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2195 Aluminum-Copper-Lithium Friction Plug Welding Development

Technology developments and applications of friction plug welding is presented. This friction repair welding technology is being studied for implementation on the Space Transportation System's Super Light Weight External Tank. Single plug repairs will be used on a vast majority of weld defects, however, linear defects of up to several inches can be repaired by overlapping plug welds. Methods and results of tensile, bend, simulated service, surface crack tension and other tests at room and cryogenic temperatures is discussed. Attempts to implement Friction Plug Welding has led to both tool and process changes in an attempt to minimize expansive tooling and lengthy implementation times. Process control equipment and data storage methods intended for large scale production will also be addressed. Benefits include increased strength and toughness, decreased weld repair time, automated and highly reliable process, and a lower probability of having to re-repair defect locations.

Takeshita, Rike P.↗

NASA In-Situ Resource Utilization (ISRU) Technology and Development Project Overview

Since the Vision for Space Exploration (VSE) was released in 2004, NASA, in conjunction with international space agencies, industry, and academia, has continued to define and refine plans for sustained and affordable robotic and human exploration of the Moon and beyond. With the goal of establishing a lunar Outpost on the Moon to extend human presence, pursue scientific activities, use the Moon to prepare for future human missions to Mars, and expand Earth s economic sphere, a change in how space exploration is performed is required. One area that opens up the possibility for the first time of breaking our reliance on Earth supplied consumables and learn to live off the land is In-Situ Resource Utilization (ISRU). ISRU, which involves the extraction and processing of space resources into useful products, can have a substantial impact on mission and architecture concepts. In particular, the ability to make propellants, life support consumables, and fuel cell reagents can significantly reduce the cost, mass, and risk of sustained human activities beyond Earth. However, ISRU is an unproven capability for human lunar exploration and can not be put in the critical path of lunar Outpost success until it has been proven. Therefore, ISRU development and deployment needs to take incremental steps toward the desired end state. To ensure ISRU capabilities are available for pre-Outpost and Outpost deployment by 2020, and mission and architecture planners are confident that ISRU can meet initial and long term mission requirements, the ISRU Project is developing technologies and systems in three critical areas: (1) Regolith Excavation, Handling and Material Transportation; (2) Oxygen Extraction from Regolith; and (3) Volatile Extraction and Resource Prospecting, and in four development stages: (I) Demonstrate feasibility; (II) Evolve system w/ improved technologies; (III) Develop one or more systems to TRL 6 before start of flight development; and (IV) Flight development for Outpost. To minimize cost and ensure that ISRU technologies, systems, and functions are integrated properly into the Outpost, technology development efforts are being coordinated with other development areas such as Surface Mobility, Surface Power, Life Support, EVA, and Propulsion. Lastly, laboratory and field system-level tests and demonstrations will be performed as often as possible to demonstrate improvements in: Capabilities (ex. digging deeper); Performance (ex. lower power); and Duration (ex. more autonomy or more robustness). This presentation will provide the status of work performed to date within the NASA ISRU project with respect to technology and system development and field demonstration activities, as well as the current strategy to implement ISRU in future robotic and human lunar exploration missions.

Sanders, Gerald B.↗

Electrically Driven Thermal Management: Flight Validation, Experiment Development, Future Technologies

Electrically Driven Thermal Management is an active research and technology development initiative incorporating ISS technology flight demonstrations (STP-H5), development of Microgravity Science Glovebox (MSG) flight experiment, and laboratory-based investigations of electrically based thermal management techniques. The program targets integrated thermal management for future generations of RF electronics and power electronic devices. This presentation reviews four program elements: i.) results from the Electrohydrodynamic (EHD) Long Term Flight Demonstration launched in February 2017 ii.) development of the Electrically Driven Liquid Film Boiling Experiment iii.) two University based research efforts iv.) development of Oscillating Heat Pipe evaluation at Goddard Space Flight Center.

Thermal Control Multifunctional Hardware↗

Towards Autonomous Operations of the Robonaut 2 Humanoid Robotic Testbed

The Robonaut project has been conducting research in robotics technology on board the International Space Station (ISS) since 2012. Recently, the original upper body humanoid robot was upgraded by the addition of two climbing manipulators ("legs"), more capable processors, and new sensors, as shown in Figure 1. While Robonaut 2 (R2) has been working through checkout exercises on orbit following the upgrade, technology development on the ground has continued to advance. Through the Active Reduced Gravity Offload System (ARGOS), the Robonaut team has been able to develop technologies that will enable full operation of the robotic testbed on orbit using similar robots located at the Johnson Space Center. Once these technologies have been vetted in this way, they will be implemented and tested on the R2 unit on board the ISS. The goal of this work is to create a fully-featured robotics research platform on board the ISS to increase the technology readiness level of technologies that will aid in future exploration missions. Technology development has thus far followed two main paths, autonomous climbing and efficient tool manipulation. Central to both technologies has been the incorporation of a human robotic interaction paradigm that involves the visualization of sensory and pre-planned command data with models of the robot and its environment. Figure 2 shows screenshots of these interactive tools, built in rviz, that are used to develop and implement these technologies on R2. Robonaut 2 is designed to move along the handrails and seat track around the US lab inside the ISS. This is difficult for many reasons, namely the environment is cluttered and constrained, the robot has many degrees of freedom (DOF) it can utilize for climbing, and remote commanding for precision tasks such as grasping handrails is time-consuming and difficult. Because of this, it is important to develop the technologies needed to allow the robot to reach operator-specified positions as autonomously as possible. The most important progress in this area has been the work towards efficient path planning for high DOF, highly constrained systems. Other advances include machine vision algorithms for localizing and automatically docking with handrails, the ability of the operator to place obstacles in the robot's virtual environment, autonomous obstacle avoidance techniques, and constraint management.

Badger, Julia↗

Selected OAST/OSSA space experiment activities in support of Space Station Freedom

The Space Experiments Division at NASA Lewis Research Center is developing technology and science space experiments for the Office of Aeronautics and Space Technology (OAST) and the Office of Space Sciences and Applications (OSSA). Selected precursor experiments and technology development activities supporting the Space Station Freedom (SSF) are presented. The Tank Pressure Control Experiment (TPCE) is an OAST-funded cryogenic fluid dynamics experiment, the objective of which is to determine the effectiveness of jet mixing as a means of equilibrating fluid temperatures and controlling tank pressures, thereby permitting the design of lighter cryogenic tanks. The information from experiments such as this will be utilized in the design and operation of on board cryogenic storage for programs such as SSF. The Thermal Energy Storage Flight Project (TES) is an OAST-funded thermal management experiment involving phase change materials for thermal energy storage. The objective of this project is to develop and fly in-space experiments to characterize void shape and location in phase change materials used in a thermal energy storage configuration representative of an advanced solar dynamic system design. The information from experiments such as this will be utilized in the design of future solar dynamic power systems. The Solar Array Module Plasma Interaction Experiment (SAMPIE) is an OAST-funded experiment to determine the environmental effects of the low earth orbit (LEO) space plasma environment on state-of-the-art solar cell modules biased to high potentials relative to the plasma. Future spacecraft designs and structures will push the operating limits of solar cell arrays and other high voltage systems. SAMPIE will provide key information necessary for optimum module design and construction. The Vibration Isolation Technology (VIT) Advanced Technology Development effort is funded by OSSA to provide technology necessary to maintain a stable microgravity environment for sensitive payloads on board spacecraft. The proof of concept will be demonstrated by laboratory tests and in low-gravity aircraft flights. VIT is expected to be utilized by many SSF microgravity science payloads. The Space Acceleration Measurement System (SAMS) is an OSSA-funded instrument to measure the microgravity acceleration environment for OSSA payloads on the shuttle and SSF.

Delombard, Richard↗

High-Power Krypton Hall Thruster Technology Being Developed for Nuclear-Powered Applications

The NASA Glenn Research Center has been performing research and development of moderate specific impulse, xenon-fueled, high-power Hall thrusters for potential solar electric propulsion applications. These applications include Mars missions, reusable tugs for low-Earth-orbit to geosynchronous-Earth-orbit transportation, and missions that require transportation to libration points. This research and development effort resulted in the design and fabrication of the NASA-457M Hall thruster that has been tested at input powers up to 95 kW. During project year 2003, NASA established Project Prometheus to develop technology in the areas of nuclear power and propulsion, which are enabling for deep-space science missions. One of the Project-Prometheus-sponsored Nuclear Propulsion Research tasks is to investigate alternate propellants for high-power Hall thruster electric propulsion. The motivation for alternate propellants includes the disadvantageous cost and availability of xenon propellant for extremely large scale, xenon-fueled propulsion systems and the potential system performance benefits of using alternate propellants. The alternate propellant krypton was investigated because of its low cost relative to xenon. Krypton propellant also has potential performance benefits for deep-space missions because the theoretical specific impulse for a given voltage is 20 percent higher than for xenon because of krypton's lower molecular weight. During project year 2003, the performance of the high-power NASA-457M Hall thruster was measured using krypton as the propellant at power levels ranging from 6.4 to 72.5 kW. The thrust produced ranged from 0.3 to 2.5 N at a discharge specific impulse up to 4500 sec.

Jacobson, David T.↗

NASA Development of Aerocapture Technologies

Aeroassist technology development is a vital part of the NASA ln-Space Propulsion Program (ISP), which is managed by the NASA Headquarters Office of Space Science, and implemented by the Marshall Space Flight Center in Huntsville, Alabama. Aeroassist is the general term given to various techniques to maneuver a space vehicle within an atmosphere, using aerodynamic forces in lieu of propulsive fuel. Within the ISP, the current aeroassist technology development focus is aerocapture. The objective of the ISP Aerocapture Technology Project (ATP) is to develop technologies that can enable and/or benefit NASA science missions by significantly reducing cost, mass, and/or travel times. To accomplish this objective, the ATP identifies and prioritizes the most promising technologies using systems analysis, technology advancement and peer review, coupled with NASA Headquarters Office of Space Science target requirements. Plans are focused on developing mid-Technology Readiness Level (TRL) technologies to TRL 6 (ready for technology demonstration in space).

James, Bonnie↗

NASA Development of Aerocapture Technologies

Aeroassist technology development is a vital part of the NASA In-Space Propulsion Program (ISP), which is managed by the NASA Headquarters Office of Space Science, and implemented by the Marshall Space Flight Center in Huntsville, Alabama. Aeroassist is the general term given to various techniques to maneuver a space vehicle within an atmosphere, using aerodynamic forces in lieu of propulsive fuel. Within the ISP, the current aeroassist technology development focus is aerocapture. The objective of the ISP Aerocapture Technology Project (ATP) is to develop technologies that can enable and/or benefit NASA science missions by significantly reducing cost, mass, and/or travel times. To accomplish this objective, the ATP identifies and prioritizes the most promising technologies using systems analysis, technology advancement and peer review, coupled with NASA Headquarters Office of Space Science target requirements. Plans are focused on developing mid-Technology Readiness Level (TRL) technologies to TRL 6 (ready for technology demonstration in space).

James, Bonnie↗

Development of Lightweight Mirror Technology for the NGST Program

Recognizing the need to launch larger aperture telescopes to orbit with current launch capability, the NGST program began in 1997, an aggressive technology development effort in lightweight optics. This effort has developed technologies in silicon Carbide, Beryllium, silicon, glass and hybrid mirrors to name a few. The advancement of mirror technology to below the 15 kg/ni2 areal density is challenging enough without the added requirements for NGST that the mirror operate at approximately 35 Kelvin. This paper will discuss the various NGST technology developments including applications relative to bonding or joining mirror materials, subscale developments, the mirror system demonstrator program, the advance mirror demonstrator program and development of the mirror test program. Specific attention will be given to technical issues related to lightweight mirror development and processing. Other issues to be addressed are the development of the roadmap to the NGST flight mirror development and to assess the technology readiness for NGST.

Jacobson, David N.↗

NASA's In Space Propulsion Technology Program Accomplishments and Lessons Learned

NASA's In-Space Propulsion Technology (ISPT) Program was managed for 5 years at the NASA MSFC and significant strides were made in the advancement of key transportation technologies that will enable or enhance future robotic science and deep space exploration missions. At the program's inception, a set of technology investment priorities were established using an NASA-wide, mission-driven prioritization process and, for the most part, these priorities changed little - thus allowing a consistent framework in which to fund and manage technology development. Technologies in the portfolio included aerocapture, advanced chemical propulsion, solar electric propulsion, solar sail propulsion, electrodynamic and momentum transfer tethers, and various very advanced propulsion technologies with significantly lower technology readiness. The program invested in technologies that have the potential to revolutionize the robotic exploration of deep space. For robotic exploration and science missions, increased efficiencies of future propulsion systems are critical to reduce overall life-cycle costs and, in some cases, enable missions previously considered impossible. Continued reliance on conventional chemical propulsion alone will not enable the robust exploration of deep space - the maximum theoretical efficiencies have almost been reached and they are insufficient to meet needs for many ambitious science missions currently being considered. By developing the capability to support mid-term robotic mission needs, the program was to lay the technological foundation for travel to nearby interstellar space. The ambitious goals of the program at its inception included supporting the development of technologies that could support all of NASA's missions, both human and robotic. As time went on and budgets were never as high as planned, the scope of the program was reduced almost every year, forcing the elimination of not only the broader goals of the initial program, but also of funding for over half of the technologies in the original portfolio. In addition, the frequency at which the application requirements for the program changed exceeded the development time required to mature technologies: forcing sometimes radical rescoping of research efforts already halfway (or more) to completion. At the end of its fifth year, both the scope and funding of the program were at a minimum despite the program successfully meeting all of it's initial high priority objectives. This paper will describe the program, its requirements, technology portfolio, and technology maturation processes. Also discussed will be the major technology milestones achieved and the lessons learned from managing a $100M+ technology program.

Johnson, Les C.↗

Space Resources Roundtable 2

Contents include following: Developing Technologies for Space Resource Utilization - Concept for a Planetary Engineering Research Institute. Results of a Conceptual Systems Analysis of Systems for 200 m Deep Sampling of the Martian Subsurface. The Role of Near-Earth Asteroids in Long-Term Platinum Supply. Core Drilling for Extra-Terrestrial Mining. Recommendations by the "LSP and Manufacturing" Group to the NSF-NASA Workshop on Autonomous Construction and Manufacturing for Space Electrical Power Systems. Plasma Processing of Lunar and Planetary Materials. Percussive Force Magnitude in Permafrost. Summary of the Issues Regarding the Martian Subsurface Explorer. A Costing Strategy for Manufacturing in Orbit Using Extraterrestrial Resources. Mine Planning for Asteroid Orebodies. Organic-based Dissolution of Silicates: A New Approach to Element Extraction from LunarRegohth. Historic Frontier Processes Active in Future Space-based Mineral Extraction. The Near-Earth Space Surveillance (NIESS) Mission: Discovery, Tracking, and Characterization of Asteroids, Comets, and Artificial Satellites with a microsatellite. Privatized Space Resource Property Ownership. The Fabrication of Silicon Solar Cells on the Moon Using In-Situ Resources. A New Strategy for Exploration Technology Development: The Human Exploration and Development of Space (HEDS) Exploratiori/Commercialization Technology Initiative. Space Resources for Space Tourism. Recovery of Volatiles from the Moon and Associated Issues. Preliminary Analysis of a Small Robot for Martian Regolith Excavation. The Registration of Space-based Property. Continuous Processing with Mars Gases. Drilling and Logging in Space; An Oil-Well Perspective. LORPEX for Power Surges: Drilling, Rock Crushing. An End-To-End Near-Earth Asteroid Resource Exploitation Plan. An Engineering and Cost Model for Human Space Settlement Architectures: Focus on Space Hotels and Moon/Mars Exploration. The Development and Realization of a Silicon-60-based Economy in CisLunar Space. Our Lunar Destiny: Creating a Lunar Economy. Cost-Effective Approaches to Lunar Passenger Transportation. Lunar Mineral Resources: Extraction and Application. Space Resources Development - The Link Between Human Exploration and the Long-term Commercialization of Space. Toward a More Comprehensive Evaluation of Space Information. Development of Metal Casting Molds by Sol-Gel Technology Using Planetary Resources. A New Concept in Planetary Exploration: ISRU with Power Bursts. Bold Space Ventures Require Fervent Public Support. Hot-pressed Iron from Lunar Soil. The Lunar Dust Problem: A Possible Remedy. Considerations on Use of Lunar Regolith in Lunar Constructions. Experimental Study on Water Production by Hydrogen Reduction of Lunar Soil Simulant in a Fixed Bed Reactor.

Ignatiev, A.↗

Status of a Power Processor for the Prometheus-1 Electric Propulsion System

NASA is developing technologies for nuclear electric propulsion for proposed deep space missions in support of the Exploration initiative under Project Prometheus. Electrical power produced by the combination of a fission-based power source and a Brayton power conversion and distribution system is used by a high specific impulse ion propulsion system to propel the spaceship. The ion propulsion system include the thruster, power processor and propellant feed system. A power processor technology development effort was initiated under Project Prometheus to develop high performance and lightweight power-processing technologies suitable for the application. This effort faces multiple challenges including developing radiation hardened power modules and converters with very high power capability and efficiency to minimize the impact on the power conversion and distribution system as well as the heat rejection system. This paper documents the design and test results of the first version of the beam supply, the design of a second version of the beam supply and the design and test results of the ancillary supplies.

Pinero, Luis R.↗

Research in Hypersonic Airbreathing Propulsion at the NASA Langley Research Center

The NASA Langley Research Center has been conducting research for over four decades to develop technology for an airbreathing-propelled vehicle. Several other organizations within the United States have also been involved in this endeavor. Even though significant progress has been made over this period, a hypersonic airbreathing vehicle has not yet been realized due to low technology maturity. One of the major reasons for the slow progress in technology development has been the low level and cyclic nature of funding. The paper provides a brief historical overview of research in hypersonic airbreathing technology and then discusses current efforts at NASA Langley to develop various analytical, computational, and experimental design tools and their application in the development of future hypersonic airbreathing vehicles. The main focus of this paper is on the hypersonic airbreathing propulsion technology.

Kumar, Ajay↗

Full Scale Engine Demonstration of Additively Manufactured High Gamma Prime Turbine Blade

Additive manufacturing (AM), also known as 3D printing, is a rapidly developing technology with tremendous potential in both developmental and production applications. Solar Turbines Incorporated is committed to AM technology development for gas turbine applications. The ability to metal 3D print novel designs of turbine blades capable of actual turbine engine operation would effectively reduce design validation cycle time and allow acquisition of key performance data early in a design campaign. In support of Solar’s advanced manufacturing development and ongoing engine efficiency improvement goals, ORNL and Solar conducted a project to 3D print, machine, inspect, and engine test a full set of Mercury TM 50 stage 2 turbine blades. This full-scale, hot-fired engine demonstration has identified both the capabilities and limitations of the current technologies required to produce turbine hot-section AM components.

36 MATERIALS SCIENCE↗

Recent Status of SIM Lite Astrometric Observatory Mission: Flight Engineering Risk Reduction Activities

The SIM Lite Astrometric Observatory is a mission concept for a space-borne instrument to perform micro-arc-second narrow-angle astrometry to search 60 to 100 nearby stars for Earth-like planets, and to perform global astrometry for a broad astrophysics program. The instrument consists of two Michelson stellar interferometers and a telescope. The first interferometer chops between the target star and a set of reference stars. The second interferometer monitors the attitude of the instrument in the direction of the target star. The telescope monitors the attitude of the instrument in the other two directions. The main enabling technology development for the mission was completed during phases A & B. The project is currently implementing the developed technology onto flight-ready engineering models. These key engineering tasks will significantly reduce the implementation risks during the flight phases C & D of the mission. The main optical interferometer components, including the astrometric beam combiner, the fine steering optical mechanism, the path-length-control and modulation optical mechanisms, focal-plane camera electronics and cooling heat pipe, are currently under development. Main assemblies are built to meet flight requirements and will be subjected to flight qualification level environmental testing (random vibration and thermal cycling) and performance testing. This paper summarizes recent progress in engineering risk reduction activities.

astrometry↗

Autonomous flight and remote site landing guidance research for helicopters

Automated low-altitude flight and landing in remote areas within a civilian environment are investigated, where initial cost, ongoing maintenance costs, and system productivity are important considerations. An approach has been taken which has: (1) utilized those technologies developed for military applications which are directly transferable to a civilian mission; (2) exploited and developed technology areas where new methods or concepts are required; and (3) undertaken research with the potential to lead to innovative methods or concepts required to achieve a manual and fully automatic remote area low-altitude and landing capability. The project has resulted in a definition of system operational concept that includes a sensor subsystem, a sensor fusion/feature extraction capability, and a guidance and control law concept. These subsystem concepts have been developed to sufficient depth to enable further exploration within the NASA simulation environment, and to support programs leading to the flight test.

Denton, R. V.↗

Hydropower Capital and O&M Costs: An Exploration of the FERC Form 1 Data

This report explores the potential for using responses from the Federal Energy Regulatory Commission’s (FERC’s) “Electric Utility Annual Report,” also known as FERC Form 1, as a cost database for conventional and pumped storage hydropower (PSH). The report outlines the process used to compile an easy-to-access database from the original FERC Form 1 data and discusses the historical cost/performance data. The steps for developing the database include downloading the annual FoxPro files from the FERC website (FERC, 2020), reading them into an Excel format, and reconciling naming issues across years, repeated entries, and shared assets, among others. The cleaned and compiled Form 1 database is available on Oak Ridge National Laboratory’s (ORNL’s) HydroSource website. For this report, the compiled Form 1 database was linked to two other hydropower databases, the National Inventory of Dams and the ORNL Existing Hydropower Assets, that provide additional information on the characteristics and other features of plants in the Form 1 data. Explorations of the plant characteristics, performance, capital costs, and operation and maintenance (O&M) cost data in the combined database were presented separately for conventional hydropower and PSH projects. Form 1 has several advantages as a hydropower cost database. First, the cost data is reported directly by plant owners. Second, Form 1 provides cost breakdowns of capital and operating costs for large conventional and PSH plants enabling more detailed tracking of hydropower costs compared with typical total cost estimates. Third, although the Form 1 data is not reported by all operational hydropower plants in the United States, the available data represents a wide range of plant characteristics and a sizable proportion of the hydropower fleet (61% of PSH plants and 22% of conventional hydropower plants by capacity). The lower proportion of the conventional hydropower fleet is because Form 1 reporting requirements apply only to private utilities that meet given size thresholds, leaving out federally owned facilities and many smaller hydropower plants. Overall, the Form 1 cost database represents a unique, publicly available database on hydropower asset capital and O&M costs. This report leads to a compiled database for the reporting years 1994 to 2020 that helps resolve issues with accessibility and use of the FERC Form 1 data by hydropower plant owners, project developers, technology developers, and regulators.

13 HYDRO ENERGY↗