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NASA NTRS2015

Insulation Reformulation Development

The current Space Launch System (SLS) internal solid rocket motor insulation, polybenzimidazole acrylonitrile butadiene rubber (PBI-NBR), is a new insulation that replaced asbestos-based insulations found in Space Shuttle heritage solid rocket boosters. PBI-NBR has some outstanding characteristics such as an excellent thermal erosion resistance, low thermal conductivity, and low density. PBI-NBR also has some significant challenges associated with its use: Air entrainment/entrapment during manufacture and lay-up/cure and low mechanical properties such as tensile strength, modulus, and fracture toughness. This technology development attempted to overcome these challenges by testing various reformulated versions of booster insulation. The results suggest the SLS program should continue to investigate material alternatives for potential block upgrades or use an entirely new, more advanced booster. The experimental design was composed of a logic path that performs iterative formulation and testing in order to maximize the effort. A lab mixing baseline was developed and documented for the Rubber Laboratory in Bldg. 4602/Room 1178.

Chapman, Cynthia↗

NASA NTRS2018

Development of High-Performance Solar Cells for the Jupiter and Saturn Environments

Many of the mission targets that NASA and the planetary-science community are interested in are located in deep space, in the 5-10AU range. This provides compelling motivation to develop solar cells and arrays that are highly efficient in low irradiance low temperature (LILT) environments. We give several examples of the iterative process our team has employed to develop cell designs that optimize the performance at LILT. We also provide results on advanced-architecture devices that have already demonstrated very high efficiencies in the Jupiter and Saturn LILT and radiation environments, specifically four-junction inverted metamorphic and triple-junction upright metamorphic solar cells, respectively.

Boca, Andreea↗

NASA NTRSDate not supplied

Evaluation of Preliminary Buffet Forcing Function Development based on Wind-Tunnel Tests of Geometrically-similar Models

The current state-of-the-art for launch vehicle buffet load estimation involves wind tunnel testing of highly instrumented rigid models and data processing of experimental unsteady pressure measurements to estimate the fluctuating aerodynamic loads. The model and instrumentation requirements to accomplish this type of testing are significant. The rigid model, in particular, must be built with relatively high geometric fidelity to approximate similar aerodynamic phenomena that will occur during the full-scale vehicle flight. Due to this requirement, several iterative wind tunnel tests are often required during the design maturation of the vehicle. For preliminary buffet load estimation, however, data from previous launch vehicle wind tunnel tests of geometrically similar models can be used to provide initial buffet environment estimates before a high geometric fidelity wind tunnel test has been conducted. In this paper, two components of this preliminary buffet estimation process are described: (1) assembly of buffet forcing functions from multiple data sources and (2) scaling of these buffet forcing functions to geometrically-similar components of a target vehicle configuration. The impacts of these estimation methods on the full-vehicle buffet forcing functions, including their longitudinal distribution along the vehicle, frequency-content at individual stations, and station-to-station coherence, are investigated. Considerations for using these methods to extrapolate wind tunnel data to geometrically similar models are also discussed.

Patrick S Heaney↗

NASA NTRSDate not supplied

A Crew Seat for Human Exploration in Multiple Gravity Environments

This work attempts to develop a single crew seating solution that is applicable across a range of gravity environments encountered by spacecraft proposed in several conceptual spacecraft architectures. All of these spacecraft will need to provide some sort of stationary accommodation for the crew for performing various activities such as work in science laboratories, maintenance and repair facilities, medical care facilities, and spacecraft operations centers, as well as for basic habitation in crew quarters, entertainment / relaxation facilities, and crew dining facilities. Depending on the spacecraft or architecture, this stationary accommodation may be experienced continuously in microgravity, such as would be the case for the Deep Space Exploration Vehicle. Alternately, it could be in continuous lunar or Martian gravity, such as the Common Habitat base camps. It could experience fractional gravity, such as a Pressurized Rover for In-Space Missions at a Near Earth Asteroid or one of the Martian moons. It could alternate between artificial gravity and microgravity, such as the Nautilus-X. It could alternate between microgravity and lunar or Martian gravity, such as the SpaceX Starship Human Landing System or the Blue Origin Blue Moon Block 2 Human Landing System. Or it could be in continuous Earth gravity, such as ground trainer systems. Prior human spaceflight systems for stationary accommodation have been focused on microgravity applications. These systems have their own limitations and cannot be used in a gravity environment. A public crowdsourcing campaign generated dozens of ideas, which ultimately generated a Gecko Mobility Aids system for crew translation and the Multi-Gravity Crew Seat (MGCS) for stationary accommodation. The MGCS functions in gravity as a traditional terrestrial seat, performing functions of load for the overall body and forearms, as well as head and neck load relief while positioning the body within range of an intended task. In microgravity, the MGCS functions as a body restraint, securing the body against inadvertent drifting by applying a restraining pressure at the front and back of the thighs, shoulders, and back. The initial MGCS concept was developed in a NASA hackathon and was refined through a review of dozens of terrestrial seating styles. Additionally, a review of anthropometry and biomechanics data related to the neutral body posture was conducted to help inform the microgravity configuration of the MGCS. A series of CAD models were iteratively developed, with subject matter expert reviews leading to design improvements. A scale model was constructed and used with a humanoid model to demonstrate MGCS accommodation of a human-like body in both gravity and microgravity modes. Work to develop a full-scale protype of the MGCS is discussed, including design and fabrication of the headrest, arm rest, seat back, seat pan, seat base, and the conversion mechanisms. A 1-g human-in-the-loop evaluation of the prototype assessed the acceptability of performing seated activities in the MGCS, collecting data on the usability, comfort, and ease of ingress/egress. Based on the evaluation results, design modifications needed for reduced gravity testing are documented and initial work is indicated for a reduced gravity test plan.

Restraints and Mobility Aids↗

NASA NTRSDate not supplied

Probabilistic Calibration of Expensive Models using Efficiently Trained Surrogates

Calibration of computational models in the presence of uncertainty is often cast as a Bayesian inference problem and solved via sampling methods, e.g., Markov chain Monte Carlo. When the computational model is expensive, this task becomes intractable due to the large number of samples required to accurately estimate the posterior distribution of the calibration parameters. A popular solution to this problem is to use machine learning to develop a faster-to-evaluate, lower-fidelity substitute for the original model to serve as a surrogate while solving the inference problem. Although considered an offline cost, generating training data to construct this surrogate model can still be an expensive task in practice. An active learning algorithm is presented that focuses training on improving surrogate accuracy specifically in and around the bulk of the posterior distribution, as this is where the model is exercised during calibration. Candidate samples are drawn from families of distributions related to an approximation of the posterior. The sample maximizing predictive variance is then selected for evaluation by the original computational model, yielding a label for the training point. Iterating this approach increases efficiency relative to space filling designs (e.g., Latin hypercube sampling) by avoiding low probability points. Practical considerations are discussed, including the benefits of using a sequential Monte Carlo sampling approach, convergence heuristics, and the importance of both exploration and exploitation given that the true posterior is unknown a priori.

uncertainty quantification↗

DOE OSTI2026

A Sub-electron-noise Skipper-CCD Readout ASIC with Improved Channel-to-channel Isolation and an Integrated Cryogenic Voltage Reference

The MIDNA application specific integrated circuits (ASICs) are a series of skipper-CCD readout chips fabricated in a 65 nm low-power CMOS process that implement a correlated double sampling signal processing chain based on dual-slope integrators. They are capable of working from room to cryogenic temperatures, down to 84 K. The present iteration of the ASIC has been fabricated including several design updates and the addition of an on-chip voltage reference, resulting in improved performance. This work presents the main vulnerabilities solved, the changes carried out, and the resulting performance benefits. Measurements with a skipper-CCD and the ASIC at 140 K showed that the single-electron resolution can be reached by averaging the measured charge in the analog domain using the analog pile-up technique with a readout noise as low as 0.11 erms of equivalent charge for 1200 samples. The channel-to-channel crosstalk was also characterized showing values better than -62 dB.

Alcalde Bessia, Fabricio↗

DOE OSTI2026

A Sub-electron-noise Skipper-CCD Readout ASIC with Improved Channel-to-channel Isolation and an Integrated Cryogenic Voltage Reference

Alcalde Bessia, Fabricio↗

DOE OSTI2025

From Obsolete to Optimal (ATR Demineralized Water System)

My project was migrating a Human-Machine Interface (HMI) and Programmable Logic Controller (PLC) program from legacy software to a modern platform, enhancing operational efficiency and eliminating unsupported, obsolete equipment. Initially, I used a migration tool to transfer the programs to the new software, then manually updated variables to align with the new PLC. I optimized the PLC code by leveraging new scaling features in the I/O cards, removing over 45 obsolete rungs, and enhancing clarity with functional tag aliases. Next, I modernized the HMI's visuals with an updated color scheme and 3D buttons. I developed multiple interface versions iteratively refining them based on operator feedback. I also designed and created a dedicated "Rounds" screen incorporating insights from a previous intern’s project to streamline daily rounds. To improve clarity, consistency, and efficiency I redesigned the entire interface. Adding visual indicators to enhance operational awareness: red is used for values outside normal specifications, green for normal operating modes, yellow for manual mode, and grey for offline units. Additionally, I added a dynamic visual representation of tank levels, creating PLC logic to show the level in inches as well as inches and feet. I then incorporated a navigation sidebar to facilitate efficient screen transitions. Risk of human error was mitigated by defining narrow input ranges for tank level shutoff and password protecting setpoint changes. I also fixed issues with datatypes that caused inaccuracies in the original code. Overall, this comprehensive upgrade significantly enhanced the HMI's functionality, user experience, and operational reliability.

47 - OTHER INSTRUMENTATION↗

NASA NTRS1999

Rotor Re-Design for the SSME Fuel Flowmeter

The present report describes the process of redesigning a new rotor for the SSME Fuel Flowmeter. The new design addresses the specific requirement of a lower rotor speed which would allow the SSME operation at 1 15% rated power level without reaching a blade excitation by the wakes behind the hexagonal flow straightener upstream at frequencies close to the blade natural frequency. A series of calculations combining fleet flowmeters test data, airfoil fluid dynamics and CFD simulations of flow patterns behind the flowmeter's hexagonal straightener has led to a blade twist design alpha = alpha (radius) targeting a kf constant of 0.8256. The kf constant relates the fuel volume flow to the flowmeter rotor speed, for this particular value 17685 GPM at 3650 RPM. Based on this angle distribution, two actual blade designs were developed. A first design using the same blade airfoil as the original design targeted the new kf value only. A second design using a variable blade chord length and airfoil relative thickness targeted simultaneously the new kf value and an optimum blade design destined to provide smooth and stable operation and a significant increase in the blade natural frequency associated with the first bending mode, such that a comfortable margin could be obtained at 115% RPL. The second design is a result of a concurrent engineering process, during which several iterations were made in order to achieve a targeted blade natural frequency associated with the first bending mode of 1300 Hz. Water flow tests preliminary results indicate a kf value of 0.8179 for the f-irst design, which is within 1% of the target value. The second design rotor shows a natural frequency associated with the first bending mode of 1308 Hz, and a water-flow calibration constant of kf 0.8169.

Marcu, Bogdan↗

NASA NTRS1972

Automated design and optimization of flexible booster autopilots via linear programming, volume 1

A nonlinear programming technique was developed for the automated design and optimization of autopilots for large flexible launch vehicles. This technique, which resulted in the COEBRA program, uses the iterative application of linear programming. The method deals directly with the three main requirements of booster autopilot design: to provide (1) good response to guidance commands; (2) response to external disturbances (e.g. wind) to minimize structural bending moment loads and trajectory dispersions; and (3) stability with specified tolerances on the vehicle and flight control system parameters. The method is applicable to very high order systems (30th and greater per flight condition). Examples are provided that demonstrate the successful application of the employed algorithm to the design of autopilots for both single and multiple flight conditions.

Hauser, F. D.↗

NASA NTRS2016

Phase Retrieval Implementation for the WFIRST Coronagraph Development Testbed

The Wide-Field Infrared Survey Telescope (WFIRST) is a 2.4m diameter space telescope NASA program. The payload will include two instruments, including a coronagraph instrument (CGI). The CGI will be the first active, high-contrast stellar coronagraph in space intended for imaging, discovery, and spectral characterization of exoplanets and debris discs. The CGI designs under development use deformable mirrors (DM) to create a point spread function (PSF) with a dark region around the obscured star object. Each DM consists of an array of actuators, and each actuator causes a local displacement to a thin, mirror-coated, glass face sheet. The actuator displacements are designed to create the PSF. Typically, phase retrieval is used to set the DM actuator displacements to their designed pattern, and then the actuators are further modified by an iterative control loop to correct for system non-idealities. To observe an exoplanet near the star object, the contrast in the annular region must be better than 10^8 (10^9 after post processing) relative to the unobstructed image of the star [1,2]. The coronagraph testbed at Jet Propulsion Laboratory is used to test coronagraph design and control algorithms. The optical system (Fig. 1) is maintained in a vacuum tank so that the PSF is stable for long integration times. Phase retrieval is an important tool for the testbed and serves several purposes, in addition to setting initial DM actuator displacements. Other uses include evaluation of systematic wavefront error introduced by system components, and alignment of the DMs and pupil masks. For example, the location of specific DM actuators relative to the Lyot mask can be determined by displacing the actuator, then measuring the location of the phase disturbance in the pupil plane with phase retrieval. In the next section we further describe the optical train of the testbed and the collection of source and pupil images available as inputs for phase retrieval, as well as one phase retrieval algorithm employed. Section 3 shows example phase retrieval results.

Marx, David↗

NASA NTRS1998

On Managing the Use of Surrogates in General Nonlinear Optimization and MDO

This paper is concerned with a trust region approximation management framework (AMF) for solving the nonlinear programming problem in general and multidisciplinary optimization problems in particular The intent of the AMF methodology is to facilitate the solution of optimization problems with high-fidelity models. While such models are designed to approximate the physical phenomena they describe to a high degree of accuracy, their use in a repetitive procedure, for example, iterations of an optimization or a search algorithm, make such use prohibitively expensive. An improvement in design with lower-fidelity, cheaper models, however, does not guarantee a corresponding improvement for the higher-fidelity problem. The AMF methodology proposed here is based on a class of multilevel methods for constrained optimization and is designed to manage the use of variable-fidelity approximations or models in a systematic way that assures convergence to critical points of the original high-fidelity problem.

Alexandrov, Natalia M.↗

NASA NTRS1995

Aerothermodynamic testing requirements for future space transportation systems

Aerothermodynamics, encompassing aerodynamics, aeroheating, and fluid dynamic and physical processes, is the genesis for the design and development of advanced space transportation vehicles. It provides crucial information to other disciplines involved in the development process such as structures, materials, propulsion, and avionics. Sources of aerothermodynamic information include ground-based facilities, computational fluid dynamic (CFD) and engineering computer codes, and flight experiments. Utilization of this triad is required to provide the optimum requirements while reducing undue design conservatism, risk, and cost. This paper discusses the role of ground-based facilities in the design of future space transportation system concepts. Testing methodology is addressed, including the iterative approach often required for the assessment and optimization of configurations from an aerothermodynamic perspective. The influence of vehicle shape and the transition from parametric studies for optimization to benchmark studies for final design and establishment of the flight data book is discussed. Future aerothermodynamic testing requirements including the need for new facilities are also presented.

Paulson, John W., Jr.↗

NASA NTRSDate not supplied

Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗

DOE OSTI2021

Modeling iterative reconstruction and displacement field in the large scale structure

The next generation of galaxy surveys like the Dark Energy Spectroscopic Instrument and Euclid will provide datasets orders of magnitude larger than anything available to date. Our ability to model nonlinear effects in late time matter perturbations will be a key to unlock the full potential of these datasets, and the area of initial condition reconstruction is attracting growing attention. Iterative reconstruction developed by Marcel Schmittfull et al. is a technique designed to reconstruct the displacement field from the observed galaxy distribution. The nonlinear displacement field and initial linear density field are highly correlated. Therefore, reconstructing the nonlinear displacement field enables us to extract the primordial cosmological information better than from the late time density field at the level of the two-point statistics. This paper will test to what extent the iterative reconstruction can recover the true displacement field and construct a perturbation theory model for the postreconstructed field. We model the iterative reconstruction process with Lagrangian perturbation theory (LPT) up to third order for dark matter in real space and compare it with N-body simulations. Here we find that the simulated iterative reconstruction does not converge to the nonlinear displacement field, and the discrepancy mainly appears in the shift term, i.e., the term correlated directly with the linear density field. On the contrary, our 3LPT model predicts that the iterative reconstruction should converge to the nonlinear displacement field. We discuss the sources of discrepancy, including numerical noise/artifacts on small scales, and present an ad hoc phenomenological model that improves the agreement.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS2008

Development and Application of an Integrated Approach toward NASA Airspace Systems Research

The National Aeronautics and Space Administration's (NASA) Airspace Systems Program is contributing air traffic management research in support of the 2025 Next Generation Air Transportation System (NextGen). Contributions support research and development needs provided by the interagency Joint Planning and Development Office (JPDO). These needs generally call for integrated technical solutions that improve system-level performance and work effectively across multiple domains and planning time horizons. In response, the Airspace Systems Program is pursuing an integrated research approach and has adapted systems engineering best practices for application in a research environment. Systems engineering methods aim to enable researchers to methodically compare different technical approaches, consider system-level performance, and develop compatible solutions. Systems engineering activities are performed iteratively as the research matures. Products of this approach include a demand and needs analysis, system-level descriptions focusing on NASA research contributions, system assessment and design studies, and common systemlevel metrics, scenarios, and assumptions. Results from the first systems engineering iteration include a preliminary demand and needs analysis; a functional modeling tool; and initial system-level metrics, scenario characteristics, and assumptions. Demand and needs analysis results suggest that several advanced concepts can mitigate demand/capacity imbalances for NextGen, but fall short of enabling three-times current-day capacity at the nation s busiest airports and airspace. Current activities are focusing on standardizing metrics, scenarios, and assumptions, conducting system-level performance assessments of integrated research solutions, and exploring key system design interfaces.

Barhydt, Richard↗

DOE OSTI2020

ANDRA's Underground Research Laboratory in Bure: Major Role in the Cigeo Development - 20005

The Industrial Center for Geological Disposal, also called Cigeo, is the deep geological disposal facility project developed by Andra since 1991. It is intended for the final disposal of High-Level Waste (HLW) and Intermediate Level Waste-Long Lived (ILW-LL) generated in France by the nuclear industry. Cigeo is located in the east of France (Meuse/Haute-Marne site). The disposal will be implemented in a 140 to 160 m thick clay layer at about 500 m depth. The license application file will be submitted in 2020. If the license is granted, the construction of the pilot phase of Cigeo (ramp, shafts, drifts, initial disposal vaults) could start in 2025 at the earliest. Since 2000, the development of the safety case of Cigeo for post closure has been supported by a three-stage construction, design, and scientific and technological experiment program performed in the French Underground Research Laboratory (URL) in Bure. These stages of the URL activities supported the iterative interactions between the knowledge acquired by scientific and technological R and D program, the design process and the safety assessment. The stages focused on assessing the suitability of the disposal concept, providing the basis for safety options and construction design, and preparing for licensing using large scale demonstrations. Recently, Andra launched the fourth development stage of the URL to implement a new set of technological experiments aiming at consolidating the design options of disposal cells and galleries for the pilot phase of Cigeo and at assessing monitoring technologies. Recently, Andra launched the fourth development stage of the URL to implement a new set of technological experiments aiming at consolidating the design of the pilot phase of Cigeo and at assessing design options and monitoring technologies. Removal of a segment ring, construction of an X drift crossing, improved construction techniques for HLW vaults, and construction of an ILW-LL prototype disposal vault are example activities during the fourth phase. In the future, the URL in Bure will remain a unique location to carry out research on promising technical solutions, to reduce Cigeo's construction and operation risks and strengthen the long-term safety assessment. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2016

Computational Study of Flow Interactions in Coaxial Rotors

Although the first idea of coaxial rotors appeared more than 150 years ago, most helicopters have used single main-rotor/tail-rotor combination. Since reactive moments of coaxial rotors are canceled by contra-rotation, no tail rotor is required to counter the torque generated by the main rotor. Unlike the single main rotor design that distributes power to both main and tail rotors, all of the power for coaxial rotors is used for vertical thrust. Thus, no power is wasted for anti-torque or directional control. The saved power helps coaxial rotors reach a higher hover ceiling than single rotor helicopters. Another advantage of coaxial rotors is that the overall rotor diameter can be reduced for a given vehicle gross weight because each rotor provides a maximum contribution to vertical thrust to overcome vehicle weight. However, increased mechanical complexity of the hub has been one of the challenges for manufacturing coaxial rotorcraft. Only the Kamov Design Bureau of Russia had been notably successful in production of coaxial helicopters until Sikorsky built X2, an experimental compound helicopter. Recent developments in unmanned aircraft systems and high-speed rotorcraft have renewed interest in the coaxial configuration. Multi-rotors are frequently used for small electric unmanned rotorcraft partly due to mechanical simplicity. The use of multiple motors provides redundancy as well as cost-efficiency. The multi-rotor concept has rarely been used until recently because of its inherent stability and control problems. However, advances in inexpensive electronic flight control systems have opened the floodgates for small drones using multirotors. Coaxial rotors have started to appear in some multi-rotor configurations. Small coaxial rotors have often been designed using a hundred year old approach that is "sketch, build, fly, and iterate." In that approach, there is no systematic way to explore trade-offs or determine logical next steps. It is neither possible to account for multiple real-world constraints up front in design nor possible to know what performance is possible with a given design. Since unmanned vehicles are sized and optimized for the particular mission, a modern low-fidelity conceptual design and sizing tool that has been used for the design of large helicopters can be used for design of small coaxial rotorcraft. However, unlike most helicopters with single main rotor, the interactions between the upper and lower rotors emerge as an important factor to consider in design because an increase in performance of a multi-rotor system is not proportional to the number of rotors. Interference losses and differences in thrusts between the upper and lower rotors were investigated by theoretical methods as well as a computational fluid dynamics (CFD) method using the Reynolds-Averaged Navier-Stokes (RANS) equations. In this work, hybrid turbulence models are used to investigate the physics of interactions between coaxial rotors and a fuselage that are not well understood. Present study covers not only small-scale drones but also large-scale coaxial rotors for heavy-lifting missions. Considering the recently proposed FAA drone rules that require the flight only in visual line-of-sight, a large multirotor might be used as an airborne carrier for launch and recovery of unmanned aircraft systems with a human operator onboard. For applications to civil operations, their aerodynamic performance and noise levels need to be assessed. Noise is one of the largest limiting factors to rotorcraft operations in urban area. Since the high-frequency noise of multi-rotors may increase the annoyance, noise may turn out to be a key issue that must be addressed for market acceptability. One of the objectives of the present work is to study the effects of inter-rotor spacing and collectives on the performance, efficiency, and acoustics of coaxial rotor systems.

Study↗