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Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

DeVieneni, Alayna↗

Environmental Barrier Coating (EBC) Durability Modeling; An Overview and Preliminary Analysis

A study outlining a fracture mechanics based model that is being developed to investigate crack growth and spallation of environmental barrier coating (EBC) under thermal cycling conditions is presented. A description of the current plan and a model to estimate thermal residual stresses in the coating and preliminary fracture mechanics concepts for studying crack growth in the coating are also discussed. A road map for modeling life and durability of the EBC and the results of FEA model(s) developed for predicting thermal residual stresses and the cracking behavior of the coating are generated and described. Further initial assessment and preliminary results showed that developing a comprehensive EBC life prediction model incorporating EBC cracking, degradation and spalling mechanism under stress and temperature gradients typically seen in turbine components is difficult. This is basically due to mismatch in thermal expansion difference between sub-layers of EBC as well as between EBC and substrate, diffusion of moisture and oxygen though the coating, and densification of the coating during operating conditions as well as due to foreign object damage, the EBC can also crack and spall from the substrate causing oxidation and recession and reducing the design life of the EBC coated substrate.

Abdul-Aziz, A.↗

Thermal Vacuum Test Correlation of A Zero Propellant Load Case Thermal Capacitance Propellant Gauging Analytics Model

This thesis describes the development and test data validation of the thermal model that is the foundation of a thermal capacitance spacecraft propellant load estimator. Specific details of creating the thermal model for the diaphragm propellant tank used on NASA's Magnetospheric Multiscale spacecraft using ANSYS and the correlation process implemented to validate the model are presented. The thermal model was correlated to within plus or minus 3 degrees Centigrade of the thermal vacuum test data, and was found to be relatively insensitive to uncertainties in applied heat flux and mass knowledge of the tank. More work is needed, however, to refine the thermal model to further improve temperature predictions in the upper hemisphere of the propellant tank. Temperatures predictions in this portion were found to be 2-2.5 degrees Centigrade lower than the test data. A road map to apply the model to predict propellant loads on the actual MMS spacecraft toward its end of life in 2017-2018 is also presented.

Thermal↗

Thermal Vacuum Test Correlation of a Zero Propellant Load Case Thermal Capacitance Propellant Gauging Analytical Model

This thesis describes the development and correlation of a thermal model that forms the foundation of a thermal capacitance spacecraft propellant load estimator. Specific details of creating the thermal model for the diaphragm propellant tank used on NASA's Magnetospheric Multiscale spacecraft using ANSYS and the correlation process implemented are presented. The thermal model was correlated to within plus or minus 3 degrees Celsius of the thermal vacuum test data, and was determined sufficient to make future propellant predictions on MMS. The model was also found to be relatively sensitive to uncertainties in applied heat flux and mass knowledge of the tank. More work is needed to improve temperature predictions in the upper hemisphere of the propellant tank where predictions were found to be 2 to 2.5 C lower than the test data. A road map for applying the model to predict propellant loads on the actual MMS spacecraft toward its end of life in 2017-2018 is also presented.

Gauging↗

On-Demand Mobility (ODM) Technical Pathway: Enabling Ease of Use and Safety

On-demand mobility (ODM) through aviation refers to the ability to quickly and easily move people or equivalent cargo without delays introduced by lack of, or infrequently, scheduled service. A necessary attribute of ODM is that it be easy to use, requiring a minimum of special training, skills, or workload. Fully-autonomous vehicles would provide the ultimate in ease-of-use (EU) but are currently unproven for safety-critical applications outside of a few, situationally constrained applications (e.g. automated trains operating in segregated systems). Applied to aviation, the current and near-future state of the art of full-autonomy, may entail undesirable trade-offs such as very conservative operational margins resulting in reduced trip reliability and transportation utility. Furthermore, acceptance by potential users and regulatory authorities will be challenging without confidence in autonomous systems in developed in less critical, but still challenging applications. A question for the aviation community is how we can best develop practical ease-of-use for aircraft that are sized to carry a small number of passengers (e.g. 1-9) or equivalent cargo. Such development is unlikely to be a single event, but rather a managed, evolutionary process where responsibility and authority transitions from human to automation agents as operational experience is gained with increasingly intelligent systems. This talk presents a technology road map being developed at NASA Langley, as part of an overall strategy to foster ODM, for the development of ease-of-use for ODM aviation.

Goodrich, Ken↗

A Quantum Annealing Computer Team Addresses Climate Change Predictability

The near confluence of the successful launch of the Orbiting Carbon Observatory2 on July 2, 2014 and the acceptance on August 20, 2015 by Google, NASA Ames Research Center and USRA of a 1152 qubit D-Wave 2X Quantum Annealing Computer (QAC), offered an exceptional opportunity to explore the potential of this technology to address the scientific prediction of global annual carbon uptake by land surface processes. At UMBC,we have collected and processed 20 months of global Level 2 light CO2 data as well as fluorescence data. In addition we have collected ARM data at 2sites in the US and Ameriflux data at more than 20 stations. J. Dorband has developed and implemented a multi-hidden layer Boltzmann Machine (BM) algorithm on the QAC. Employing the BM, we are calculating CO2 fluxes by training collocated OCO-2 level 2 CO2 data with ARM ground station tower data to infer to infer measured CO2 flux data. We generate CO2 fluxes with a regression analysis using these BM derived weights on the level 2 CO2 data for three Ameriflux sites distinct from the ARM stations. P. Gentine has negotiated for the access of K34 Ameriflux data in the Amazon and is applying a neural net to infer the CO2 fluxes. N. Talik validated the accuracy of the BM performance on the QAC against a restricted BM implementation on the IBM Softlayer Cloud with the Nvidia co-processors utilizing the same data sets. G. Nearing and K. Harrison have extended the GSFC LIS model with the NCAR Noah photosynthetic parameterization and have run a 10 year global prediction of the net ecosystem exchange. C. Pellisier is preparing a BM implementation of the Kalman filter data assimilation of CO2 fluxes. At UMBC, R. Prouty is conducting OSSE experiments with the LISNoah model on the IBM iDataPlex to simulate the impact of CO2 fluxes to improve the prediction of global annual carbon uptake. J. LeMoigne and D. Simpson have developed a neural net image registration system that will be used for MODIS ENVI and will be converted to a BM algorithm implementation on the QAC. The first integer adder has been implemented on the D-Wave 2X by A. Shehab that will perform HAAR wavelets for image compression of MODIS scenes. Finally, based on the next generations of QACs, we are preparing a 5-year performance road map on the scalability of the current QAC algorithms.

Science Data Processing↗

NASA's Advanced Solar Sail Propulsion System for Low-Cost Deep Space Exploration and Science Missions that Use High Performance Rollable Composite Booms

Several low-cost solar sail technology demonstrator missions are under development in the United States. However, the mass saving derived benefits that composites can offer to such a mass critical spacecraft architecture have not been realized yet. This is due to the lack of suitable composite booms that can fit inside CubeSat platforms and ultimately be readily scalable to much larger sizes, where they can fully optimize their use. With this aim, a new effort focused at developing scalable rollable composite booms for solar sails and other deployable structures has begun. Seven meter booms used to deploy a 90 m2 class solar sail that can fit inside a 6U CubeSat have already been developed. The NASA road map to low-cost solar sail capability demonstration envisioned, consists of increasing the size of these composite booms to enable sailcrafts with a reflective area of up to 2000 m2 housed aboard small satellite platforms. This paper presents a solar sail system initially conceived to serve as a risk reduction alternative to Near Earth Asteroid (NEA) Scout's baseline design but that has recently been slightly redesigned and proposed for follow-on missions. The features of the booms and various deployment mechanisms for the booms and sail, as well as ground support equipment used during testing, are introduced. The results of structural analyses predict the performance of the system under microgravity conditions. Finally, the results of the functional and environmental testing campaign carried out are shown.

Fernandez, Juan M.↗

Ionic Polyimides: New High Performance Polymers for Additive Manufacturing

There is currently a very limited set of engineering polymers that have been demonstrated as viable for use in 3-D printing. Additive manufacturing of custom components will require a much larger array of polymers, especially those with physical, thermal, chemical, and mechanical properties that can be tailor-made. The development of ‘Ionic Polyimides’ offers a solution to this shortage by combining the well understood and widely accepted properties of conventional polyimides, with a new approach to polymer synthesis. Polyimides and polymeric ionic liquids (poly(ILs)) are at the forefront of advanced polymer materials, each with their own set of advantages and disadvantages. While it is clear that more types of polymer materials are needed for fused deposition modeling (FDM) additive manufacturing, there is a need to explore these classes of materials. The synthesis process developed by the Bara Research Group at the University of Alabama allows full control over polymer structure, nanostructure, thermal, electrical, and physical properties making them a prime candidate for use in the additive manufacturing process. Furthermore, the new process allows us to tailor-make a high strength polymer that can be used to fabricate filament feedstock instead of pellets for 3D printing. The primary objective of this proposal is to determine the relationship between molecular structure, physical properties, and performance of ionic polyimides. Further, we seek to determine their utility as materials suitable for additive manufacturing of components used in aerospace vehicles, with an emphasis on characterizing and simulating their thermal behaviors and properties. This proposal addresses the need for fundamental research on a customizable polymer filament feedstock for 3-D printing with tailor-made properties potentially making it superior to the commercial blends offered in industry today. The deliverables for this project are the creation of a database that will detail the relationships between the molecular structure and physical properties for the ionic polyimide of interest (e.g. Tg/Tm (Glass Transition Temperature divided by Melting Point)) relative to different ionic polyimide structures). This new database will provide a “road map” to the development of the first generation of materials and ultimately proof-of-concept.

Jackson, Enrique↗

NASA 2018 Green Propulsion Roadmap

The Green Propulsion Working Group (GPWG) is a technical guidance working group formed April 2017 under the Agency's Capability Leadership Team The GPWG was tasked with recommending an agency road map and providing guidance to NASA on green propulsion technology development and infusion The GPWG's efforts focus on ionic liquid propellants and related technologies The GPWG was chartered with three representatives from NASA Centers currently exploring green propulsion technologies As other Centers may explore programs that utilize green propulsion, membership of the working group can be expanded to include more interested parties Working group also solicits and coordinates with other government agencies (e.g. AFRL, MDA) In 2015, JANNAF hosted a Technical Interchange Meeting (TIM) on Green Monopropellant Alternatives to Hydrazine (GMAH) Included both Government and non-Government contributions on the State-of-the-Art in Green Propulsion Technology Following the TIM, a Government-only session (USAF/AFRL/NASA/MDA/DLA) reviewed and identified remaining technical gaps in Green Propulsion In 2016, an inter-agency team (AFRL/NASA/MDA) worked together to develop an informal inter-agency "roadmap" based on the outcome of the TIM Approach consisted of near-term, mid-term, and long-term technology advancement areas, approaching incrementally larger thrust classes The NASA Green Propulsion Working Group reviewed the work of the 2016 Inter-Agency Working Group, and concurs that the identified technical gaps and technology development areas are still relevant and necessary to see green propulsion technology advanced The GPWG recommends the 2016 roadmap be adopted as baseline for NASA needs, with some additions The focus of the 2016 inter-agency roadmap was primarily on the thruster technology. The Agency must also invest in understanding the broader propulsion system-level technology gaps in parallel. Timeframes are considered suggested from a priority standpoint, but are also flexible as some efforts will need to occur in the nearer term or concurrently in order to meet specific mission requirements The GPWG developed 2018 roadmap breaks down the technology development goals into Technology Development Areas (TDA's), and identifies the near-, mid, and long-term sub-goals within those areas. Those TDA's are: Thruster Hardware Development Modeling & Tools Development Materials Properties and Compatibility Propellant Development.

Cavender, Dan↗

NASA GMAO Integrated Earth System Analysis

An Integrated Earth System Analysis (IESA) is the only possible way to assimilate all the available observations of separate components of the earth system (atmosphere, ocean, cryosphere, land, constituents, etc) into a single consistent Coupled Data Assimilation System (CDAS). The NASA Global Modeling and Assimilation Office (GMAO) is developing an IESA for Reanalysis in an incremental fashion by coupling different components- one at a time, for e.g., the MERRA-2 reanalysis coupled aerosol and meteorological data assimilation systems. Following a similar approach the ocean (including sea-ice) is being coupled to the atmosphere, starting with the air-sea interface. This presentation briefly outlines GMAO's reanalysis road map and summarizes our recent work in that direction.

Akella, Santha↗

NASA’s Surface Deformation and Change Mission Study

The National Academies of Science, Engineering and Medicine 2017 Decadal Survey of Earth Science and Applications identified geodetic measurements of surface deformation and related change as one of the top five “observables” to be prioritized in NASA’s future program. In response, NASA commissioned a multi-center Surface Deformation and Change(SDC) team to perform a five year study of mission architectures that would support SDC observables and provide the most value to the diverse science and applications communities it serves. The study is being conducted in phases, in which the science and applications capabilities identified in the Decadal Survey are refined, candidate architectures and associated technologies to support these needs are identified, architectures are assessed against a science value framework specific to SDC, and recommendations to NASA are made. Ultimately, NASA will decide which amongst these recommendations will proceed to mission formulation. As synthetic aperture radar (SAR) was identified as the prime sensor technology to satisfy SDC observational needs, a key component of the SDC study is to assess the current state of the art in SAR sensor and supporting technology. The number of SAR systems, both civil and commercial, is growing rapidly, requiring that mission architectures not only consider technology, but availability of data from other missions, possible partnerships or collaborations, and even data purchase. The mechanism for assessment involves development of an end-to-end science performance evaluation tool for multi-satellite con-stellations, which feeds into a science value framework that con-siders science performance, technological programmatic risks, and cost. This paper will present an overview of the ongoing study including the candidate architectures and the technology road map needed to achieve the objectives of the mission.

Stephen Horst↗

NASA's Surface Deformation and Change Mission Study

The National Academies of Science, Engineering and Medicine 2017 Decadal Survey of Earth Science and Applications identified geodetic measurements of surface deformation and related change as one of the top five "observables" to be prioritized in NASA's program going forward. In response, NASA commissioned a multi-center Surface Deformation and Change (SDC) team to perform a five year study of mission architectures that would support SDC observables and provide the most value to the diverse science and applications communities it serves. The study is being conducted in phases, in which the science and applications capabilities identified in the Decadal Survey are interpreted and refined, candidate mission architectures and associated technologies to support these needs are identified, architectures are assessed against a science value framework specific to SDC, and recommendations to NASA are made. Ultimately, NASA will decide which amongst these recommendations will proceed to mission formulation. As synthetic aperture radar (SAR) was identified as the prime sensor technology to satisfy SDC observational needs, a key component of the SDC study is to assess the current state of the art in SAR sensor and spacecraft systems and components. The number of SAR systems, both civil and commercial, is growing rapidly, requiring that mission architectures not only consider technology, but availability of data from other missions, possible partnerships or collaborations, and even data purchase. The mechanism for assessment involves development of an end-to-end science performance evaluation tool for multi-satellite constellations, which feeds into a science value framework that considers science performance, technological programmatic risks, and cost. This paper will present an overview of the ongoing study including the architectures under consideration and the technology road map needed to achieve the objectives of the mission.

Rosen, Paul↗

The need for reference-able and peer reviewed position papers

Space Physics community members are putting substantial efforts and ideas into position papers, in preparation for the U.S. Heliophysics Decadal Survey process; an analysis of the current state of the field and where future research, mission programs, and funding should focus. Furthermore, Space Physics community members in Europe and the U.S. have recently put substantial efforts and ideas into position papers for Vision 2050 and Heliophysics 2050. There are also other ideas in the community about the needs and focus of future Space Physics research efforts, whether they were submitted to other road mapping activities, or have yet to find the appropriate home. With this in mind, we have created a Frontiers in Astronomy and Space Sciences Research Topic ’The Future of Space Physics 2022’, to provide a format for a reference-able, peer reviewed, archived, accessible collection of these ideas from around the world. We wish to make these ideas available to the national academies decadal survey committees, the broader research community and a wider audience, by developing this collection. The collection will publish high-quality papers on key topics across the field of Space Physics, aiming to highlight recent advances in the field, whilst emphasizing important directions and new possibilities for future inquiries.

Alexa Jean Halford↗

Prototype Global Analysis of LISA Data with Multiple Source Types

The novel data analysis challenges posed by the Laser Interferometer Space Antenna (LISA) arise from the overwhelmingly large number of astrophysical sources in the measurement band and the density with which they are found in the data. Robust detection and characterization of the numerous gravitational wave sources in LISA data can not be done sequentially, but rather through a simultaneous global fit of a data model containing the full suite of astrophysical and instrumental features present in the data. While previous analyses have focused on individual source types in isolation, here we present the first demonstration of a LISA global fit analysis containing combined astrophysical populations. The prototype pipeline uses a blocked Metropolis Hastings algorithm to alternatingly fit to a population of ultra compact galactic binaries, known “verification binaries” already identified by electromagnetic observations, a population of massive black hole mergers, and an instrument noise model. The Global LISA Analysis Software Suite (GLASS) is assembled from independently developed samplers for the different model components. The modular design enables flexibility to future development by defining standard interfaces for adding new, or updating additional, components to the global fit without being overly prescriptive for how those modules must be internally designed. The GLASS pipeline is demonstrated on data simulated for the LISA Data Challenge 2b. Results of the analysis and a road-map for continued development are described in detail.

Gravitational Waves↗

Enabling Model Organism and Commercial Astronaut Data Access Through the NASA Open Science Data Repository

NASA’s Open Science Data Repository (OSDR) brings together omics data from NASA’s GeneLab project and non-omics data, including physiological, phenotypic, imaging, and behavioral data from NASA’s Ames Life Sciences Data Archive (ALSDA) collected from decades of space biology research, providing open and FAIR (findable, accessible, interoperable, and reusable) access of these precious data to scientists world-wide. This rich source of meticulously curated metadata and data from spaceflight and analog studies has been mined by the scientific community resulting in dozens of high impact scientific publications that reveals a complex network of molecular and physiological effects of spaceflight across living systems, from microbes to plants, to mammals. Understanding how these effects translate to the human condition is critical as we move deeper into the era of commercial space travel. However, the integration of data, specifically omics data, from astronauts is particularly challenging due to their sensitive nature. OSDR has risen to this challenge by developing a mechanism to control access to identifiable levels of omics data, such as raw sequence data, while enabling public access to processed, unidentifiable, data and associated metadata that will allow the scientific community to interrogate human astronaut data alongside data from model organisms to begin answering these critical questions. The 2021 SpaceX Inspiration4 (I4) mission collected a comprehensive atlas of biological measurements from four civilian astronauts, providing a wealth of data to characterize the effects of spaceflight on the human body. These data include both non-omics and omics assays such as direct RNA sequencing (RNA-seq), single nuclei ATAC-seq and RNA-seq, metagenomics, proteomics, and comprehensive metabolic and cytokine panels, all of which have been integrated into the OSDR system across no less than 9 studies. Each study has been carefully curated using community-backed OSDR standards for sample and assay level metadata ensuring these data are findable and accessible. In addition to hosting both raw and processed data from the principal investigator team for each assay type, the GeneLab team plans to re-process the I4 omics data using GeneLab’s standard processing pipelines. The GeneLab processed data outputs will allow for comparisons across studies on OSDR and enable visualization of these data through the OSDR data visualization platform thereby enabling data reusability and interoperability. Here we describe the robust privacy and security protocols implemented by OSDR to safeguard sensitive health data from astronauts while facilitating metadata and processed data sharing for research purposes. We further provide a road map for navigating the vast amount of data provided for each I4 study on the OSDR, including experimental design, associated experiments, payloads, and missions, data generation and analysis protocols, and associated scientific articles. Additionally, we illustrate how to interrogate the standardized metadata provided in the sample and assay tables as well as various means to download and access the data including programmatically through the GeneLab Open API (GLOpenAPI). The open access of datasets in NASA’s OSDR provides a unique opportunity for the scientific community, as well as citizen scientists and students, to continue using OSDR resources to further unlock profound insights into the consequences of space travel on the human body. Through implementation of security measures to protect sensitive human data, the OSDR seeks to strengthen the science exchange between the Biological and Physical Sciences Program and the Human Research Program, per recommendation 4-1 of the 2023-2032 Decadal Survey, and encourage further sharing and dissemination of astronaut data to provide the scientific community with the resources needed to lay the groundwork for developing targeted mitigation strategies to help withstand the rigors of long-duration spaceflight.

Amanda Marie Saravia-butler↗

Enabling Model Organism and Commercial Astronaut Data Access Through the NASA Open Science Data Repository

NASA’s Open Science Data Repository (OSDR) brings together omics data from NASA’s GeneLab project and non-omics data, including physiological, phenotypic, imaging, and behavioral data from NASA’s Ames Life Sciences Data Archive (ALSDA) collected from decades of space biology research, providing open and FAIR (findable, accessible, interoperable, and reusable) access of these precious data to scientists world-wide. This rich source of meticulously curated metadata and data from spaceflight and analog studies has been mined by the scientific community resulting in dozens of high impact scientific publications that reveals a complex network of molecular and physiological effects of spaceflight across living systems, from microbes to plants, to mammals. Understanding how these effects translate to the human condition is critical as we move deeper into the era of commercial space travel. However, the integration of data, specifically omics data, from astronauts is particularly challenging due to their sensitive nature. OSDR has risen to this challenge by developing a mechanism to control access to identifiable levels of omics data, such as raw sequence data, while enabling public access to processed, unidentifiable, data and associated metadata that will allow the scientific community to interrogate human astronaut data alongside data from model organisms to begin answering these critical questions. The 2021 SpaceX Inspiration4 (I4) mission collected a comprehensive atlas of biological measurements from four civilian astronauts, providing a wealth of data to characterize the effects of spaceflight on the human body. These data include both non-omics and omics assays such as direct RNA sequencing (RNA-seq), single nuclei ATAC-seq and RNA-seq, metagenomics, proteomics, and comprehensive metabolic and cytokine panels, all of which have been integrated into the OSDR system across no less than 9 studies. Each study has been carefully curated using community-backed OSDR standards for sample and assay level metadata ensuring these data are findable and accessible. In addition to hosting both raw and processed data from the principal investigator team for each assay type, the GeneLab team plans to re-process the I4 omics data using GeneLab’s standard processing pipelines. The GeneLab processed data outputs will allow for comparisons across studies on OSDR and enable visualization of these data through the OSDR data visualization platform thereby enabling data reusability and interoperability. Here we describe the robust privacy and security protocols implemented by OSDR to safeguard sensitive health data from astronauts while facilitating metadata and processed data sharing for research purposes. We further provide a road map for navigating the vast amount of data provided for each I4 study on the OSDR, including experimental design, associated experiments, payloads, and missions, data generation and analysis protocols, and associated scientific articles. Additionally, we illustrate how to interrogate the standardized metadata provided in the sample and assay tables as well as instructions for how to download and access the data. The I4 datasets described here re present the first ever comprehensive collection of commercial astronaut data.

Amanda M Saravia-Butler↗