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NASA NTRS2024

Plasma Rapid Oxidation Technique for Extending Component Tenability (PROTECT)

Additive manufacturing (AM) is increasingly utilized in aerospace applications. However, post-processing is required for many applications, so intricate designs are limited. Plasma electrolytic oxidation (PEO) was investigated as a post-processing treatment on Ti-6-4 (or Ti-6Al-4V: Alpha-beta titanium alloy with a high specific strength and excellent corrosion resistance)additively manufactured specimens. The “Keronite Black” PEO treatment reduced the surface roughness (Ra) of test specimens by approximately 0.5 μm. This reduction in Ra compared to the as-printed sample was hypothesized to benefit corrosion and fatigue properties because increased Ra is known to negatively impact corrosion and fatigue characteristics. Up to a 101% improvement in the corrosion potential (Ɛcorr) was observed. Although fatigue characteristics varied by PEO parameters, there was no significant fatigue debit due to the PEO treatment. Additionally, no effect to adhesion characteristics was observed due to PEO treatment. It is recommended that additional studies investigate the ability of PEO treatments to improve the corrosion, fatigue, chemical compatibility, radiation hardening, particle shedding characteristics, and flammability/oxidizer compatibility of aerospace additively manufactured components.

Jennifer Williams↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Metals for Aerospace Applications

High temperature refractory metals are required for a number of high temperature propulsion applications. Refractory metals are expensive, difficult to manufacture with high buy-to-fly ratios, and few vendors. Additive manufacture (AM) is used to produce C103, Molybdenum (Mo), and Tungsten (W) reaction chamber and thrust stand-off as well as Iridium ultra-fine lattice catalysts for integration into 1 N green propulsion thrusters. Refractory AM is in development and like traditional AM alloys requires substantial post-processing to include powder heat treatment, surface finish enhancement, inspection, and machining before placed in service. The combination of limited feedstock sources, high temperature processing, oxygen sensitivity, fracture prone nature, and need for elevated temperature mechanical testing limit the number of qualified facilities capable of post-processing AM refractory materials, which add to cost and schedule constraints. However, properly implemented refractory metal AM can overcome existing manufacture limitations by greatly increasing design flexibility, new material options, reduced price, decreased lead-time, and leverage the ever growing AM commercial supply base.

Refractory metal additive manufacture↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Metals for Aerospace Applications

Refractory metal additive manufacture↗

NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗

NASA NTRS2014

Novel Overhang Support Designs for Powder-Based Electron Beam Additive Manufacturing (EBAM)

NASA Marshall Space Flight Center, in collaboration with the University of Alabama, has developed a contact-free support structure used to fabricate overhang-type geometries via EBAM. The support structure is used for 3-D metal-printed components for the aerospace, automotive, biomedical and other industries. Current techniques use support structures to address deformation challenges inherent in 3-D metal printing. However, these structures (overhangs) are bonded to the component and need to be removed in post-processing using a mechanical tool. This new technology improves the overhang support structure design for components by eliminating associated geometric defects and post-processing requirements.

Nabors, Sammy A.↗

NASA NTRS2002

Reducing the Requirements and Cost of Astronomical Telescopes

Limits on astronomical telescope apertures are being rapidly approached. These limits result from logistics, increasing complexity, and finally budgetary constraints. In an historical perspective, great strides have been made in the area of aperture, adaptive optics, wavefront sensors, detectors, stellar interferometers and image reconstruction. What will be the next advances? Emerging data analysis techniques based on communication theory holds the promise of yielding more information from observational data based on significant computer post-processing. This paper explores some of the current telescope limitations and ponders the possibilities increasing the yield of scientific data based on the migration computer post-processing techniques to higher dimensions. Some of these processes hold the promise of reducing the requirements on the basic telescope hardware making the next generation of instruments more affordable.

Smith, W. Scott↗

NASA NTRS1982

Evaluation of automated decisionmaking methodologies and development of an integrated robotic system simulation, volume 2, part 1. Appendix A: Software documentation

Documentation of the preliminary software developed as a framework for a generalized integrated robotic system simulation is presented. The program structure is composed of three major functions controlled by a program executive. The three major functions are: system definition, analysis tools, and post processing. The system definition function handles user input of system parameters and definition of the manipulator configuration. The analysis tools function handles the computational requirements of the program. The post processing function allows for more detailed study of the results of analysis tool function executions. Also documented is the manipulator joint model software to be used as the basis of the manipulator simulation which will be part of the analysis tools capability.

Lowrie, J. W.↗

NASA NTRS2022

Europa Clipper Payload Verification and Validation: Avionics-Instrument Interface Test Campaign

NASA's Europa Clipper mission will investigate Jupiter's icy moon Europa using a payload suite consisting of nine instruments to address a range of scientific objectives concerning Europa's habitability. As the project proceeds past its Critical Design Review, confidence is being built in the system's ability to achieve mission objectives through the implementation of a rigorous payload verification and validation (V&V) program. As part of this payload V&V program, instrument box-level testing was performed by the payload team to verify select instrument-avionics interface requirements. This testing was performed at JPL using the avionics testbed's Bulk Data Storage Emulator (BDSEM) with visiting instrument Test Models. This paper summarizes the Data Link test campaign involving roughly four days of functional testing per instrument, including planning, testing methods, types of issues found, and the requirement closure process. Detail is also provided on the development, deployment, and validation of a standardized analysis tool used in data reviews. This testing verified requirements related to commanding rates, loss of link, packet format, clock counters, loopback test capability, and SpaceWire jitter and skew margins. Additional risk reduction testing of basic commanding, counter behavior, science data collection and transfer, and interface swapping was also performed. Because the BDSEM venue was not originally designed to be a run for record venue, the process of characterizing venue fidelity and establishing suitability for requirement closure using data collected in this venue will also be addressed.In order to close requirements, an extensible tool was developed to post-process instrument command and telemetry data from their original binary to a human-readable format and give visibility to errors detected within the data, such as packets with Cyclic Redundancy Check errors. This tool, called payload-packet-parser, is a Python 3.9 command line tool built using a variety of open-source Python libraries. Payload-packet-parser was designed to support parsing command and telemetry packets for all Europa Clipper instruments and additional analysis tools were developed for verification of specific information interface requirements. This test campaign, including post-processing using a single parsing and verification toolset, allowed for early interface testing, alleviating testing burdens on instrument teams and buying down risk on the instrument-avionics interface by finding hardware and software issues and idiosyncrasies prior to integration with system test venues. Over twenty issues were discovered across the payload, resulting in software updates and instrument rework well in advance of any system impacts. This paper concludes with an assessment of benefits and costs of this type of testing and lessons learned.

Montanez, Leticia↗

NASA NTRS2015

Space Telescope Design to Directly Image the Habitable Zone of Alpha Centauri

The scientific interest in directly imaging and identifying Earth-like planets within the Habitable Zone (HZ) around nearby stars is driving the design of specialized direct imaging missions such as ACESAT, EXO-C, EXO-S and AFTA-C. The inner edge of Alpha Cen A&B Habitable Zone is found at exceptionally large angular separations of 0.7" and 0.4" respectively. This enables direct imaging of the system with a 0.3m class telescope. Contrast ratios on the order of 10(exp 10) are needed to image Earth-brightness planets. Low-resolution (5-band) spectra of all planets may allow establishing the presence and amount of an atmosphere. This star system configuration is optimal for a specialized small, and stable space telescope that can achieve high-contrast but has limited resolution. This paper describes an innovative instrument design and a mission concept based on a full Silicon Carbide off-axis telescope, which has a Phase Induced Amplitude Apodization coronagraph embedded in the telescope. This architecture maximizes stability and throughput. A Multi-Star Wave Front algorithm is implemented to drive a deformable mirror controlling simultaneously diffracted light from the on-axis and binary companion star. The instrument has a Focal Plane Occulter to reject starlight into a high precision pointing control camera. Finally we utilize a Orbital Differential Imaging (ODI) post-processing method that takes advantage of a highly stable environment (Earth-trailing orbit) and a continuous sequence of images spanning 2 years, to reduce the final noise floor in post processing to approximately 2e-11 levels, enabling high confidence and at least 90% completeness detections of Earth-like planets.

Low-resolution (5-band) spectra↗

NASA NTRS2009

Synthetic Foveal Imaging Technology

Synthetic Foveal imaging Technology (SyFT) is an emerging discipline of image capture and image-data processing that offers the prospect of greatly increased capabilities for real-time processing of large, high-resolution images (including mosaic images) for such purposes as automated recognition and tracking of moving objects of interest. SyFT offers a solution to the image-data processing problem arising from the proposed development of gigapixel mosaic focal-plane image-detector assemblies for very wide field-of-view imaging with high resolution for detecting and tracking sparse objects or events within narrow subfields of view. In order to identify and track the objects or events without the means of dynamic adaptation to be afforded by SyFT, it would be necessary to post-process data from an image-data space consisting of terabytes of data. Such post-processing would be time-consuming and, as a consequence, could result in missing significant events that could not be observed at all due to the time evolution of such events or could not be observed at required levels of fidelity without such real-time adaptations as adjusting focal-plane operating conditions or aiming of the focal plane in different directions to track such events. The basic concept of foveal imaging is straightforward: In imitation of a natural eye, a foveal-vision image sensor is designed to offer higher resolution in a small region of interest (ROI) within its field of view. Foveal vision reduces the amount of unwanted information that must be transferred from the image sensor to external image-data-processing circuitry. The aforementioned basic concept is not new in itself: indeed, image sensors based on these concepts have been described in several previous NASA Tech Briefs articles. Active-pixel integrated-circuit image sensors that can be programmed in real time to effect foveal artificial vision on demand are one such example. What is new in SyFT is a synergistic combination of recent advances in foveal imaging, computing, and related fields, along with a generalization of the basic foveal-vision concept to admit a synthetic fovea that is not restricted to one contiguous region of an image.

Hoenk, Michael↗

NASA NTRS2008

Hyperspectral Fluorescence and Reflectance Imaging Instrument

The system is a single hyperspectral imaging instrument that has the unique capability to acquire both fluorescence and reflectance high-spatial-resolution data that is inherently spatially and spectrally registered. Potential uses of this instrument include plant stress monitoring, counterfeit document detection, biomedical imaging, forensic imaging, and general materials identification. Until now, reflectance and fluorescence spectral imaging have been performed by separate instruments. Neither a reflectance spectral image nor a fluorescence spectral image alone yields as much information about a target surface as does a combination of the two modalities. Before this system was developed, to benefit from this combination, analysts needed to perform time-consuming post-processing efforts to co-register the reflective and fluorescence information. With this instrument, the inherent spatial and spectral registration of the reflectance and fluorescence images minimizes the need for this post-processing step. The main challenge for this technology is to detect the fluorescence signal in the presence of a much stronger reflectance signal. To meet this challenge, the instrument modulates artificial light sources from ultraviolet through the visible to the near-infrared part of the spectrum; in this way, both the reflective and fluorescence signals can be measured through differencing processes to optimize fluorescence and reflectance spectra as needed. The main functional components of the instrument are a hyperspectral imager, an illumination system, and an image-plane scanner. The hyperspectral imager is a one-dimensional (line) imaging spectrometer that includes a spectrally dispersive element and a two-dimensional focal plane detector array. The spectral range of the current imaging spectrometer is between 400 to 1,000 nm, and the wavelength resolution is approximately 3 nm. The illumination system consists of narrowband blue, ultraviolet, and other discrete wavelength light-emitting-diode (LED) sources and white-light LED sources designed to produce consistently spatially stable light. White LEDs provide illumination for the measurement of reflectance spectra, while narrowband blue and UV LEDs are used to excite fluorescence. Each spectral type of LED can be turned on or off depending on the specific remote-sensing process being performed. Uniformity of illumination is achieved by using an array of LEDs and/or an integrating sphere or other diffusing surface. The image plane scanner uses a fore optic with a field of view large enough to provide an entire scan line on the image plane. It builds up a two-dimensional image in pushbroom fashion as the target is scanned across the image plane either by moving the object or moving the fore optic. For fluorescence detection, spectral filtering of a narrowband light illumination source is sometimes necessary to minimize the interference of the source spectrum wings with the fluorescence signal. Spectral filtering is achieved with optical interference filters and absorption glasses. This dual spectral imaging capability will enable the optimization of reflective, fluorescence, and fused datasets as well as a cost-effective design for multispectral imaging solutions. This system has been used in plant stress detection studies and in currency analysis.

Ryan, Robert E.↗

NASA NTRS2005

Chimera Grid Tools

Chimera Grid Tools (CGT) is a software package for performing computational fluid dynamics (CFD) analysis utilizing the Chimera-overset-grid method. For modeling flows with viscosity about geometrically complex bodies in relative motion, the Chimera-overset-grid method is among the most computationally cost-effective methods for obtaining accurate aerodynamic results. CGT contains a large collection of tools for generating overset grids, preparing inputs for computer programs that solve equations of flow on the grids, and post-processing of flow-solution data. The tools in CGT include grid editing tools, surface-grid-generation tools, volume-grid-generation tools, utility scripts, configuration scripts, and tools for post-processing (including generation of animated images of flows and calculating forces and moments exerted on affected bodies). One of the tools, denoted OVERGRID, is a graphical user interface (GUI) that serves to visualize the grids and flow solutions and provides central access to many other tools. The GUI facilitates the generation of grids for a new flow-field configuration. Scripts that follow the grid generation process can then be constructed to mostly automate grid generation for similar configurations. CGT is designed for use in conjunction with a computer-aided-design program that provides the geometry description of the bodies, and a flow-solver program.

Chan, William M.↗

NASA NTRS2019

Photon Sieve Design and Fabrication for Imaging Characteristics Using UAV Flight

The Photon Sieve (PS) team at NASA Langley Research Center (LaRC) began receiving support for the development and characterization of PS devices through the NASA Internal Research & Development Program (IRAD) in 2015. The project involves ascertaining the imaging characteristics of various PS devices. These devices hold the potential to significantly reduce mission costs and improve imaging quality by replacing traditional reflector telescopes. The photon sieve essentially acts as a lens to diffract light to a concentrated point on the focal plane like a Fresnel Zone Plate (FZP). PS’s have the potential to focus light to a very small spot which is not limited by the width of the outermost zone as for the FZP and offers a promising solution for high resolution imaging. In the fields of astronomy, remote sensing, and other applications that require imaging of distant objects both on the ground and in the sky, it is often necessary to perform post-process filtering in order to separate noise signals that arise from multiple scattering events near the collection optic. The PS exhibits a novel filtering technique that rejects the unwanted noise without the need for time consuming post processing of the images. This project leverages key Langley resources to design, manufacture, and characterize a series of photon sieve specimens. After a prototype was developed and characterized in the Langley ISO5 optical cleanroom and laboratory, outside testing was conducted via the capture of images of the moon by using a telescopic setup. This next goal of the project is to design and develop a telescope and image capture system as a drone-based instrument payload. The vehicle utilized for the initial demonstration was a NASA hive model 1200 XE-8 research Unmanned Aerial Vehicle (UAV), capable of handling a 20-pound maximum payload with a 25-minute flight time. This NASA Technical Memorandum (NASA-TM) introduces preliminary results obtained using a PS-based imaging system on the UAV. The next version of the telescope structure will be designed around diffractive optical components and commercially available camera electronics to create a lightweight payload.

Kim, Hyun Jung↗

NASA NTRS2017

Relay Communications Support to the ExoMars Schiaparelli Lander

The European Space Agency’s ExoMars Trace Gas Orbiter (TGO) arrived at Mars on October 19, 2016, three days after releasing the Schiaparelli Lander on a ballistic trajectory to Meridiani Planum. During the separation event, and subsequently during Schiaparelli’s Entry, Descent, and Landing (EDL), the NASA-provided Electra UHF payload onboard TGO was used to record signals from the Schiaparelli Lander for post-processing on the ground to recover both tracking of the lander’s carrier signal and reconstruction of the lander’s 8 kb/s telemetry. In addition, ESA’s Mars Express orbiter also recorded the Schiaparelli signal, with ground post-processing providing independent tracking of the lander carrier signal, and the Giant Metrewave Radio Telescope near Pune, India was configured to provide real-time detection of the lander carrier signal. While an anomaly in the latter stages of EDL led to loss of the lander, these critical event data sets, and in particular the telemetry reconstruction enabled by the TGO Electra recording, proved essential in enabling detailed diagnosis of the anomaly. And while the loss of the lander during EDL precluded the planned surface relay operations, the preparations for that activity provide important lessons learned for future Mars relay support scenarios.

Edwards, Charles D., Jr.↗

NASA NTRS2017

A Compilation of MATLAB Scripts and Functions for MACGMC Analyses

The primary aim of the current effort is to provide scripts that automate many of the repetitive pre- and post-processing tasks associated with composite materials analyses using the Micromechanics Analysis Code with the Generalized Method of Cells. This document consists of a compilation of hundreds of scripts that were developed in MATLAB (The Mathworks, Inc., Natick, MA) programming language and consolidated into 16 MATLAB functions. (MACGMC). MACGMC is a composite material and laminate analysis software code developed at NASA Glenn Research Center. The software package has been built around the generalized method of cells (GMC) family of micromechanics theories. The computer code is developed with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated to increase the user friendliness, as well as to make it more robust in terms of input preparation and code execution. Finally, classical lamination theory has been implemented within the software, wherein GMC is used to model the composite material response of each ply. Thus, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. The pre-processing tasks include generation of a multitude of different repeating unit cells (RUCs) for CMCs and PMCs, visualization of RUCs from MACGMC input and output files and generation of the RUC section of a MACGMC input file. The post-processing tasks include visualization of the predicted composite response, such as local stress and strain contours, damage initiation and progression, stress-strain behavior, and fatigue response. In addition to the above, several miscellaneous scripts have been developed that can be used to perform repeated Monte-Carlo simulations to enable probabilistic simulations with minimal manual intervention. This document is formatted to provide MATLAB source files and descriptions of how to utilize them. It is assumed that the user has a basic understanding of how MATLAB scripts work and some MATLAB programming experience.

Materials Engineering↗

NASA NTRS2000

A New Eddy Dissipation Rate Formulation for the Terminal Area PBL Prediction System(TAPPS)

The TAPPS employs the MASS model to produce mesoscale atmospheric simulations in support of the Wake Vortex project at Dallas Fort-Worth International Airport (DFW). A post-processing scheme uses the simulated three-dimensional atmospheric characteristics in the planetary boundary layer (PBL) to calculate the turbulence quantities most important to the dissipation of vortices: turbulent kinetic energy and eddy dissipation rate. TAPPS will ultimately be employed to enhance terminal area productivity by providing weather forecasts for the Aircraft Vortex Spacing System (AVOSS). The post-processing scheme utilizes experimental data and similarity theory to determine the turbulence quantities from the simulated horizontal wind field and stability characteristics of the atmosphere. Characteristic PBL quantities important to these calculations are determined based on formulations from the Blackadar PBL parameterization, which is regularly employed in the MASS model to account for PBL processes in mesoscale simulations. The TAPPS forecasts are verified against high-resolution observations of the horizontal winds at DFW. Statistical assessments of the error in the wind forecasts suggest that TAPPS captures the essential features of the horizontal winds with considerable skill. Additionally, the turbulence quantities produced by the post-processor are shown to compare favorably with corresponding tower observations.

Charney, Joseph J.↗

NASA NTRS2013

A Lightweight I/O Scheme to Facilitate Spatial and Temporal Queries of Scientific Data Analytics

In the era of petascale computing, more scientific applications are being deployed on leadership scale computing platforms to enhance the scientific productivity. Many I/O techniques have been designed to address the growing I/O bottleneck on large-scale systems by handling massive scientific data in a holistic manner. While such techniques have been leveraged in a wide range of applications, they have not been shown as adequate for many mission critical applications, particularly in data post-processing stage. One of the examples is that some scientific applications generate datasets composed of a vast amount of small data elements that are organized along many spatial and temporal dimensions but require sophisticated data analytics on one or more dimensions. Including such dimensional knowledge into data organization can be beneficial to the efficiency of data post-processing, which is often missing from exiting I/O techniques. In this study, we propose a novel I/O scheme named STAR (Spatial and Temporal AggRegation) to enable high performance data queries for scientific analytics. STAR is able to dive into the massive data, identify the spatial and temporal relationships among data variables, and accordingly organize them into an optimized multi-dimensional data structure before storing to the storage. This technique not only facilitates the common access patterns of data analytics, but also further reduces the application turnaround time. In particular, STAR is able to enable efficient data queries along the time dimension, a practice common in scientific analytics but not yet supported by existing I/O techniques. In our case study with a critical climate modeling application GEOS-5, the experimental results on Jaguar supercomputer demonstrate an improvement up to 73 times for the read performance compared to the original I/O method.

Temporal Queries↗

NASA NTRSDate not supplied

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗