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The Impact of Back-Sputtered Carbon on the Accelerator Grid Wear Rates of the NEXT and NSTAR Ion Thrusters
A study was conducted to quantify the impact of back-sputtered carbon on the downstream accelerator grid erosion rates of the NEXT (NASA's Evolutionary Xenon Thruster) Long Duration Test (LDT1). A similar analysis that was conducted for the NSTAR (NASA's Solar Electric Propulsion Technology Applications Readiness Program) Life Demonstration Test (LDT2) was used as a foundation for the analysis developed herein. A new carbon surface coverage model was developed that accounted for multiple carbon adlayers before complete surface coverage is achieved. The resulting model requires knowledge of more model inputs, so they were conservatively estimated using the results of past thin film sputtering studies and particle reflection predictions. In addition, accelerator current densities across the grid were rigorously determined using an ion optics code to determine accelerator current distributions and an algorithm to determine beam current densities along a grid using downstream measurements. The improved analysis was applied to the NSTAR test results for evaluation. The improved analysis demonstrated that the impact of back-sputtered carbon on pit and groove wear rate for the NSTAR LDT2 was negligible throughout most of eroded grid radius. The improved analysis also predicted the accelerator current density for transition from net erosion to net deposition considerably more accurately than the original analysis. The improved analysis was used to estimate the impact of back-sputtered carbon on the accelerator grid pit and groove wear rate of the NEXT Long Duration Test (LDT1). Unlike the NSTAR analysis, the NEXT analysis was more challenging because the thruster was operated for extended durations at various operating conditions and was unavailable for measurements because the test is ongoing. As a result, the NEXT LDT1 estimates presented herein are considered preliminary until the results of future posttest analyses are incorporated. The worst-case impact of carbon back-sputtering was determined to be the full power operating condition, but the maximum impact of back-sputtered carbon was only a four percent reduction in wear rate. As a result, back-sputtered carbon is estimated to have an insignificant impact on the first failure mode of the NEXT LDT at all operating conditions.
The Impact of Back-Sputtered Carbon on the Accelerator Grid Wear Rates of the NEXT and NSTAR Ion Thrusters
A study was conducted to quantify the impact of back-sputtered carbon on the downstream accelerator grid erosion rates of the NASA's Evolutionary Xenon Thruster (NEXT) Long Duration Test (LDT1). A similar analysis that was conducted for the NASA's Solar Electric Propulsion Technology Applications Readiness Program (NSTAR) Life Demonstration Test (LDT2) was used as a foundation for the analysis developed herein. A new carbon surface coverage model was developed that accounted for multiple carbon adlayers before complete surface coverage is achieved. The resulting model requires knowledge of more model inputs, so they were conservatively estimated using the results of past thin film sputtering studies and particle reflection predictions. In addition, accelerator current densities across the grid were rigorously determined using an ion optics code to determine accelerator current distributions and an algorithm to determine beam current densities along a grid using downstream measurements. The improved analysis was applied to the NSTAR test results for evaluation. The improved analysis demonstrated that the impact of back-sputtered carbon on pit and groove wear rate for the NSTAR LDT2 was negligible throughout most of eroded grid radius. The improved analysis also predicted the accelerator current density for transition from net erosion to net deposition considerably more accurately than the original analysis. The improved analysis was used to estimate the impact of back-sputtered carbon on the accelerator grid pit and groove wear rate of the NEXT Long Duration Test (LDT1). Unlike the NSTAR analysis, the NEXT analysis was more challenging because the thruster was operated for extended durations at various operating conditions and was unavailable for measurements because the test is ongoing. As a result, the NEXT LDT1 estimates presented herein are considered preliminary until the results of future post-test analyses are incorporated. The worst-case impact of carbon back-sputtering was determined to be the full power operating condition, but the maximum impact of back-sputtered carbon was only a 4 percent reduction in wear rate. As a result, back-sputtered carbon is estimated to have an insignificant impact on the first failure mode of the NEXT LDT1 at all operating conditions.
Advanced Near Net Shape Technology
The objective of the Advanced Near Net Shape Technology (ANNST) project is to radically improve near net shape manufacturing methods from the current Technology/ Manufacturing Readiness Levels (TRL/MRL 3-4) to the point where they are viable candidates (TRL/ MRL-6) for shortening the time and cost for insertion of new aluminum alloys and revolutionary manufacturing methods into the development/improvement of space structures. Conventional cyrotank manufacturing processes require fabrication of multiple pieces welded together to form a complete tank. A variety of near net shape manufacturing processes has demonstrated excellent potential for enabling single-piece construction of components such as domes, barrels, and ring frames. Utilization of such processes can dramatically reduce the extent of welding and joining needed to construct cryogenic tanks and other aerospace structures. The specific focus of this project is to successfully mature the integrally stiffened cylinder (ISC) process in which a single-piece cylinder with integral stiffeners is formed in one spin/flow forming process. Structural launch vehicle components, like cryogenic fuel tanks (e.g., space shuttle external tank), are currently fabricated via multipiece assembly of parts produced through subtractive manufacturing techniques. Stiffened structural panels are heavily machined from thick plate, which results in excessive scrap rates. Multipiece construction requires welds to assemble the structure, which increases the risk for defects and catastrophic failures.
Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status
The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.
The Role of Analysis and Testing in the Service Life Assessment of Ion Engines
Experience from tests and flights and engineering analysis represent the two sources of information on which to base conclusions on the reliability or failure risk of aerospace flight systems. It is rarely feasible to establish high reliability at high confidence by testing aerospace flight systems or components. The limitations of testing in evaluating failure risk are discussed and an alternate statistical approach which relies on both test experience and analysis to quantitatively assess reliability is outlined. The implementation of this methodology in the service life assessment of ion thrusters is discussed and examples of failure modes being addressed in the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) program are given.
High Speed Interferometry for James Webb Space Telescope Testing
High speed interferometry (HSI) was one of the enabling technologies to the successful development and testing of the James Webb Space Telescope (JWST) optical system that consists of a 6.5 meter diameter, segmented, lightweight primary mirror and lightweight carbon fiber composite structure. This paper reviews the interferometry that was used first to demonstrate that the lightweight mirror and lightweight composite structure technologies were ready for JWST and later to verify performance of the fully assembled primary mirror and the telescope at cryogenic temperature. The tools and techniques developed for JWST are being advanced to benefit future missions that require stable mirrors, precision metering structures, active controls and diagnostic metrology.
In Space Production Applications (InSPA) - Enabling U.S. Leadership of In-Space Manufacturing in Low-Earth Orbit for Terrestrial Markets – In Space for Earth!
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Next Generation X-ray Optics for Astrophysics: High Resolution, Light Weight, and Low Cost
Ready a technology with the following features, compared to Chandra’s. Much better angular resolution: - On-axis: Comparable(~0.5”HPD) by 2026, 5Xbetter by ~2030 - Off-axis: 10Xbetter at 10-arcmin off-axis Much lighter weight per unit area–at least 10Xlighter Much lower cost per unit area–at least 10X lower in real year dollars
Funding and Strategic Alignment Guidance for Infusing Small Business Innovation Research Technology Into Human Exploration and Operations Mission Directorate Projects at Glenn Research Center for 2015
This report is intended to help NASA program and project managers incorporate Glenn Research Center Small Business Innovation Research/Small Business Technology Transfer (SBIR)/(STTR) technologies into NASA Human Exploration and Operations Mission Directorate (HEOMD) programs and projects. Other Government and commercial project managers can also find this useful. Introduction Incorporating Small Business Innovation Research (SBIR)-developed technology into NASA projects is important, especially given the Agency's limited resources for technology development. The SBIR program's original intention was for technologies that had completed Phase II to be ready for integration into NASA programs, however, in many cases there is a gap between Technology Readiness Levels (TRLs) 5 and 6 that needs to be closed. After SBIR Phase II projects are completed, the technology is evaluated against various parameters and a TRL rating is assigned. Most programs tend to adopt more mature technologies-at least TRL 6 to reduce the risk to the mission rather than adopt TRLs between 3 and 5 because those technologies are perceived as too risky. The gap between TRLs 5 and 6 is often called the "Valley of Death" (Figure 1), and historically it has been difficult to close because of a lack of funding support from programs. Several papers have already suggested remedies on how to close the gap (Refs. 1 to 4).
Nuclear electric propulsion: An integral part of NASA's nuclear propulsion project
NASA has initiated a technology program to establish the readiness of nuclear propulsion technology for the Space Exploration Initiative (SEI). This program was initiated with a very modest effort identified with nuclear thermal propulsion (NTP); however, nuclear electric propulsion (NEP) is also an integral part of this program and builds upon NASA's Base Research and Technology Program in power and electric propulsion as well as the SP-100 space nuclear power program. Although the Synthesis Group On America's SEI has identified NEP only as an option for cargo missions, recent studies conducted by NASA-Lewis show that NEP offers the potential for early manned Mars missions as well. Lower power NEP is also of current interest for outer planetary robotic missions. Current plans are reviewed for the overall nuclear propulsion project, with emphasis on NEP and those elements of NTP program which have synergism with NEP.
Challenging Technology, and Technology Infusion into 21st Century
In preparing for the space exploration challenges of the next century, the National Aeronautics and Space Administration (NASA) Center for Integrated Space Micro-Systems (CISM) is chartered to develop advanced spacecraft systems that can be adapted for a large spectrum of future space missions. Enabling this task are revolutions in the miniaturization of electrical, mechanical, and computational functions. On the other hand, these revolutionary technologies usually have much lower readiness levels than those required by flight projects. The mission of the Advanced Micro Spacecraft (AMS) task in CISM is to bridge the readiness gap between advanced technologies and flight projects. Additional information is contained in the original extended abstract.
CASPEr: an Approach to Characterize the Performance of Onboard Airplane Energy State and Automation Mode Prediction Functions
The Commercial Aviation Safety Team (CAST) has identified a set of safety enhancements to mitigate the risks of loss of control in-flight (LOCI) accidents and incidents involving commercial transport airplanes. In support of this, NASA has been developing technologies intended to enhance flight crew awareness of airplane systems, attitude, and energy state. This report describes preliminary ideas for a methodology to assess the goodness of onboard airplane energy state and automation mode prediction functions. The methodology is intended to contribute to the goal of moving these prediction technologies to the readiness level required for transition to industry and reduce the technology certification risks. In addition, this report describes a simulation-based approach named CASPEr (Characterization of Airplane State Prediction Error) to characterize the performance of these predictive functions over a wide range of operational conditions. The first exploratory version of this approach is described. The bulk of the report documents the initial results of tests to characterize the performance of an airplane trajectory prediction function. Future reports will give additional performance characterization results for this function and a complete description of the proposed methodology to assess such functions.
Forward Technology Solar Cell Experiment (FTSCE) for MISSE-5 Verified and Readied for Flight on STS-114
The Forward Technology Solar Cell Experiment (FTSCE) is a space solar cell experiment built as part of the Fifth Materials on the International Space Station Experiment (MISSE-5): Data Acquisition and Control Hardware and Software. It represents a collaborative effort between the NASA Glenn Research Center, the Naval Research Laboratory, and the U.S. Naval Academy. The purpose of this experiment is to place current and future solar cell technologies on orbit where they will be characterized and validated. This is in response to recent on-orbit and ground test results that raised concerns about the in-space survivability of new solar cell technologies and about current ground test methodology. The various components of the FTSCE are assembled into a passive experiment container--a 2- by 2- by 4-in. folding metal container that will be attached by an astronaut to the outer structure of the International Space Station. Data collected by the FTSCE will be relayed to the ground through a transmitter assembled by the U.S. Naval Academy. Data-acquisition electronics and software were designed to be tolerant of the thermal and radiation effects expected on orbit. The experiment has been verified and readied for flight on STS-114.
An Assessment of the Technical Readiness of the Vapor Phase Catalytic Ammonia Removal Process (VPCAR) Technology
This poster provides an assessment of the technical readiness of the Vapor Phase Catalytic Ammonia Removal Process (VPCAR). The VPCAR technology is a fully regenerative water recycling technology designed specifically for applications such as a near term Mars exploration mission. The VPCAR technology is a highly integrated distillation/catalytic oxidation based water processor. It is designed to accept a combined wastewater stream (urine, condensate, and hygiene) and produces potable water in a single process step which requires -no regularly scheduled re-supply or maintenance for a 3 year mission. The technology is designed to be modular and to fit into a volume comparable to a single International Space Station Rack (when sized for a crew of 6). This poster provides a description of the VPCAR technology and a summary of the current performance of the technology. Also provided are the results of two separate NASA sponsored system trade studies which investigated the potential payback of further development of the VPCAR technology.
Evaluating the Viability of Compact and Portable X-Ray Systems for an Exploration Medical System in a Ground Demonstration
MOTIVATION FOR INCLUDING X-RAY CAPABILITIES For upcoming exploration missions, the need for enhanced medical care becomes critical due to extended mission durations, significant communication delays, and minimal evacuation opportunities. Previous evidence by our team has revealed that among the 119 medical conditions targeted for management during spaceflight within NASA Exploration Medical Capability’s IMPACT Condition List, at least 36 could benefit from radiography (XR). Utilizing XR for diagnosis and management is hypothesized to significantly improve management of crew health by enabling the immediate evaluation and confirmation of potential injuries or illnesses. Beyond clinical applications, XR also holds potential for non-destructive testing (NDT). This includes applications such as assessing the structural integrity of the spacecraft, analyzing surface and meteorite samples, and inspecting onboard electronics. THREE CANDIDATE X-RAY SYSTEMS CHOSEN FOR GROUND DEMONSTRATION The Exploration Medical Capability Element (ExMC) and the Exploration Medical Integrated Product Team (XMIPT) of the Mars Campaign Office initiated early background work for ground demonstrations. In FY21, ExMC published a Concept of Operations to guide requirements development. By FY23, XMIPT and yet2, a technology scouting and open innovation consulting firm, had completed a market survey and trade study to identify potential miniature XR systems. Selection criteria included commercial-off-the-shelf availability, low mass and volume, and regulatory compliance. The top three candidate devices—Remedi REMEX-KA6, MinXray Impact, and FujiFilm Xair—were acquired to characterize the requirements and capabilities of each device. To facilitate testing, phantoms, and radiographic personal protective equipment (PPE) were purchased, and a dedicated space was designated for XRS usage at Glenn Research Center. During this presentation, the mass, volume, and power requirements for each of the three piloted devices are revealed, as well as information regarding the detector, mA, and kV of the devices. GOAL AND OBJECTIVES OF A MINI XRS GROUND DEMONSTRATION The primary goal of ExMC/XMIPT technology demonstrations is to bridge the gap in available, flight-ready medical device technology by flight-testing diagnostic and treatment technologies essential for managing medical conditions during exploration missions. These technologies must adhere to vehicle constraints such as mass, volume, power, and data requirements, integrate seamlessly with medical decision-support tools, and support increasingly Earth-independent operations. There are three main objectives for the future ground demonstration of these three devices. First, we aim to determine the full capabilities of these three miniature XR systems within the context of the spaceflight environment. While medical applications are the primary focus for the miniature XR, a comprehensive exploration of non-medical uses has been initiated by an XMIPT-sponsored NASA SPARK campaign to identify collaborators. Second, we plan to establish criteria and to use insights gained from evaluating each miniature XR against those criteria to select the most suitable system among the three candidates. Third, we intend to evaluate their suitability for flight certification, which includes assessing its durability for launch, reentry, and exposure to high background radiation, as well as its compatibility with existing data architecture systems. Numerous subject matter experts from NASA and partner institutions will support these objectives.
Station Readiness Test for the Earth Resources Technology Satellite (ERTS) Mission
The purpose of this SRT is to establish testing procedures which will verify that ERTS supporting stations can effectively support the ERTS mission. This SRT is applicable to all supporting stations for the ERTS-A and ERTS-B mission.
Heatshield for Extreme Entry Environment Technology (Heeet) and 3D Woven TPS Readiness for Outer Planet Probe Missions
Recent mission studies have shown entry at Uranus or at Neptune will require 3-D Woven TPS, either the two-layer HEEET or the single layer 3MDCP, with 3MDCP being more mass efficient. The 3MDCP capability being developed to support MSR EES is sufficient for the Ice Giants if the probe size is 1.25 m or less. [The Uranus Orbiter Probe (UOP) Flagship study for the Decadal used a 1.26m diameter probe.] For larger diameters, dual layer HEEET is easily scalable and is already at TRL 6. It is possible to develop a seam approach that would allow the use of 3MDCP; the resultant mass savings could warrant such a development. Ames is already working on a concept towards this. If aerocapture becomes part of the mission design for Uranus, delivery of the probe from orbit will be easier. Whether or not the probe is delivered from orbit, 3-D Woven (HEEET or 3MDCP) is the only TPS qualified to enable Ice Giant in situ probes. In addition to UOP, Saturn probe mission concepts will be enabled by 3-D Woven, either HEEET or 3MDCP. Launch periods for the UOP flagship or a Saturn probe mission in the early to mid 2030s requires the community to ensure that the 3D woven capability does not atrophy. Currently other than MSR EES, no other mission requires 3-D wovens, and the manufacturing for MSR will be completed by 2023. A gap in production of 5 or more years requires careful monitoring of the industrial base. In addition, manufacturing of 3-D woven TPS, from procurement and weaving to molding and infusion, is a minimum 2-year activity. In response to the threat of atrophy and the time critical and intensive nature of restarting weaving, advocacy from OPAG to NASA SMD for a sustainability effort would ensure in situ exploration of the outer planets in the decades to come.