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NASA NTRS1978

Quantitative Ultrasonic Evaluation of Mechanical Properties of Engineering Materials

Progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength of engineering materials is reviewed. A dormant concept in nondestructive evaluation (NDE) is invoked. The availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions is discussed. It was shown that ultrasonic methods yield measurements of elastic moduli, microstructure, hardness, fracture toughness, tensile strength, yield strength, and shear strength for a wide range of materials (including many types of metals, ceramics, and fiber composites). It was also indicated that although most of these methods were shown feasible in laboratory studies, more work is needed before they can be used on actual parts in processing, assembly, inspection, and maintenance lines.

Vary, A.↗

DOE OSTI2022

A Multi-Scale Computational Platform for Predictive Modeling of Corrosion in Al-Steel Joints (Final Report)

The research team proposed to develop innovative multi-scale models to predict corrosion and the resulting mechanical performances in aluminum-steel joints. The methods of joining considered are resistance spot welding, self-piercing riveting, and rivet-welding, all suitable for mass production applications. The multi-scale models integrate high throughput first-principle calculations based on density functional theory (DFT), high throughput calculation of phase diagrams (CALPHAD) modeling, and finite element method (FEM) simulations. These models are to be validated through laboratory experiments. Furthermore, the models are available as open source so as to enable scientists and engineers in the community to adapt and contribute to the development and application. The approaches rely on the research team’s extensive experience on the prediction of properties of individual phases at finite temperatures and variable compositions through DFT calculations, and our broad expertise on dissimilar material joining and their corrosion. The proposed computational framework enables high throughput computations for improved predictions of corrosion and the associated mechanical performance in dissimilar material joints, resulting in significant reduction in computational time needed by the current state-of-the-art methods. With the participation of researchers from three universities, an auto manufacturer, two manufacturing technology/equipment suppliers, and a software developer/vendor, the interdisciplinary research team applies the technical development on both phase-based modeling and laboratory experiments into the automobile body joining processes for validation and technology demonstration. The global cost of corrosion was estimated at about 3.4% of the global GDP in 2013. By using available corrosion control practices, it is estimated a saving between 15-35% of the cost of corrosion. In the U.S., more than $276 billion is spent repairing corrosion damage. Prediction of the corrosion and its impact on performance of the dissimilar material joints is critical for reducing the massive number of the current corrosion-based recalls for automobiles. Thus, the project goal is to develop models to enable predictive maintenance and end-of-life planning of multi-metal joints with risk of corrosion under different conditions such as exposure to high temperatures in summer and salt solutions in winter, quantified through its pH. An academia-industry consortium led by the University of Michigan and including Pennsylvania State University, University of Illinois Urbana-Champaign, University of Georgia, General Motors Company, Livermore Software Technology Corporation, and Optimal Process Technologies, LLC. created multi-scale models for prediction of corrosion in aluminum-steel joint structures such of them used in vehicle subassemblies – chassis and transmission systems. Starting from the first principle calculations, the team developed mathematical and data-driven models to predict the metallic components, which are formed during joining of two metals, for example aluminum and steel - a lightweight multilateral system which is currently used in more than 60% car bodies. These models were used for simulating chemical reactions that are happening when the joining metallic components are exposed to high temperatures and different pH values. The team was able to predict how the corrosion installs on the metallic components and how they lead to a sudden failure of components in cars. Newly developed machine learning algorithms combining Science, Technology, Engineering and Math disciplines, advanced finite element simulation and experimental validations have been integrated in a platform for prediction of the corrosion evolution and prediction the failure of joints under mechanical loadings and fatigue. Moreover, based on machine learning and inverse analysis, the team proposed solutions for designing new metallic alloys less susceptible to corrosion when joining multi-material assembles. An average of 4% error compared with experiments was achieved for the most common joints that are used in vehicle subassemblies.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Viper cabin-fuselage structural design concept with engine installation and wing structural design

This report describes the process and considerations in designing the cabin, nose, drive shaft, and wing assemblies for the 'Viper' concept aircraft. Interfaces of these assemblies, as well as interfaces with the sections of the aircraft aft of the cabin, are also discussed. The results of the design process are included. The goal of this project is to provide a structural design which complies with FAR 23 requirements regarding occupant safety, emergency landing loads, and maneuvering loads. The design must also address the interfaces of the various systems in the cabin, nose, and wing, including the drive shaft, venting, vacuum, electrical, fuel, and control systems. Interfaces between the cabin assembly and the wing carrythrough and empennage assemblies were required, as well. In the design of the wing assemblies, consistency with the existing cabin design was required. The major areas considered in this report are materials and construction, loading, maintenance, environmental considerations, wing assembly fatigue, and weight. The first three areas are developed separately for the nose, cabin, drive shaft, and wing assemblies, while the last three are discussed for the entire design. For each assembly, loading calculations were performed to determine the proper sizing of major load carrying components. Table 1.0 lists the resulting margins of safety for these key components, along with the types of the loads involved, and the page number upon which they are discussed.

Marchesseault, B.↗

NASA NTRS1994

Catalog of lunar and Mars science payloads

This catalog collects and describes science payloads considered for future robotic and human exploration missions to the Moon and Mars. The science disciplines included are geosciences, meteorology, space physics, astronomy and astrophysics, life sciences, in-situ resource utilization, and robotic science. Science payload data is helpful for mission scientists and engineers developing reference architectures and detailed descriptions of mission organizations. One early step in advanced planning is formulating the science questions for each mission and identifying the instrumentation required to address these questions. The next critical element is to establish and quantify the supporting infrastructure required to deliver, emplace, operate, and maintain the science experiments with human crews or robots. This requires a comprehensive collection of up-to-date science payload information--hence the birth of this catalog. Divided into lunar and Mars sections, the catalog describes the physical characteristics of science instruments in terms of mass, volume, power and data requirements, mode of deployment and operation, maintenance needs, and technological readiness. It includes descriptions of science payloads for specific missions that have been studied in the last two years: the Scout Program, the Artemis Program, the First Lunar Outpost, and the Mars Exploration Program.

Budden, Nancy Ann↗

NASA NTRS2009

Damage Detection and Self-Repair in Inflatable/Deployable Structures

Inflatable/deployable structures are under consideration for applications as varied as expansion modules for the International Space Station to destinations for space tourism to habitats for the lunar surface. Monitoring and maintaining the integrity of the physical structure is critical, particularly since these structures rely on non-traditional engineering materials such as fabrics, foams, and elastomeric polymers to provide the primary protection for the human crew. The closely related prior concept of monitoring structural integrity by use of built-in or permanently attached sensors has been applied to structures made of such standard engineering materials as metals, alloys, and rigid composites. To effect monitoring of flexible structures comprised mainly of soft goods, however, it will be necessary to solve a different set of problems - especially those of integrating power and data-transfer cabling that can withstand, and not unduly interfere with, stowage and subsequent deployment of the structures. By incorporating capabilities for self-repair along with capabilities for structural health monitoring, successful implementation of these technologies would be a significant step toward semi-autonomous structures, which need little human intervention to maintain. This would not only increase the safety of these structures, but also reduce the inspection and maintenance costs associated with more conventional structures.

Brandon, Erik↗

NASA NTRS2020

Is Structured Agile an Oxymoron? Tales from Implementing and Executing Agile in a US Government Environment

To paraphrase a famous quote, "No plan survives contact with the reality." Software (SW) development is often a classic example of this: whatever the plan was for a particular development, it often does not survive contact with technical realities, budget realities, program realities and schedule realities. Traditionally, SW development has followed a waterfall methodology with requirements being rigorously specified before the design, which was completed before the coding and unit testing started, which were in turn finished before validation and verification started. This model of SW engineering derives much from the HW engineering of large systems, and has been the standard methodology used in US government software acquisitions and systems for decades, with highly variable results. US Government SW requirements are built around Waterfall concepts, which assume that the plan will survive contact with reality, or at least that modifications to the plan are relatively small, and relatively few.Because of the inefficiencies and difficulties inherent in Waterfall, the commercial SW world started using a different SW development methodology called Agile more than 20 years ago. Agile believes that a plan should evolve and learn rapidly in response to the realities encountered. At its core, there are a few key elements of Agile:- A small team of people which is highly flexible and adaptive. The team collaborates and interoperates through sophisticated development architectures and release environments- An iterative, incremental development and release approach which is based upon the concept that knowledge comes from experience within the team, and that the team makes decisions based upon what it knows- A team culture which prizes transparency, inspection and adaptation. These values are necessary so that the team experience and decision making is transparent and responsive to the realities encountered during development and testingSo, how to use Agile in a US Government environment? GMSEC (Goddard Mission Services Evolution Center) develops satellite ground system software for NASA and other US Government agencies. The SW developed by the team contains a large code base of many applications used within satellite mission operations centers. It spans the full gamut of SW development types: from SW which is in a classic maintenance and sustainment mode, to new developments with a fairly well understood scope and approach, to new developments whose scope and approach are quite unclear and which require significant research and prototyping. Team members move between all of these different types of SW development. Waterfall was inadequate to the programmatic and technical needs of the team, as well as the various types of SW development being done. The software plan was not surviving contact with the technical and programmatic realities experienced by the team. To address this, the team started a small pilot project in 2016 to test the use of Agile within a small subset of the team for a new web services application. In early 2018, the use of Agile was expanded to the whole team and all the software, but we had to fulfill the NASA SW development requirements. And we needed to do this while still remaining true to the key Agile elements of transparency, inspection and adaption. In order to do this, the team worked very closely with the Software Process Improvement (SPI) team at NASA Goddard, as well as NASA engineering manageme

Beech, Theresa W.↗

NASA NTRS2003

Reusable Rack Interface Controller Common Software for Various Science Research Racks on the International Space Station

The purpose of the EXPRESS (Expedite the PRocessing of Experiments to Space Station) rack project is to provide a set of predefined interfaces for scientific payloads which allow rapid integration into a payload rack on International Space Station (ISS). VxWorks' was selected as the operating system for the rack and payload resource controller, primarily based on the proliferation of VME (Versa Module Eurocard) products. These products provide needed flexibility for future hardware upgrades to meet everchanging science research rack configuration requirements. On the International Space Station, there are multiple science research rack configurations, including: 1) Human Research Facility (HRF); 2) EXPRESS ARIS (Active Rack Isolation System); 3) WORF (Window Observational Research Facility); and 4) HHR (Habitat Holding Rack). The RIC (Rack Interface Controller) connects payloads to the ISS bus architecture for data transfer between the payload and ground control. The RIC is a general purpose embedded computer which supports multiple communication protocols, including fiber optic communication buses, Ethernet buses, EIA-422, Mil-Std-1553 buses, SMPTE (Society Motion Picture Television Engineers)-170M video, and audio interfaces to payloads and the ISS. As a cost saving and software reliability strategy, the Boeing Payload Software Organization developed reusable common software where appropriate. These reusable modules included a set of low-level driver software interfaces to 1553B. RS232, RS422, Ethernet buses, HRDL (High Rate Data Link), video switch functionality, telemetry processing, and executive software hosted on the FUC computer. These drivers formed the basis for software development of the HRF, EXPRESS, EXPRESS ARIS, WORF, and HHR RIC executable modules. The reusable RIC common software has provided extensive benefits, including: 1) Significant reduction in development flow time; 2) Minimal rework and maintenance; 3) Improved reliability; and 4) Overall reduction in software life cycle cost. Due to the limited number of crew hours available on ISS for science research, operational efficiency is a critical customer concern. The current method of upgrading RIC software is a time consuming process; thus, an improved methodology for uploading RIC software is currently under evaluation.

Lu, George C.↗

NASA NTRS1986

A study of the use of abstract types for the representation of engineering units in integration and test applications

Physical quantities using various units of measurement can be well represented in Ada by the use of abstract types. Computation involving these quantities (electric potential, mass, volume) can also automatically invoke the computation and checking of some of the implicitly associable attributes of measurements. Quantities can be held internally in SI units, transparently to the user, with automatic conversion. Through dimensional analysis, the type of the derived quantity resulting from a computation is known, thereby allowing dynamic checks of the equations used. The impact of the possible implementation of these techniques in integration and test applications is discussed. The overhead of computing and transporting measurement attributes is weighed against the advantages gained by their use. The construction of a run time interpreter using physical quantities in equations can be aided by the dynamic equation checks provided by dimensional analysis. The effects of high levels of abstraction on the generation and maintenance of software used in integration and test applications are also discussed.

Johnson, Charles S.↗

DOE OSTI2020

Changes in SSL Device Efficiency and Optical Performance Under Accelerated Aging Conditions

Lighting application efficiency (LAE) describes the efficient delivery of light from the light source to the lighted task and is viewed as a new frontier—increasing energy savings with solid-state lighting (SSL) technologies. The framework for LAE that is proposed by the U.S. Department of Energy (DOE) consists of four major elements: light source efficiency, optical delivery efficiency, spectral efficiency, and intensity effectiveness. This report focuses on a sampling of the available SSL products that can be broadly defined as having modified spectral output because the method of spectra modification has a significant impact on light source efficiency and long-term optical delivery and spectral efficiencies. This report focused on the changes in light source, optical delivery, and spectral efficiencies that occur during aging of SSL devices. An accelerated stress test (AST) regiment was developed for the devices under test (DUTs) examined in this report to provide insights into how the performance of SSL devices change with aging. The AST protocols demonstrate that the SSL products discussed in this report often reduce light source efficiency to achieve different spectral characteristics. In addition, aging of the optical components (e.g., lenses, solder masks) in SSL devices can produce increased light absorption, which negatively impacts optical delivery efficiency and light source efficiency. The modified spectral outputs of the selected SSL products discussed in this report come in a variety of form factors and achieve enhanced optical performance by using a variety of methods. All of the products examined in this study use mid-power light-emitting diodes (MP-LEDs), although the number, configuration, phosphor content, and light-emitting diode (LED) pump of the MP-LEDs differ. Product MS-1 is a 60-watt (W) replacement A19 lamp with a hermetically sealed glass globe, which contains an embedded optical filter to absorb green and yellow emissions, thereby creating a “sunlike” modified spectrum. Product MS-2 is a 60-W replacement A19 lamp with 30 MP-LEDs, and it uses a violet LED pump, along with green and red phosphor emissions, to produce a “healthy” spectrum. This spectrum omits blue emissions in an effort to reduce melanopic lux. Product MS-3 is an LED module consisting of 21 MP-LEDs that use a violet LED pump, along with blue, green, and red phosphors, to produce a “sunlike” spectrum. Products MS-4 and MS-5 are both 6-inch (in) downlights that use a manual switching mechanism so that users can select application-specific correlated color temperatures before installation. Products MS-4 and MS-5 both contain two LED primaries (2,700 Kelvin [K] and 5,000 K) for spectral tuning. Product MS-4 contains 12 MP-LEDs for each LED primary, and Product MS-5 contains 10 MP-LEDs for each LED primary. This report summarizes the overall findings from up to 8,000 hours (hrs) of AST on the lamp DUTs (Products MS-1 and MS-2); up to 5,000 hrs of AST on the LED light engine DUTs (Product MS-3); and up to 7,000 hrs of AST on the downlight DUTs (Products MS-4 and MS-5). The AST procedures used in this study included a room temperature operational life (RTOL) test, an operational life test conducted at 45 degrees Celsius (°C; 45OL) test, an operational life test conducted at 75°C (75OL), a wet high-temperature operational life test performed at 65°C and 90% relative humidity (6590), and a wet high-temperature operational life test performed at 75°C and 75% relative humidity (7575). The AST procedures used for Products MS-1 and MS-2 were RTOL, 45OL, and 6590. The AST procedures used for Products MS-3, MS-4, and MS-5 were RTOL, 75OL, and 7575. During the ASTs described herein, separate populations of each product (three DUTs in each population for Products MS-1, MS-2, MS-4, and MS-5; four DUTs in each population for Product MS-3) were subjected to power cycling of 1 hr on and 1 hr off. The key findings from this study include the following. Enhanced optical performance came at the cost of reduced light source efficiency for the lamps and light engines examined in this study. The optical filter used to produce a “sunlike” spectrum for Product MS-1 reduced light source efficiency by 26%, from 113 lumens per watt (lm/W) to 85 lm/W. Products MS-2 and MS-3 that used a violet-pumped LED to achieve “healthy” and “sunlike” enhanced optical performance, respectively, suffered the largest reduction in initial light source efficiency (49 lm/W for Product MS-2 and 68 lm/W for Products MS-3) perhaps because of the use of violet LED as the optical pump. Product MS-2 also had the poorest color fidelity because of undersaturation of blues and oversaturation of greens and yellows. Chromaticity maintenance of the products in this study was generally good, with parametric failure only occurring for one product at one AST condition (i.e., Product MS-3 at 7575). The chromaticity shift for Product MS-3 in 7575 test conditions resulted from reduced emissions of the broad green and red phosphors used to mimic sunlight in the 500–750 nanometer (nm) range. As a result of these phosphor emission losses, chromaticity shifted toward the more stable violet-pumped LED and blue phosphor. Although chromaticity maintenance was acceptable for most products tested, different chromaticity shift mechanisms were observed for temperature and humidity tests compared with temperature alone for Products MS-1, MS-2, and MS-3. For Product MS-1, a relative increase in green emissions was observed with humidity, which may indicate humidity-accelerated degradation of the optical filter at green wavelengths (optical delivery efficiency reduction) or degradation of the emitters in the red region (spectral efficiency reduction). The violet-pumped products (i.e., MS-2 and MS-3) exhibited different chromaticity shift behavior in the temperature-humidity environments, with Product MS-2 shifting generally yellow because of photo-induced oxidation of the plastic globe (i.e., a reduction of optical delivery efficiency) and Product MS-3 shifting toward violet and blue emitters because of faster loss of emission from green and red phosphors (i.e., a reduction in spectral efficiency). Because of an initial drop in power consumption, the light source efficiency of downlights (Products MS-4 and MS-5) increased at RTOL throughout the test duration. The light source efficiency initially increased during 75OL until a decay in luminous flux maintenance (LFM) dominated light source efficiency, whereas the light source efficiency decreased for the entire 7575 test duration. It was found that increasing the ambient environment of an SSL device from 25°C to 75°C decreases the LFM by 2.7 to 5.5, depending on design of the SSL device. Adding humidity to the system (75OL to 7575) was found to decrease LFM by another factor of approximately 3.0. A common location of failure was identified for the downlights (Products MS-4 and MS-5) operated in the 7575 environment. This failure abruptly occurred between 3,000 to 5,000 hrs of testing on the film capacitor of the electromagnetic interference (EMI) filter near the diode bridge for 11 of the 12 downlights. It is likely that this failure was caused by a combination of the high electrical voltage across the capacitor, the location of the capacitor near the heat sources (e.g., transformers, diode bridges, power resistors), and the high stress environment of 7575. Longer test times are needed to fully understand the LFM, luminous efficacy changes, and chromaticity shifts for some of the products. Because of the high reliability, light source efficiency, and spectral tuning capabilities of LEDs, the expectations of LAE for SSL products are greatly increased over traditional lighting products. The data gathered in this report begin to provide an understanding of the tradeoffs that current SSL products undergo when optimizing the different efficiency elements of LAE. As discussed in this report, the findings from the tests conducted show that the optimization of spectral efficiency can come at the cost of initial light source efficiency. Furthermore, the introduction of violet LEDs can promote long-term optical delivery efficiency degradation, and the introduction of optical filters or new phosphors can lead to unwanted spectral efficiency changes because the ratio of phosphor emitters changes with aging. The data presented in this report also identified a common failure location in 6-in downlights. The results regarding long-term behavior of the modified spectra devices studied provide valuable information about changes to the light source, spectral, and optical delivery efficiencies as the devices age. This information can be used to improve future SSL designs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1974

OMS engine shutoff valve and actuation system design and evaluation

Shutoff valve and actuation system concepts that are most suitable for the Orbital Maneuvering Systems engine application were determined. Emphasis was placed on the ten year and 100 mission life requirement, propellant and propellant residue compatibility and weight. It was found that poppet or ball valves utilizing electric or electropneumatic actuation were most applicable. Preliminary design layouts of a number of valve and actuation concepts were prepared and analyzed to make the optimum concept selection. Pneumatic actuation systems were required to feature their own pneumatic supply so that for the quad redundant valve, it was necessary to include two pneumatic supply systems, one for each of the series legs of the quad redundant package. The requirement for the pneumatic package placed heavy reliability, weight, and maintenance penalties upon electropneumatic actuation systems. The two valve and actuation systems concepts selected featured electric torque motor operation and a poppet as well as a ball valve concept with a retractable seal.

Wichmann, H.↗

NASA NTRS2006

Exploration Health Risks: Probabilistic Risk Assessment

Maintenance of human health on long-duration exploration missions is a primary challenge to mission designers. Indeed, human health risks are currently the largest risk contributors to the risks of evacuation or loss of the crew on long-duration International Space Station missions. We describe a quantitative assessment of the relative probabilities of occurrence of the individual risks to human safety and efficiency during space flight to augment qualitative assessments used in this field to date. Quantitative probabilistic risk assessments will allow program managers to focus resources on those human health risks most likely to occur with undesirable consequences. Truly quantitative assessments are common, even expected, in the engineering and actuarial spheres, but that capability is just emerging in some arenas of life sciences research, such as identifying and minimize the hazards to astronauts during future space exploration missions. Our expectation is that these results can be used to inform NASA mission design trade studies in the near future with the objective of preventing the higher among the human health risks. We identify and discuss statistical techniques to provide this risk quantification based on relevant sets of astronaut biomedical data from short and long duration space flights as well as relevant analog populations. We outline critical assumptions made in the calculations and discuss the rationale for these. Our efforts to date have focussed on quantifying the probabilities of medical risks that are qualitatively perceived as relatively high risks of radiation sickness, cardiac dysrhythmias, medically significant renal stone formation due to increased calcium mobilization, decompression sickness as a result of EVA (extravehicular activity), and bone fracture due to loss of bone mineral density. We present these quantitative probabilities in order-of-magnitude comparison format so that relative risk can be gauged. We address the effects of conservative and nonconservative assumptions on the probability results. We discuss the methods necessary to assess mission risks once exploration mission scenarios are characterized. Preliminary efforts have produced results that are commensurate with earlier qualitative estimates of risk probabilities in this and other operational contexts, indicating that our approach may be usefully applied in support of the development of human health and performance standards for long-duration space exploration missions. This approach will also enable mission-specific probabilistic risk assessments for space exploration missions.

Rhatigan, Jennifer↗

DOE OSTI2023

Co-design optimization of combined heat and power-based microgrids

With the emergent need for clean and reliable energy resources, hybrid energy systems, such as the microgrid, are widely adopted in the United States. A microgrid can consist of various distributed energy resources, for instance, combined heat and power (CHP) systems. Here, the CHP module is a distributed cogeneration technology that produces electricity and recaptures heat generated as a by-product. It is an energy-efficient technology converting heat that would otherwise be wasted to valuable thermal energy. For an optimal system configuration, this study develops a novel co-design optimization framework for CHP-based cogeneration microgrids. The framework provides the stakeholder with a method to optimize investments and attain resilient operations. The proposed co-design framework has a mixed integer programming (MIP) model that outputs decisions for both plant designs and operating controls. The microgrid considered in this study contains six components: the CHP, boiler, heat recovery unit, thermal storage system, power storage system, and photovoltaic plant. After solving the MIP model, the optimal design parameters of each component can be found to minimize the total installation cost of all components in the microgrid. Furthermore, the online costs from energy production, operation, maintenance, machine startup, and disruption-induced unsatisfied loads are minimized by solving the optimal control decisions for operations. Case studies based on designing a CHP-based microgrid with empirical data are conducted. Moreover, we consider both nominal and disruptive operational scenarios to validate the performance of the proposed co-design framework in terms of a cost-effective, resilient system.

42 ENGINEERING↗

NASA NTRSDate not supplied

NextSTEP Appendix A Modular ECLSS Effort Lessons Learned

NASA’s Artemis program provides the first steps for earth-independent exploration starting with crewed habitats in cislunar space and progressing toward crewed landings on the lunar surface that will prepare systems and crews for the exploration of Mars. The Next Space Technology for Exploration Partnerships (NextSTEP) is a public-private partnership model that facilitates commercial development of deep space exploration capabilities in support of more extensive human spaceflight missions in and beyond cislunar space. NASA issued the original NextSTEP Broad Agency Announcement (BAA) to U.S. industry in late 2014 and issued the second BAA (NextSTEP-2) in April 2016. The first appendix under NextSTEP-2, Appendix A, focused on developing deep space habitation concepts, engineering design and development, and risk reduction efforts leading to a habitation capability in cislunar space. NASA solicited concepts to develop and refine the evolvable, modular architecture, functional allocation options, standards, and common interfaces required to enable interoperability of the aggregate system to provide long duration deep space transit habitation, specifically enhancements and testing of deep space Environmental Control and Life Support Systems (ECLSS). Collins Aerospace, formerly UTC Aerospace Systems (UTAS), was awarded a Phase 1 and subsequent Phase 2 contract to “develop concepts that group ECLS systems into logical modules maximizing the use of common components and the development of unique methods and design concepts that support in-flight maintenance and repair for future exploration systems.” This paper summarizes the work accomplished under this effort, the lessons that can be applied to development of forthcoming habitation elements, and the gaps remaining to achieve a more resilient, maintainable, repairable and adaptable system capable of installation on a wide variety of habitat platforms. A primary accomplishment of this effort is the development and maturation of a modular palletization concept to enable standard rack interfaces, post-launch outfitting, and decoupling of structural supports that withstand launch environments from those needed for lower on-orbit loads in order to reduce installed mass and repurposing of panels within the habitat. In the course of the effort, Collins assessed numerous architecture trades, including the use of condensing and noncondensing heat exchangers, the ability of modular units to accommodate various habitat volumes and thermal loading, and the most appropriate order of and timing of delivery of regenerative ECLSS hardware to orbital habitats. In addition to the modularity of hardware elements, Collins developed software approaches for distributed/modular command, control, and communication systems and innovative Bayesian fault detection and isolation techniques. Finally, the effort explored advanced maintainability and supportability concepts including the definition of maintenance units (MUs) in place of the traditional Orbital Replacement Units (ORUs), increasing parts commonality to reduce the number and type of spare parts, the use of augmented reality to guide crews during maintenance and repair procedures, and how crews would prepare for and recover from long durations of habitat dormancy. Now that the NextSTEP Modular ECLSS effort has come to a close, it’s important to identify the lessons learned and where they can be leveraged to improve NASA’s broader program of ECLSS technology development and demonstration and ultimately how they can increase the performance of future surface and orbital habitats.

NextSTEP↗

NASA NTRSDate not supplied

NextSTEP Appendix A Modular ECLSS Effort Lessons Learned

NextSTEP↗

NASA NTRS1983

Radioactive nuclear waste stabilization - Aspects of solid-state molecular engineering and applied geochemistry

Stabilization techniques for the storage of radioactive wastes are surveyed, with emphasis on immobilization in a primary barrier of synthetic rock. The composition, half-life, and thermal-emission characteristics of the wastes are shown to require thermally stable immobilization enduring at least 100,000 years. Glass materials are determined to be incapable of withstanding the expected conditions, average temperatures of 100-500 C for the first 100 years. The geological-time stability of crystalline materials, ceramics or synthetic rocks, is examined in detail by comparing their components with similar naturally occurring minerals, especially those containing the same radioactive elements. The high-temperature environment over the first 100 years is seen as stabilizing, since it can recrystallize radiation-induced metamicts. The synthetic-rock stabilization technique is found to be essentially feasible, and improvements are suggested, including the substitution of nepheline with freudenbergite and priderite for alkaline-waste stabilization, the maintenance of low oxygen fugacity, and the dilution of the synthetic-rock pellets into an inert medium.

Haggerty, S. E.↗

NASA NTRSDate not supplied

Extended Duration: The SIRIUS 21 Crew Perspective

The SIRIUS (Scientific International Research In a Unique terrestrial Station) missions represent a collaborative effort between NASA and Russia’s Institute for Biomedical Problems (IBMP) to conduct a series of long duration isolation and confinement spaceflight analog missions. Three missions of 17-day, 4-month, and 8-month duration (SIRIUS 17, 19, and 21) have been completed at IBMP’s Ground-Based Experimental Complex / Nazemnyy eksperimental'nyy kompleks (NEK) in Moscow, Russia. The international SIRIUS 21 crew comprising representatives from the United States, United Arab Emirates and Russia recently completed the 8-month analog lunar mission. The extended duration mission included simulated lunar transit, orbital, and surface operations with corresponding deep space communication delay, during which the crew participated in nearly 70 studies, eight of which were sponsored by NASA’s Human Research Program. The studies examined the effect of isolation and confinement on the behavioral health of research subjects, and investigated medical countermeasures, team performance, crew dynamics, crew autonomy, food system risks, consequences of confinement and associated physiological stressors. SIRIUS 21 crewmembers also participated in operational tasks such as Rover and CubeSat assembly, simulated lunar sample assessment, VR activities, robotic arm training, environmental systems monitoring, exercise, greenhouse maintenance and 3D printing. Communication with Mission Control was limited to 30-minute periods every two hours. Since access to the internet and email was restricted, simulated ground support provided the Crew’s primary source of daily news and mission information. This panel discussion will include presentations from the US SIRIUS 21 crewmembers – William Brown and Ashley Kowalski – about their experience participating in the mission and science. A facilitated question and answer session will follow with attendees encouraged to ask questions and join in discussion with the SIRIUS 21 crewmembers about their experiences. William Brown came to SIRIUS 21 with experience spread across multiple industries, including the military, defense contracting, healthcare consulting, software engineering, and logistics. He has lived in the Middle East, Central Asia, and Russia. A former Boren Scholar, Brown is fluent in Russian. He holds a Master of International Business degree from the University of South Carolina’s Darla Moore School of Business. Prior to that, he earned a bachelor’s degree in Russian language, literature, and culture from the University of South Carolina. There, he also completed additional undergraduate coursework in computer science. Ashley Kowalski is a Project Leader in The Aerospace Corporation’s International Partnerships Department, where she works with, represents, and provides technical support to the the U.S. Space Force Space Systems Command International Affairs (SSC/IA) office. Through her numerous national and international assignments (Russia, China, and Germany), she has worked on topics related to international space systems, national security space systems, civil systems (including human spaceflight and civil launch projects), space policy, satellite industry analysis, and satellite manufacturing start-ups. She is proficient in Russian and German, and fluent in Polish. Kowalski received her Bachelor of Science and Master of Science degrees in mechanical and aerospace engineering from George Washington University in 2011 and 2012, respectively.

S. E. Whiting↗

DOE OSTI2023

Conceptual design of the LHCD system on CFETR

With the capability of saving flux consumption in the current ramp up phase, controlling the safety factor (q) profile, providing the required off-axis current drive (CD), a lower hybrid current drive (LHCD) system was eventually determined to be used on the China Fusion Engineering Test Reactor (CFETR). Here, in this paper, a 20 MW/4.6 GHz system composed of 40 units of 500 kW continuous wave (CW) klystron amplifier is preliminarily designed. The feasibility of the frequency choice of 4.6 GHz in the physical aspect is discussed. In order to minimize the transmission loss, a TE01 over-mode of circular waveguide will be used in the transmission system. Although previous calculations indicates that high field side (HFS) launcher location results in waves damping at inner region than low field side (LFS) launcher, which is favorable for plasma stability, HFS launcher will be extremely difficult in engineering due to the limited space. Calculations show that the tritium breeding ratio (TBR) will be decreased by ~ 1.5% with HFS launcher, while it will be decreased by ~ 0.22% only with LFS launcher. As a result, the LH power will be coupled to plasma from the top port at LFS. The designed passive active multi-junction (PAM) launcher is arranged in an array of 5 rows and 8 columns with the height of 1181 mm and the width of 794 mm. A shielding block with a thickness of 20 cm will be equipped around the feeding waveguides to protect the feeding waveguides and to prevent neutron leakage. A preliminary scheme of the remote maintenance for the LFS launcher is given. The modeling results shows that the density for optimum coupling is ~ 1.8 × 10 17 /m 3 , lower than the 4.6 GHz cut-off density n e_co = 2.6 × 10 17 /m 3 . Around this density, the power directivity (D p ) can be high as 71%.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Design for Remanufacturing

The objective of this project was to develop relationships between published scholarship, industry experience, and remanufacturing design rules and identify a clear path for integrating remanufacturing design rules into CAD tools and design practices. To accomplish this, remanufacturing knowledge was compiled, and then the relationships between this knowledge and a prioritized set of product design guidelines was developed. Next, a process to create rules out of guidelines was developed by first defining life extension as a primary function, and remanufacturing as effective tasks to control the failure modes that would restrict the product life. The reliability centered maintenance (RCM) process was used to identify proactive tasks and default actions to mitigate the effects of failure modes. These tasks were developed into expert system rules. The impact of design on remanufacturing was then validated through implementing a prioritized set of design rules for a Heavy Duty Off-Road (HDOR) techno-economic case study. Finally, detailed steps on how to define, develop, and integrate these rules into CAD were created.

42 ENGINEERING↗