 strategic goal to create innovative new space technologies for our exploration, science, and economic future. As a result of this focus on undertaking many and more complex missions, NASA placed its attention on a greater investment in technology development, and this shift resulted in the establishment of the Technology Demonstrations Missions (TDM) Program. The TDM Program, within the newly formed NASA Office of the Chief Technologist, supports NASA s grand challenges by providing a steady cadence of advanced space technology demonstrations (Figure 1), allowing the infusion of flexible path capabilities for future exploration. The TDM Program's goal is to mature crosscutting capabilities to flight readiness in support of multiple future space missions, including flight test projects where demonstration is needed before the capability can transition to direct mission The TDM Program has several unique criteria that set it apart from other NASA program offices. For instance, the TDM Office matures a small number of technologies that are of benefit to multiple customers to flight technology readiness level (TRL) 6 through relevant environment testing on a 3-year development schedule. These technologies must be crosscutting, which is defined as technology with potential to benefit multiple mission directorates, other government agencies, or the aerospace industry, and they must capture significant public interest and awareness. These projects will rely heavily on industry partner collaboration, and funding is capped for all elements of the flight test demonstration including planning, hardware development, software development, launch costs, ground operations, and post-test assessments. In order to inspire collaboration across government and industry, more than 70% of the TDM funds will be competitively awarded as a result of yearly calls for proposed flight demonstrators and selected based on possible payoff to NASA, technology maturity, customer interest, cost, and technical risk reduction. This paper will give an overview of the TDM Program s mission and organization, as well as its current status in delivering advanced space technologies that will enable more flexible and robust future missions. It also will provide several examples of missions that fit within these parameters and expected outcomes.

Turner, Susan

Demonstration of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Burke, Kenneth A.

Integrated Ground Operations Demonstration for Responsive Space Access

Integrated Ground Operations Demonstration Units (IGODU) project developed to mature, integrate and demonstrate advancements in cryogenics, system health management and command and control technologies. Two Distinct Testing Environments: a) GODU Integrated Refrigeration and Storage - GODU LH2; b) GODU Autonomous Control - GODU LO2. Scope: I. GODU LH2: a) Investigate alternative storage and distribution architecture for future cryogenic propellant operations. b) Demonstrate advanced cryogenic propellant handling operations (liquefaction, storage and distribution) of normal boiling point and sub-cooled cryogenic propellants. II. GODU L02: a) Develop and demonstrate advanced control and health management technologies and techniques to autonomously control cryogenic propellant servicing operations. b) Investigate modern COTS hardware and control systems in an effort to reduce the "standing army" of engineers associated with maintaining and operating ground systems through the use of health management and autonomous control technologies. Goals: a) Raise Technology Readiness Levels (TRL) and Integration Readiness Levels (IRL) of several key technology development areas. b) Reduce operations lifecycle costs of future test programs and launch complexes. c) Demonstrate technologies for future exploration beyond low earth orbit. d) Serve as test environments for extraterrestrial surface operations.

Johnson, Robert G.

Cryogenic Propellant Storage and Transfer (CPST) Technology Maturation: Establishing a Foundation for a Technology Demonstration Mission (TDM)

As part of U.S. National Space Policy, NASA is seeking an innovative path for human space exploration, which strengthens the capability to extend human and robotic presence throughout the solar system. NASA is laying the groundwork to enable humans to safely reach multiple potential destinations, including asteroids, Lagrange points, the Moon and Mars. In support of this, NASA is embarking on the Technology Demonstration Mission Cryogenic Propellant Storage and Transfer (TDM CPST) Project to test and validate key cryogenic capabilities and technologies required for future exploration elements, opening up the architecture for large cryogenic propulsion stages (CPS) and propellant depots. The TDM CPST project will provide an on-orbit demonstration of the capability to store, transfer, and measure cryogenic propellants for a duration which is relevant to enable long term human space exploration missions beyond low Earth orbit (LEO). Recognizing that key cryogenic fluid management technologies anticipated for on-orbit (flight) demonstration needed to be matured to a readiness level appropriate for infusion into the design of the flight demonstration, the NASA Headquarters Space Technology Mission Directorate authorized funding for a one-year (FY12) ground based technology maturation program. The strategy, proposed by the CPST Project Manager, focused on maturation through modeling, studies, and ground tests of the storage and fluid transfer Cryogenic Fluid Management (CFM) technology sub-elements and components that were not already at 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. This paper will present the testing, studies, and modeling that occurred in FY12 to mature cryogenic fluid management technologies for propellant storage, transfer, and supply, to examine extensibility to full scale, long duration missions, and to develop and validate analytical models. Finally, the paper will briefly describe an upcoming test to demonstrate Liquid Oxygen (LO2) Zero Boil- Off (ZBO).

Doherty, Michael P.

CO2 Reduction Assembly Prototype Using Microlith-Based Sabatier Reactor for Ground Demonstration

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA's cabin Atmosphere Revitalization System (ARS) and In-Situ Resource Utilization (ISRU) architectures for both low-earth orbit and long-term manned space missions. Carbon dioxide can be reacted with H2, obtained from the electrolysis of water, via Sabatier reaction to produce methane and H2O. Methane can be stored and utilized as propellant while H2O can be either stored or electrolyzed to produce oxygen and regain the hydrogen atoms. Depending on the application, O2 can be used to replenish the atmosphere in human-crewed missions or as an oxidant for robotic and return missions. Precision Combustion, Inc. (PCI), with support from NASA, has previously developed an efficient and compact Sabatier reactor based on its Microlith® catalytic technology and demonstrated the capability to achieve high CO2 conversion and CH4 selectivity (i.e., ≥90% of the thermodynamic equilibrium values) at high space velocities and low operating temperatures. This was made possible through the use of high-heat-transfer and high-surface-area Microlith catalytic substrates. Using this Sabatier reactor, PCI designed, developed, and demonstrated a stand-alone CO2 Reduction Assembly (CRA) test system for ground demonstration and performance validation. The Sabatier reactor was integrated with the necessary balance-of-plant components and controls system, allowing an automated, single "push-button" start-up and shutdown. Additionally, the versatility of the test system prototype was demonstrated by operating it under H2-rich (H2/CO2 of >4), stoichiometric (ratio of 4), and CO2-rich conditions (ratio of <4) without affecting its performance and meeting the equilibrium-predicted water recovery rates. In this paper, the development of the CRA test system for ground demonstration will be discussed. Additionally, the performance results from testing the system at various operating conditions and the results from durability testing will be presented.

Junaedi, Christian

Cryogenic Propellant Storage and Transfer (CPST) Technology Maturation: Establishing a Foundation for a Technology Demonstration Mission (TDM)

As part of U.S. National Space Policy, NASA is seeking an innovative path for human space exploration, which strengthens the capability to extend human and robotic presence throughout the solar system. NASA is laying the groundwork to enable humans to safely reach multiple potential destinations, including asteroids, Lagrange points, the Moon and Mars. In support of this, NASA is embarking on the Technology Demonstration Mission Cryogenic Propellant Storage and Transfer (TDM CPST) Project to test and validate key cryogenic capabilities and technologies required for future exploration elements, opening up the architecture for large cryogenic propulsion stages (CPS) and propellant depots. The TDM CPST project will provide an on-orbit demonstration of the capability to store, transfer, and measure cryogenic propellants for a duration which is relevant to enable long term human space exploration missions beyond low Earth orbit (LEO). Recognizing that key cryogenic fluid management technologies anticipated for on-orbit (flight) demonstration needed to be matured to a readiness level appropriate for infusion into the design of the flight demonstration, the NASA Headquarters Space Technology Mission Directorate authorized funding for a one-year (FY12) ground based technology maturation program. The strategy, proposed by the CPST Project Manager, focused on maturation through modeling, studies, and ground tests of the storage and fluid transfer Cryogenic Fluid Management (CFM) technology sub-elements and components that were not already at 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. This paper will present the testing, studies, and modeling that occurred in FY12 to mature cryogenic fluid management technologies for propellant storage, transfer, and supply, to examine extensibility to full scale, long duration missions, and to develop and validate analytical models. Finally, the paper will briefly describe an upcoming test to demonstrate Liquid Oxygen (LO2) Zero Boil-Off (ZBO).

Doherty, Michael P.

Development of the Optical Communications Telescope Laboratory: A Laser Communications Relay Demonstration Ground Station

The Laser Communications Relay Demonstration (LCRD) project will demonstrate high bandwidth space to ground bi-directional optical communications links between a geosynchronous satellite and two LCRD optical ground stations located in the southwestern United States. The project plans to operate for two years with a possible extension to five. Objectives of the demonstration include the development of operational strategies to prototype optical link and relay services for the next generation tracking and data relay satellites. Key technologies to be demonstrated include adaptive optics to correct for clear air turbulence-induced wave front aberrations on the downlink, and advanced networking concepts for assured and automated data delivery. Expanded link availability will be demonstrated by supporting operations at small sun-Earth-probe angles. Planned optical modulation formats support future concepts of near-Earth satellite user services to a maximum of 1.244 Gb/s differential phase shift keying modulation and pulse position modulations formats for deep space links at data rates up to 311 Mb/s. Atmospheric monitoring instruments that will characterize the optical channel during the link include a sun photometer to measure atmospheric transmittance, a solar scintillometer, and a cloud camera to measure the line of sight cloud cover. This paper describes the planned development of the JPL optical ground station.

optical commuication

Fabrication of the HIAD Large-Scale Demonstration Assembly and Upcoming Mission Applications

Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) deployable aeroshell system and associated analytical tools. NASAs HIAD project team has developed, fabricated, and tested inflatable structures (IS) integrated with flexible thermal protection system (F-TPS), ranging in diameters from 3-6m, with cone angles of 60 and 70 deg.In 2015, United Launch Alliance (ULA) announced that they will use a HIAD (10-12m) as part of their Sensible, Modular, Autonomous Return Technology (SMART) for their upcoming Vulcan rocket. ULA expects SMART reusability, coupled with other advancements for Vulcan, will substantially reduce the cost of access to space. The first booster engine recovery via HIAD is scheduled for 2024. To meet this near-term need, as well as future NASA applications, the HIAD team is investigating taking the technology to the 10-15m diameter scale.In the last year, many significant development and fabrication efforts have been accomplished, culminating in the construction of a large-scale inflatable structure demonstration assembly. This assembly incorporated the first three tori for a 12m Mars Human-Scale Pathfinder HIAD conceptual design that was constructed with the current state of the art material set. Numerous design trades and torus fabrication demonstrations preceded this effort. In 2016, three large-scale tori (0.61m cross-section) and six subscale tori (0.25m cross-section) were manufactured to demonstrate fabrication techniques using the newest candidate material sets. These tori were tested to evaluate durability and load capacity. This work led to the selection of the inflatable structures third generation (Gen-3) structural liner. In late 2016, the three tori required for the large-scale demonstration assembly were fabricated, and then integrated in early 2017. The design includes provisions to add the remaining four tori necessary to complete the assembly of the 12m Human-Scale Pathfinder HIAD in the event future project funding becomes available.This presentation will discuss the HIAD large-scale demonstration assembly design and fabrication per-formed in the last year including the precursor tori development and the partial-stack fabrication. Potential near-term and future 10-15m HIAD applications will also be discussed.

Swanson, G. T.