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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Novel Engineering and Fabrication Techniques Tested in Low-Noise- Research Fan Blades

A major source of fan noise in commercial turbofan engines is the interaction of the wake from the fan blades with the stationary vanes (stators) directly behind them. The Trailing Edge Blowing (TEB) project team at the NASA Glenn Research Center designed and fabricated new fan blades to study the effects of fan trailing edge blowing as a potential noise-reduction concept. The intent is to fill the rotor wake by supplying air to the rotor blade trailing edge at the proper conditions to minimize the wake deficit, and thus generate less noise. The TEB hardware is designed for the Active Noise Control Fan (ANCF) test rig in Glenn's Aeroacoustic Propulsion Laboratory. For this test, the air is fed from an external supply through the shaft of the rig. It is distributed to the base of each blade through an impeller, where it is forced into a plenum at the core of each blade. In actual engine configuration, air would most likely be bled from the compressor, but only at times when noise is an issue, such as takeoffs and landings. Glenn researchers designed and manufactured the blades in-house, using new techniques and concepts. The skins, which were designed for maximum strength in the directions of highest stress, were molded from multiple layers of carbon fiber. Considerable use was made of rapid prototyping techniques, such as laser sintering. The core was sintered from a lightweight polymer, and the retainer was CNC-machined (computer numerical control machined) from aluminum. All the components were joined with a cold-cure aerospace adhesive. These techniques and processes reduced the overall cost and allowed the new concept to be studied much sooner than would be possible using traditional fabrication methods. Since this test rig did not support the use of blade-monitoring techniques such as strain gauges, extensive bench testing was required to qualify the design. The blades were examined using a variety of methods including holography, pull tests (cyclic and failure), shake tests, rap tests, and nondestructive inspection. Acoustic testing of the ANCF fan using TEB has been ongoing since January of 2001. The fan has completed about 100 hr of testing with no structural, vibrational, or fatigue problems. Far-field acoustic measurements, in-duct mode measurements, precise hot wire surveys, and detailed performance measurements are providing data for evaluating the concept. The far-field noise data show that tone noise was reduced significantly with the initial ANCF TEB fan design. In addition, a significant reduction in unsteady stator loading has been measured, indicating the potential for stator broadband noise reduction. The acoustic benefits will be assessed and important design parameters identified to improve the ability to fully exploit any benefit provided by this technique. On the basis of the success of trailing edge blowing, Glenn plans to continue this research with a higher speed, higher pressure ratio fan operating in an acoustic wind tunnel to simulate flight conditions.

Cunningham, Cameron C.↗
NASA NTRS2007

Multi-Sensor Testing for Automated Rendezvous and Docking Sensor Testing at the Flight Robotics Laboratory

The Exploration Systems Architecture defines missions that require rendezvous, proximity operations, and docking (RPOD) of two spacecraft both in Low Earth Orbit (LEO) and in Low Lunar Orbit (LLO). Uncrewed spacecraft must perform automated and/or autonomous rendezvous, proximity operations and docking operations (commonly known as AR&D). The crewed missions may also perform rendezvous and docking operations and may require different levels of automation and/or autonomy, and must provide the crew with relative navigation information for manual piloting. The capabilities of the RPOD sensors are critical to the success of the Exploration Program. NASA has the responsibility to determine whether the Crew Exploration Vehicle (CEV) contractor proposed relative navigation sensor suite will meet the requirements. The relatively low technology readiness level of AR&D relative navigation sensors has been carried as one of the CEV Project's top risks. The AR&D Sensor Technology Project seeks to reduce the risk by the testing and analysis of selected relative navigation sensor technologies through hardware-in-the-loop testing and simulation. These activities will provide the CEV Project information to assess the relative navigation sensors maturity as well as demonstrate test methods and capabilities. The first year of this project focused on a series of"pathfinder" testing tasks to develop the test plans, test facility requirements, trajectories, math model architecture, simulation platform, and processes that will be used to evaluate the Contractor-proposed sensors. Four candidate sensors were used in the first phase of the testing. The second phase of testing used four sensors simultaneously: two Marshall Space Flight Center (MSFC) Advanced Video Guidance Sensors (AVGS), a laser-based video sensor that uses retroreflectors attached to the target vehicle, and two commercial laser range finders. The multi-sensor testing was conducted at MSFC's Flight Robotics Laboratory (FRL) using the FRL's 6-DOF gantry system, called the Dynamic Overhead Target System (DOTS). The target vehicle for "docking" in the laboratory was a mockup that was representative of the proposed CEV docking system, with added retroreflectors for the AVGS. The multi-sensor test configuration used 35 open-loop test trajectories covering three major objectives: (1) sensor characterization trajectories designed to test a wide range of performance parameters; (2) CEV-specific trajectories designed to test performance during CEV-like approach and departure profiles; and (3) sensor characterization tests designed for evaluating sensor performance under more extreme conditions as might be induced during a spacecraft failure or during contingency situations. This paper describes the test development, test facility, test preparations, test execution, and test results of the multi-sensor series of trajectories.

Brewster, L.↗
NASA NTRS2008

Multi-Sensor Testing for Automated Rendezvous and Docking Sensor Testing at the Flight Robotics Lab

The Exploration Systems Architecture defines missions that require rendezvous, proximity operations, and docking (RPOD) of two spacecraft both in Low Earth Orbit (LEO) and in Low Lunar Orbit (LLO). Uncrewed spacecraft must perform automated and/or autonomous rendezvous, proximity operations and docking operations (commonly known as AR&D). The crewed missions may also perform rendezvous and docking operations and may require different levels of automation and/or autonomy, and must provide the crew with relative navigation information for manual piloting. The capabilities of the RPOD sensors are critical to the success ofthe Exploration Program. NASA has the responsibility to determine whether the Crew Exploration Vehicle (CEV) contractor-proposed relative navigation sensor suite will meet the requirements. The relatively low technology readiness level of AR&D relative navigation sensors has been carried as one of the CEV Project's top risks. The AR&D Sensor Technology Project seeks to reduce the risk by the testing and analysis of selected relative navigation sensor technologies through hardware-in-the-Ioop testing and simulation. These activities will provide the CEV Project information to assess the relative navigation sensors maturity as well as demonstrate test methods and capabilities. The first year of this project focused on a series of "pathfinder" testing tasks to develop the test plans, test facility requirements, trajectories, math model architecture, simulation platform, and processes that will be used to evaluate the Contractor-proposed sensors. Four candidate sensors were used in the first phase of the testing. The second phase of testing used four sensors simultaneously: two Marshall Space Flight Center (MSFC) Advanced Video Guidance Sensors (AVGS), a laser-based video sensor that uses retroreflectors attached to the target vehicle, and two commercial laser range finders. The multi-sensor testing was conducted at MSFC's Flight Robotics Laboratory (FRL) using the FRL's 6-DOF gantry system, called the Dynamic Overhead Target System (DOTS). The target vehicle for "docking" in the laboratory was a mockup that was representative of the proposed CEV docking system, with added retroreflectors for the AVGS.' The multi-sensor test configuration used 35 open-loop test trajectories covering three major objectives: (l) sensor characterization trajectories designed to test a wide range of performance parameters; (2) CEV-specific trajectories designed to test performance during CEV-like approach and departure profiles; and (3) sensor characterization tests designed for evaluating sensor performance under more extreme conditions as might be induced during a spacecraft failure or during contingency situations. This paper describes the test development, test facility, test preparations, test execution, and test results of the multisensor series oftrajectories

Brewster, Linda L.↗
NASA NTRS2000

Preliminary Analysis and Design of a Rocket Based Combined Cycle for Efficient Access to Space

Access to space is presently limited by cost. The cost of delivering a payload to low earth orbit (LEO) is on average $10,000 per pound of payload, in the United States. Much of this cost is incurred from the operation of vehicles developed with 30-40 year old technology. The old technology and design practices have resulted in expensive hardware and intensive maintenance requirements for current launch vehicles. In order to alleviate the cost factor, the technological advances throughout the next millennium must bring affordable development and a new invigorating desire to space exploration. National Aeronautical and Space Administration (NASA), Department of Defense (DOD), and private industry are addressing this issue by focusing on incremental improvements in the Earth- to Orbit (ETO) costs. These improvements have investigated two different approaches: 1) make space vehicles as inexpensive as possible (i.e. Evolved Expendable Launch Vehicle (EELV) and Delta IV) 2) make space vehicles as reusable as airplanes so that the initial cost of investment can be recaptured (i.e. Reusable Launch Vehicle (RLV), X-33, X-34, and X-37) These programs have made notable progress in new material, propulsion, structures, and avionics technologies, during the last 3-5 years. So far, these programs are targeted to reduce present costs by, as much as, five times the current cost. The year 2025 goal for continued space advancement is to have ETO costs reduced by a factor of ten (i.e., tenfold), as low as $100 - $200/lb payload. For the RLV, this goal translates into very low maintenance costs and higher expected reliability per flight must be obtained. Therefore, making higher launch rates possible. For the expendable vehicle, the cost of maintenance cost is minimal, but a greater reliability must exist to insure the payload; since, there would be no way to recover the payload if the mission was to an abort or failure. Overall the cost of vehicle, payload and operations of an expendable may be too high compared to those of the RLV.

Harris, Lawanna↗
NASA NTRS2007

Analytical Approach for Estimating Preliminary Mass of ARES I Crew Launch Vehicle Upper Stage Structural Components

In January 2004, President Bush gave the National Aeronautics and Space Administration (NASA) a vision for Space Exploration by setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. In response to this vision, NASA started the Constellation Program, which is a new exploration launch vehicle program. The primary mission for the Constellation Program is to carry out a series of human expeditions ranging from Low Earth Orbit to the surface of Mars and beyond for the purposes of conducting human exploration of space, as specified by the Vision for Space Exploration (VSE). The intent is that the information and technology developed by this program will provide the foundation for broader exploration activities as our operational experience grows. The ARES I Crew Launch Vehicle (CLV) has been designated as the launch vehicle that will be developed as a "first step" to facilitate the aforementioned human expeditions. The CLV Project is broken into four major elements: First Stage, Upper Stage Engine, Upper Stage (US), and the Crew Exploration Vehicle (CEV). NASA's Marshall Space Flight Center (MSFC) is responsible for the design of the CLV and has the prime responsibility to design the upper stage of the vehicle. The US is the second propulsive stage of the CLV and provides CEV insertion into low Earth orbit (LEO) after separation from the First Stage of the Crew Launch Vehicle. The fully integrated Upper Stage is a mix of modified existing heritage hardware (J-2X Engine) and new development (primary structure, subsystems, and avionics). The Upper Stage assembly is a structurally stabilized cylindrical structure, which is powered by a single J-2X engine which is developed as a separate Element of the CLV. The primary structure includes the load bearing liquid hydrogen (LH2) and liquid oxygen (LOX) propellant tanks, a Forward Skirt, the Intertank structure, the Aft Skirt and the Thrust Structure. A Systems Tunnel, which carries fluid and electrical power functions to other Elements of the CLV, is included as secondary structure. The MSFC has an overall responsibility for the integrated US element as well as structural design an thermal control of the fuel tanks, intertank, interstage, avionics, main propulsion system, Reaction Control System (RCS) for both the Upper Stage and the First Stage. MSFC's Spacecraft and Vehicle Department, Structural and Analysis Design Division is developing a set of predicted mass of these elements. This paper details the methodology, criterion and tools used for the preliminary mass predictions of the upper stage structural assembly components. In general, weight of the cylindrical barrel sections are estimated using the commercial code Hypersizer, whereas, weight of the domes are developed using classical solutions. HyperSizer is software that performs automated structural analysis and sizing optimization based on aerospace methods for strength, stability, and stiffness. Analysis methods range from closed form, traditional hand calculations repeated every day in industry to more advanced panel buckling algorithms. Margin-of-safety reporting for every potential failure provides the engineer with a powerful insight into the structural problem. Optimization capabilities include finding minimum weight panel or beam concepts, material selections, cross sectional dimensions, thicknesses, and lay-ups from a library of 40 different stiffened and sandwich designs and a database of composite, metallic, honeycomb, and foam materials. Multiple different concepts (orthogrid, isogrid, and skin stiffener) were run for multiple loading combinations of ascent design load with and with out tank pressure as well as proof pressure condition. Subsequently, selected optimized concept obtained from Hypersizer runs was translated into a computer aid design (CAD) model to account for the wall thickness tolerance, weld land etc for developing the most probable weight of the components. The flow diram summarizes the analysis steps used in developing these predicted mass.

Aggarwal, Pravin↗
NASA NTRS2005

Advanced Health Management Algorithms for Crew Exploration Applications

Achieving the goals of the President's Vision for Exploration will require new and innovative ways to achieve reliability increases of key systems and sub-systems. The most prominent approach used in current systems is to maintain hardware redundancy. This imposes constraints to the system and utilizes weight that could be used for payload for extended lunar, Martian, or other deep space missions. A technique to improve reliability while reducing the system weight and constraints is through the use of an Advanced Health Management System (AHMS). This system contains diagnostic algorithms and decision logic to mitigate or minimize the impact of system anomalies on propulsion system performance throughout the powered flight regime. The purposes of the AHMS are to increase the probability of successfully placing the vehicle into the intended orbit (Earth, Lunar, or Martian escape trajectory), increase the probability of being able to safely execute an abort after it has developed anomalous performance during launch or ascent phases of the mission, and to minimize or mitigate anomalies during the cruise portion of the mission. This is accomplished by improving the knowledge of the state of the propulsion system operation at any given turbomachinery vibration protection logic and an overall system analysis algorithm that utilizes an underlying physical model and a wide array of engine system operational parameters to detect and mitigate predefined engine anomalies. These algorithms are generic enough to be utilized on any propulsion system yet can be easily tailored to each application by changing input data and engine specific parameters. The key to the advancement of such a system is the verification of the algorithms. These algorithms will be validated through the use of a database of nominal and anomalous performance from a large propulsion system where data exists for catastrophic and noncatastrophic propulsion sytem failures.

Davidson, Matt↗
DOE OSTI2022

Upgrade of Gamma Spectrometry Systems for ORNL TRISO Fuel PIE

Gamma spectrometry is a key element in much of the post-irradiation examination (PIE) work performed under the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program (Demkowicz et al. 2015; Stempien et al. 2021). Gamma spectrometers are integrated into three major capabilities used at the Oak Ridge National Laboratory (ORNL) Irradiated Fuels Examination Laboratory (IFEL) for PIE of tristructural-isotropic (TRISO) coated particles and fuel compacts: the Core Conduction Cooldown Test Facility (CCCTF), the Vertical Counting System (VCS), and the Irradiated Microsphere Gamma Analyzer (IMGA). The CCCTF includes liquid-nitrogen-cooled traps to extract 85 Kr out of the He sweep gas that passes through the furnace in which the fuel compacts are heated during safety testing. Analysis of the 85 Kr activity in the traps is the primary indicator for TRISO failure during safety testing. The VCS is a system used to accurately measure gamma emission from components placed in a lead-shielded chamber. It is used to count the CCCTF deposition cups after removal from furnace. Each cup resides in the CCCTF furnace for typically 12–24 h and is periodically replaced with a fresh cup throughout the safety test. Metallic fission products collect on the water-cooled cups and several gamma-emitting isotopes ( 110 mAg, 134 Cs, 137 Cs, 154 Eu, and 155 Eu) are often measured and provide indication of the retention performance of the TRISO coatings. The VCS is also used to measure the presence of these isotopes on the CCCTF tantalum liner and sweep gas inlet tube for the determination of cup collection efficiency, as well as support other gamma spectrometry needs related to calibration of the 85 Kr fission gas traps and various other special PIE tasks. The IMGA uses gamma spectrometry to measure the inventory of gamma-emitting isotopes in individual TRISO particles. An automated particle handling system within the IMGA hot cell removes each particle from a source vial and positions it in front of a gamma detector, and output from the gamma spectrometer is used by the IMGA software to determine a destination vial such that particles are sorted according to their inventory and retention characteristics. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, the gamma spectrometer systems used at ORNL to support that PIE had reached the end of its life cycle due to gradual obsolescence of the hardware and software. Upgrade of the Canberra Genie 2000 software used by these systems to a Windows 10 version was not a viable option, because the newest Windows 10 version offered by Mirion (the new owner of the Canberra technology) did not include the dynamic-link libraries (DLLs) needed for integration with the custom PIE software used with the CCCTF and IMGA, and Mirion had no current plans for development and release of Windows 10 versions of these DLLs with the Model S560 Genie 2000 Programming Library. Ultimately a switch was made to ORTEC gamma spectrometry systems, which appeared to be a more sustainable solution due to more proactive vendor support. The ORTEC conversion involved replacing the aging detector preamplifier and multichannel analyzer (MCA) hardware, upgrading the obsolete Windows 7 computers to Windows 10 compatible models, adopting ORTEC GammaVision software, and extensive modification of the ORNL-developed Visual Basic .NET (VB.NET) programs that provide the CCCTF and IMGA user interfaces.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2003

Membrane-Based Gas Traps for Ammonia, Freon-21, and Water Systems to Simplify Ground Processing

Gas traps are critical for the smooth operation of coolant loops because gas bubbles can cause loss of centrifugal pump prime, interference with sensor readings, inhibition of heat transfer, and blockage of passages to remote systems. Coolant loops are ubiquitous in space flight hardware, and thus there is a great need for this technology. Conventional gas traps will not function in micro-gravity due to the absence of buoyancy forces. Therefore, clever designs that make use of adhesion and momentum are required for adequate separation, preferable in a single pass. The gas traps currently used in water coolant loops on the International Space Station are composed of membrane tube sets in a shell. Each tube set is composed of a hydrophilic membrane (used for water transport and capture of bubbles) and a hydrophobic membrane (used for venting of air bubbles). For the hydrophilic membrane, there are two critical pressures, the pressure drop and the bubble pressure. The pressure drop is the decrease in system pressure across the gas trap. The bubble pressure is the pressure required for air bubbles to pass across the water filled membrane. A significant difference between these pressures is needed to ensure complete capture of air bubbles in a single pass. Bubbles trapped by the device adsorb on the hydrophobic membrane in the interior of the hydrophilic membrane tube. After adsorption, the air is vented due to a pressure drop of approximately 1 atmosphere across the membrane. For water systems, the air is vented to the ambient (cabin). Because water vapor can also transport across the hydrophobic membrane, it is critical that a minimum surface area is used to avoid excessive water loss (would like to have a closed loop for the coolant). The currently used gas traps only provide a difference in pressure drop and bubble pressure of 3-4 psid. This makes the gas traps susceptible to failure at high bubble loading and if gas venting is impaired. One mechanism for the latter is when particles adhere to the hydrophobic membrane, promoting formation of a water layer about it that can blind the membrane for gas transport (Figure 1). This mechanism is the most probable cause for observed failures with the existing design. The objective of this project was to devise a strategy for choosing new membrane materials (database development and procedure), redesign of the gas trap to mitigate blinding effects, and to develop a design that can be used in ammonia and Freon-21 coolant loops.

Ritchie, Stephen M. C.↗
NASA NTRS2012

Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features

Phase I: The use of adhesive locking features or liquid locking compounds (LLCs) (e.g., Loctite) as a means of providing a secondary locking feature has been used on NASA programs since the Apollo program. In many cases Loctite was used as a last resort when (a) self-locking fasteners were no longer functioning per their respective drawing specification, (b) access was limited for removal & replacement, or (c) replacement could not be accomplished without severe impact to schedule. Long-term use of Loctite became inevitable in cases where removal and replacement of worn hardware was not cost effective and Loctite was assumed to be fully cured and working. The NASA Engineering & Safety Center (NESC) and United Space Alliance (USA) recognized the need for more extensive testing of Loctite grades to better understand their capabilities and limitations as a secondary locking feature. These tests, identified as Phase I, were designed to identify processing sensitivities, to determine proper cure time, the correct primer to use on aerospace nutplate, insert and bolt materials such as A286 and MP35N, and the minimum amount of Loctite that is required to achieve optimum breakaway torque values. The .1900-32 was the fastener size tested, due to wide usage in the aerospace industry. Three different grades of Loctite were tested. Results indicate that, with proper controls, adhesive locking features can be successfully used in the repair of locking features and should be considered for design. Phase II: Threaded fastening systems used in aerospace programs typically have a requirement for a redundant locking feature. The primary locking method is the fastener preload and the traditional redundant locking feature is a self-locking mechanical device that may include deformed threads, non-metallic inserts, split beam features, or other methods that impede movement between threaded members. The self-locking resistance of traditional locking features can be directly verified during assembly by measuring the dynamic prevailing torque. Adhesive locking features or LLCs are another method of providing redundant locking, but a direct verification method has not been used in aerospace applications to verify proper installation when using LLCs because of concern for damage to the adhesive bond. The reliability of LLCs has also been questioned due to failures observed during testing with coupons for process verification, although the coupon failures have often been attributed to a lack of proper procedures. It is highly desirable to have a direct method of verifying the LLC cure or bond integrity. The purpose of the Phase II test program was to determine if the torque applied during direct verification of an adhesive locking feature degrades that locking feature. This report documents the test program used to investigate the viability of such a direct verification method. Results of the Phase II testing were positive, and additional investigation of direct verification of adhesive locking features is merited.

Golden, Johnny L.↗
NASA NTRS2006

High-Performance Scanning Acousto-Ultrasonic System

A high-performance scanning acousto-ultrasonic system, now undergoing development, is designed to afford enhanced capabilities for imaging microstructural features, including flaws, inside plate specimens of materials. The system is expected to be especially helpful in analyzing defects that contribute to failures in polymer- and ceramic-matrix composite materials, which are difficult to characterize by conventional scanning ultrasonic techniques and other conventional nondestructive testing techniques. Selected aspects of the acousto-ultrasonic method have been described in several NASA Tech Briefs articles in recent years. Summarizing briefly: The acousto-ultrasonic method involves the use of an apparatus like the one depicted in the figure (or an apparatus of similar functionality). Pulses are excited at one location on a surface of a plate specimen by use of a broadband transmitting ultrasonic transducer. The stress waves associated with these pulses propagate along the specimen to a receiving transducer at a different location on the same surface. Along the way, the stress waves interact with the microstructure and flaws present between the transducers. The received signal is analyzed to evaluate the microstructure and flaws. The specific variant of the acousto-ultrasonic method implemented in the present developmental system goes beyond the basic principle described above to include the following major additional features: Computer-controlled motorized translation stages are used to automatically position the transducers at specified locations. Scanning is performed in the sense that the measurement, data-acquisition, and data-analysis processes are repeated at different specified transducer locations in an array that spans the specimen surface (or a specified portion of the surface). A pneumatic actuator with a load cell is used to apply a controlled contact force. In analyzing the measurement data for each pair of transducer locations in the scan, the total (multimode) acousto-ultrasonic response of the specimen is utilized. The analysis is performed by custom software that extracts parameters of signals in the time and frequency domains. The computer hardware and software provide both real-time and postscan processing and display options. For example, oscilloscope displays of waveforms and power spectral densities are available in real time. Images can be computed while scanning continues. Signals can be digitally preprocessed and/or post-processed by filtering, windowing, time-segmenting, and running-waveform-averaging algorithms. In addition, the software affords options for off-line simulation of the waveform-data-acquisition and scanning processes. In tests, the system has been shown to be capable of characterizing microstructural changes and defects in SiC/SiC and C/SiC ceramic-matrix composites. Delaminations, variations in density, microstructural changes attributable to infiltration by silicon, and crack-space indications (defined in the next sentence) have been revealed in images formed from several time- and frequency-domain parameters of scanning acousto-ultrasonic signals. The crack-space indications were image features that were not revealed by other nondestructive testing methods and are so named because they turned out to mark locations where cracking eventually occurred.

Roth, Don↗
NASA NTRS2018

The International Space Station Space Radiation Environment: Avionics Systems Performance in Low-Earth Orbit Single Event Effects (SEE) Environments

Single event effects (SEE) are those errors, anomalies, or failures in microelectronic devices caused by the passage of a single energetic charged particle through the device. Spacecraft SEE environments consist primarily of energetic charged particles; both primary particles originating in the natural environment and secondary particles (including secondary neutrons) produced by nuclear reactions of primary particles with spacecraft materials. The energetic charged particle components (electrons, protons, and atomic nuclei) of the spacecraft SEE environment include galactic cosmic rays (GCR), and planetary radiation belt charged particles, as well as solar energetic particle event (SPE) charged particles. The International Space Station (ISS) orbital altitude and inclination (~350 km to ~420 km at 51.6o inclination) results in a spacecraft SEE environment that varies dramatically with the location in Earth?s geomagnetic field. Geomagnetic GCR shielding diminishes with distance from the geomagnetic equator. Near + 51.6o latitude the ISS GCR environment has a high degree of similarity to the interplanetary GCR environment in cis-Lunar space.SEE environments supporting ISS avionics systems design, development, test, and verification are documented in SSP-30512, Space Station Ionizing Radiation Design Environment. Comparisons of overall ISS avionics systems in-flight performance with pre-flight verification report predictions have been previously reported and meet or exceed expectations in all cases.In this paper we report the results of more detailed investigations of the effects of geographic location, altitude, solar cycle, and shielding mass effects on the in-flight SEE performance of the ISS command and data handling system during the past 17 years. In addition, we report on the preflight testing and in-flight performance of the commercial-off-the-shelf lap top computers used on ISS. Finally, we present an assessment of ISS as an avionics SEE test and flight demonstration platform for exploration hardware destined for the cis-lunar or other inner solar system environments.

International Space Station↗
NASA NTRS1991

Lunar rovers and local positioning system

Telerobotic rovers equipped with adequate actuators and sensors are clearly necessary for extraterrestrial construction. They will be employed as substitutes for humans, to perform jobs like surveying, sensing, signaling, manipulating, and the handling of small materials. Important design criteria for these rovers include versatility and robustness. They must be easily programmed and reprogrammed to perform a wide variety of different functions, and they must be robust so that construction work will not be jeopardized by parts failures. The key qualities and functions necessary for these rovers to achieve the required versatility and robustness are modularity, redundancy, and coordination. Three robotic rovers are being built by CSC as a test bed to implement the concepts of modularity and coordination. The specific goal of the design and construction of these robots is to demonstrate the software modularity and multirobot control algorithms required for the physical manipulation of constructible elements. Each rover consists of a transporter platform, bus manager, simple manipulator, and positioning receivers. These robots will be controlled from a central control console via a radio-frequency local area network (LAN). To date, one prototype transporter platform frame was built with batteries, motors, a prototype single-motor controller, and two prototype internal LAN boards. Software modules were developed in C language for monitor functions, i/o, and parallel port usage in each computer board. Also completed are the fabrication of half of the required number of computer boards, the procurement of 19.2 Kbaud RF modems for inter-robot communications, and the simulation of processing requirements for positioning receivers. In addition to the robotic platform, the fabrication of a local positioning system based on infrared signals is nearly completed. This positioning system will make the rovers into a moving reference system capable of performing site surveys. In addition, a four degree mechanical manipulator especially suited for coordinated teleoperation was conceptually designed and is currently being analyzed. This manipulator will be integrated into the rovers as their end effector. Twenty internal LAN cards fabricated by a commercial firm are being used, a prototype manipulator and a range finder for a positioning system were built, a prototype two-motor controller was designed, and one of the robots is performing its first telerobotic motion. In addition, the robots' internal LAN's were coordinated and tested, hardware design upgrades based on fabrication and fit experience were completed, and the positioning system is running. The rover system is able to perform simple tasks such as sensing and signaling; coordination systems which allow construction tasks to begin were established, and soon coordinated teams of robots in the laboratory will be able to manipulate common objects.

Avery, James↗
NASA NTRS2005

Highly Reliable, High-Speed, Unidirectional Serial Data Links

Highly reliable, high-speed, unidirectional serial data-communication subsystems have been proposed to be installed in an upgrade of the computing systems aboard the space shuttles. The basic design concept of these serial data links is also adaptable to terrestrial use in applications in which there are requirements for highly reliable serial data communications. The hardware and software aspects of the architecture of the data links are dictated largely by a requirement, in the original space-shuttle application, for one computer to monitor the memory transactions and memory contents of other computers in real time with high reliability and without reliance on requests for retransmission. To minimize weight while affording a capability to transfer data at a required rate of 2.56 x 10(exp 8) bits per second, it was decided that the links would be serial ones of the fiber-channel type. [Fiber channel denotes a type of serial computer bus that is used to connect a computer (usually a supercomputer) with a high-speed data storage device. Depending on the specific application, the physical connection between the transmitter and receiver could be made via an optical fiber or a twisted pair of wires.] Heretofore, fiber-channel links have ordinarily been bidirectional and have operated under protocols that provide for receiving stations to detect errors and request retransmission when necessary. In the present case, the time taken by processing to request retransmission would conflict with the requirement for real-time transfer of data. To ensure reliability without retransmission, a link according to the proposal would utilize a modified version of the normal fiberchannel character set in conjunction with forward error correction by means of a Reed-Solomon code (see figure). The Reed-Solomon encoding and decoding and the translations between the normal and modified character sets would be effected by logic circuitry external to the fiber-channel transmitter and receiver, which would be commercial off-the-shelf units. The receiving end of the link could detect and correct errors at a rate as high as 4 million times per second, if necessary. The receiver detects uncorrectable double-byte errors. It has been estimated that uncorrectable-error rate would amount to one failure in about 10(exp 19) characters.

Cole, Robert M.↗
DOE OSTI2021

Considerations regarding the Use of Computer Vision Machine Learning in Safety-Related or Risk-Significant Applications in Nuclear Power Plants

With the advancements made to date in the field of artificial intelligence (AI), significant potential exists to utilize AI capabilities for nuclear power plant (NPP) applications. AI can replicate human decision making and it is usually faster and more accurate than humans. For implementations that impact critical NPP applications (e.g., safety-related or non-safety systems that potentially affect overall plant risk), a deeper safety analysis of the AI methods is necessary. AI applied to NPP operations could resemble the use of digital I&C (DI&C) because such applications involve digital computer hardware and custom-designed software that input plant data, execute complex software algorithms, and output the results to a system or licensed human operator to potentially provoke an action. For AI methods to be compliant with current safety requirements for DI&C, AI compatibility must be evaluated, and AI-related gaps may exist that prevent the prompt deployment of AI in NPPs. This effort aims to evaluate how example AI technologies align with the DI&C safety framework, and discusses how they could be analyzed, modeled, tested, and validated in a manner similar to typical DI&C technologies. Because AI is a broad field that encompasses areas such as machine learning (ML), natural language processing, and computer vision, this research focused on a subset of methods categorized as the computer vision ML (CVML) methods. This report explores two CVML use cases, gauge reading and fire watch, considered relevant to the DI&C standards, as they could play a safety-critical role. For the gauge reading use case, a CVML-enabled technology that can read gauges at oblique angles is utilized. For the fire watch use case, a CVML-enabled technology is utilized that migrates fire watch from a manual (human) approach to automated fire detection. These use cases are mainly intended to give context to the CVML system discussion. This effort assumes the worst-case scenario, with the CVML system being used to replace a safety-related or risk-significant system, thus requiring evaluation. Evaluating CVML against most of the relevant safety requirements for DI&C yielded several CVML-specific considerations due to the uniqueness of its characteristics in comparison with typical DI&C systems. For example, CVML models often employ commonly used (open-source) datasets, and it is not always possible to determine the level of overlap among open-source datasets. Therefore, the independence of the developed CVML models when demonstrating diversity is questionable, therefore creating vulnerability to common cause failure (CCF). The design verification process is also impacted since the data overlap could result in overestimation of the software validation and verification (V&V) performance results. Section 2 of this report evaluates a list of the identified CVML-specific characteristics and discusses the resulting considerations and potential solutions in the context of each referenced requirement. A summation is provided in Section 3. This report is not to be used as a guideline. It was developed to identify and consider issues in the implementation of ML technologies used to augment activities that may have a bearing on plant operation. The report draws parallels to the use of DI&C technologies, for which many standards are available to guide their use in nuclear plant operation. It considers the technologies and some of the potential implications of their use in safety-related applications but is not intended to address regulatory or licensing related issues.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2017

The Iodine Satellite (iSat) Propellant Feed System - Design and Demonstration

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cm3 and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high Delta V maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. One of the systems under development to support such a technology is the propellant feed system, which must be capable of storing solid iodine propellant, applying heat to sublime the stored solid into the vapor phase, and then control the flow of low-pressure gaseous iodine to both the thruster and cathode. In a test conducted in 2016, a first-generation iodine propellant feed system was integrated with a cathode and Hall thruster. While this test had to be terminated, the feed system in this first test was able to support both cathode and integrated cathode and thruster operation prior to the termination of the test. In the present paper, we describe work performed since that initial integrated test. The effort uses lessons learned from the previous integrated test, retiring risk associated with the iodine propellant feed system, answering open design-space questions, and demonstrating iodine flow control in an integrated system. The work is undertaken at both the component level and then at the integrated subsystem level to systematically improve the feed system design, improving the hardware fidelity so the appearance and operation of the system are as flight-like as possible. At the component level, the work focuses on the propellant tank, the feed system tubing, the valves used to control the flow to the cathode and thruster, and the heaters that maintain the temperature of the flowpaths and keep iodine from redepositing and clogging the system. Work on the propellant reservoir focuses on fabricating a tank that matches the geometry of the flight design, which allows for the identification of flight tank fabrication issues that may arise and permits thermal testing of a tank possessing the same size and thermal mass as the flight design, which can be used to anchor thermal modeling of the component. This is critical for finalizing the tank heater power requirements that feed into the heater design. All metallic materials in the feed system are hastelloy or Inconel, as these materials are resistant to chemical attack by the highly-reactive iodine vapor. The tubing in the iodine feed system must possess ports to permit a neutral gas purge of the system that clear impurities after iodine is loaded into the propellant tank. A procedure is discussed whereby these ports are crimped and sealed after the purge process is completed so as to not re-expose the iodine system to air. The valves are a critical component for control of the flow to the thruster and the cathode. Significant effort has gone into upgrading the materials of the valves to make them more resistant to chemical attack and into developing an understanding of the use of these valves during the startup and operation of the cathode and thruster. The heaters that line the entire feed system are designed to draw minimal power from the power processing unit (PPU) while still having the capacity to maintain all the feed system components at the temperatures required to discourage iodine deposition inside components downstream of the propellant tank exit. The heaters possess two separate resistive traces, giving the design redundancy should a failure occur in the primary heater circuit of one of the heater zones. The task of operating a feed system in conjunction with a thruster and cathode is undertaken in a series of sub-steps. The system is first assembled and operated on xenon gas, using the valves for cathode startup and thruster control based on measurement of the discharge current. After startup and control on xenon are demonstrated, the thruster will be transitioned to iodine operation, demonstrating thruster startup and feed system control while using a xenon-fed cathode. Finally, the last step is to integrate an iodine-compatible cathode with the system, demonstrate autonomous cathode start-up with open-loop control and thruster start-up with closed-loop control for multiple cycles.

Polzin, Kurt A.↗
NASA NTRS2003

A Program to Detect and Characterize Extra-Solar Giant Planets

We initiated a significant hardware upgrade to the AFOE, to increase its efficiency for precise radial velocity studies to the level where we can continue to contribute usefully to extrasolar planet research on relatively bright stars. The AFOE, at a 1.5-m telescope, will of course not have the sensitivity of radial velocity instruments at larger telescopes, such as the HIRES on Keck or the Hectochelle on the MMT telescope (about to come on line). However, it has been possible to increase its efficiency for precise radial velocity studies by a factor of 4 to 5, which-combined with the large amount of telescope time available at the 1.5-m telescope-will permit us to do intensive follow-up observations of stars brighter than about 8 magnitude. The AFOE was originally designed primarily for asteroseismology using a ThAr reference. This provided useful wavelength stability over tens of minutes as required for asteroseismology, but we were unable to get a long-term (month-to-month) velocity precision better than about 15 m/s with that setup. Hence, we implemented an iodine cell as a wavelength reference for extrasolar planet studies. However, the optical design of the original AFOE did not completely span the wavelength range covered by the iodine absorption spectrum, and furthermore the optics suffered significant light loss through optical obscuration in the camera secondary. To remedy this, we replaced the AFOE grating with a new one that covered the entire iodine spectral range at somewhat lower spectral resolution, and replaced the camera with a transmitting lens. (The use of a lens was made possible by restricting the spectral range covered by the upgraded AFOE to only the iodine region.) These upgrades were successfully completed, and the instrument was tested for three nights in fall of 2002. The expected improvement in sensitivity by a factor of 4 to 5 was observed: that is, the same velocity precision as previously attained (of order 5 to 7 m/s) was now obtained on a stars that are about 4 to 5 times fainter. Unfortunately, just after installing the new AFOE optics, there was a catastrophic failure of the old Tektronix CCD. A careful investigation was made, and it was determined that the failure was probably due to too many thermal cyclings over the previous 8 years. The only solution was to purchase a new CCD. Internal funds of $16,000 were found for this purpose, and the new CCD (a thinned, back-illuminated Marconi 2K x 2K device with 13.5 micron pixels, and employing dual readout channels to keep the readout time as short as 20 seconds) was ordered, has now arrived, and is currently under test before 1 being installed in the AFOE liquid nitrogen dewar. At the same time, we expect to implement new CCD control electronics. This system should be better in many ways than the previous detector (including eliminating the need for UV flashing to maximize the quantum efficiency). We plan to install the detector on the telescope and begin operations again in April of this year.

Lindstrom, David↗
NASA NTRS2018

Electrodynamic Dust Shield (EDS) Preparation for MISSE-11 Launch

The dusty surfaces of the Moon, Mars, and various asteroids present a significant challenge to NASA’s manned and unmanned space exploration efforts. The fine, electrostatically charged dust is difficult to remove and has resulted in vision obscuration, false instrument readings, contamination, elevated temperatures, performance reduction, and equipment failure. To alleviate these problems, NASA KSC’s Electrostatics and Surface Physics Laboratory (ESPL) is developing active dust mitigation systems for solar system exploration and in situ resource utilization (ISRU). Part of KSC’s Swamp Works system, the lab emphasizes fast-paced, hands-on, cost-effective, and collaborative innovation. The Electrodynamic Dust Shield (EDS) is an ESPL technology being developed to prevent dust accumulation on space components. It consists of a dielectric substrate embedded with parallel electrodes which, when applied with high voltage out-of-phase waveforms, produce a traveling electric field wave that scatters dust particles from its surface via dielectrophoretic and electrostatic forces. The EDS is currently fully functional and has been tested for scalability and endurance in reduced gravity/pressure flight. Next, it will be part of the May 2019 Materials International Space Station Experiment-11 (MISSE-11) payload, which will test small shield samples for performance durability with exposure to the harsh space environment. The summer objective was to test EDS functionality before active and passive dust shield samples launch on MISSE-11, in order to screen for good flight/control samples as well as to compare pre-flight and post-flight clearing efficiencies. I imaged glass and Kapton shields of 2-phase and 3-phase electrode configurations with the Keyence VHX-5000 digital microscope to check for damage before and after all testing for a qualitative pre-flight baseline; helped with vacuum testing of high-voltage shield breakdown; assembled shields and wires using Electrobond 004 silver epoxy; and helped with vacuum and cryogenic dust clearance testing of assembled EDS systems. I learned CAD (computer-aided design) and 3D printing skills to create parts for a shaker table/motor assembly, which will allow for repeatable experiments by evening out EDS dust distribution in a consistent manner prior to dust scattering testing. I will also be improving the interfacing with Alpha Space’s prototype Data Communications Unit (DCU), a payload component to control power to the EDS and store data, by mapping the DCU structure upon power-up and writing shell scripts to improve various processes. Finally, I also CADed and 3D-printed plastic supports for three different geometries of the Electrostatic Precipitator (ESP), a project that aims to use high voltage electrodes to charge and filter out dust from the Martian atmosphere drawn for ISRU devices. This work on dust mitigation technologies will help to support future robotic and human space exploration missions, including NASA’s Journey to Mars; the EDS has especially significant applications to spacecraft solar panels, thermal radiators, viewports, and astronaut visors. This opportunity has also allowed me to become more familiar with various lab equipment and hardware testing, develop key modeling skills in SolidWorks, explore past and present components critical to America’s space program, work with inspiring peers and mentors, and ascertain my dream of working permanently for NASA.

space↗
NASA NTRS1997

Advanced Technology for Isolating Payloads in Microgravity

One presumption of scientific microgravity research is that while in space disturbances are minimized and experiments can be conducted in the absence of gravity. The problem with this assumption is that numerous disturbances actually occur in the space environment. Scientists must consider all disturbances when planning microgravity experiments. Although small disturbances, such as a human sneeze, do not cause most researchers on earth much concern, in space, these minuscule disturbances can be detrimental to the success or failure of an experiment. Therefore, a need exists to isolate experiments and provide a quiescent microgravity environment. The objective of microgravity isolation is to quantify all possible disturbances or vibrations and then attenuate the transmission of the disturbance to the experiment. Some well-defined vibration sources are: experiment operations, pumps, fans, antenna movements, ventilation systems and robotic manipulators. In some cases, it is possible to isolate the source using simple vibration dampers, shock absorbers and other isolation devices. The problem with simple isolation systems is that not all vibration frequencies are attenuated, especially frequencies less than 0.1 Hz. Therefore, some disturbances are actually emitted into the environment. Sometimes vibration sources are not well defined, or cannot be controlled. These include thermal "creak," random acoustic vibrations, aerodynamic drag, crew activities, and other similar disturbances. On some "microgravity missions," such as the United States Microgravity Laboratory (USML) and the International Microgravity Laboratory (IML) missions, the goal was to create extended quiescent times and limit crew activity during these times. This might be possible for short periods, but for extended durations it is impossible due to the nature of the space environment. On the International Space Station (ISS), vehicle attitude readjustments are required to keep the vehicle in a minimum torque orientation and other experimental activities will occur continually, both inside and outside the station. Since all vibration sources cannot be controlled, the task of attenuating the disturbances is the only realistic alternative. Several groups have independently developed technology to isolate payloads from the space environment. Since 1970, Honeywell's Satellite Systems Division has designed several payload isolation systems and vibration attenuators. From 1987 to 1992, NASA's Lewis Research Center (LeRC) performed research on isolation technology and developed a 6 degree-of-freedom (DOF) isolator and tested the system during 70 low gravity aircraft flight trajectories. Beginning in early 1995, NASA's Marshall Space Flight Center (MSFC) and McDonnell Douglas Aerospace (MDA) jointly developed the STABLE (Suppression of Transient Accelerations By Levitation Evaluation) isolation system. This 5 month accelerated effort produced the first flight of an active microgravity vibration isolation system on STS-73/USML-02 in late October 1995. The Canadian Space Agency developed the Microgravity Vibration Isolation Mount (MIM) for isolating microgravity payloads and this system began operating on the Russian Mir Space Station in May 1996. The Boeing Defense & Space Group, Missiles & Space Division developed the Active Rack Isolation System (ARIS) for isolating payloads in a standard payload rack. ARIS was tested in September 1996 during the STS-79 mission to Mir. Although these isolation systems differ in their technological approach, the objective is to isolate payloads from disturbances. The following sections describe the technologies behind these systems and the different types of hardware used to perform isolation. The purpose of these descriptions is not to detail the inner workings of the hardware but to give the reader an idea of the technology and uses of the hardware components. Also included in the component descriptions is a paragraph detailing some of the advances in isolation technology for that particular component. The final section presents some concluding thoughts and a summary of anticipated advances in research and development for isolating microgravity experiments.

Alhorn, Dean C.↗