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NASA NTRS2018

Advantages of a Modular Mars Surface Habitat Approach

Early crewed Mars mission concepts developed by the National Aeronautics and Space Administration (NASA) assumed a single, large habitat would house six crew members for a 500-day Mars surface stay. At the end of the first mission, all surface equipment?including the habitat--would be abandoned and the process would be repeated at a different Martian landing site. This work was documented in a series of NASA publications culminating with the Mars Design Reference Mission 5.0 (NASA-SP-2009-566). The Evolvable Mars Campaign (EMC) explored whether re-using surface equipment at a single landing site could be more affordable than the Apollo-style explore-abandon-repeat mission cadence. Initial EMC assumptions preserved the single, monolithic habitat?the only difference being a new requirement to reuse the surface habitat for multiple expedition crews. A trade study comparing a single large habitat versus smaller, modular habitats leaned towards the monolithic approach as more mass-efficient. More recent work has focused on the operational aspects of building up Mars surface infrastructure over multiple missions, and has identified compelling advantages of the modular approach that should be considered before making a final decision. This paper explores Mars surface mission operational concepts and integrated system analysis, and presents an argument for the modular habitat approach.

Rucker, Michelle↗
NASA NTRS2018

Establishing and Monitoring an Aseptic Workspace

When are aseptic operations necessary? In order to meet certain bioburden requirements, some components must undergo dry heat microbial reduction (DHMR) or other sterilizing procedures. If sensitive surfaces must be re-exposed after DHMR, this could compromise the bioburden levels. Recontaminating sterilized surfaces could be costly both in time by requiring repeated DHMR and risk to the hardware, which may not be compatible with repeated high temperature bakes. In order to prevent recontamination of the sensitive surfaces, an aseptic environment and sterile technique must be employed. Aseptic environments mean working in a space with almost no detectable bioburden in the air or on surfaces. Ideally, DHMR happens as late as possible to avoid requiring aseptic operations, as it can be considered a high-risk operations. Preparing the cleanroom for aseptic operations Establishing an ISO (International Organization for Standardization) class 5 space to minimize airborne particles. Maintain low bioburden in the cleanroom by using biocidal cleaners. Using multiple biocidal techniques decreases the likelihood of selecting for resistant microorganisms. 70% Isopropyl Alcohol (IPA) denatures the proteins in a microorganism (note: 70% IPA is better at killing microorganisms than 100% IPA) 7% hydrogen peroxide: damages DNA and proteins through oxygen radical damage. Ultraviolet-C (UV-C) lamps: causes crosslinking in DNA which prevents replication. Monitor cleanroom regularly for bioburden trending: Standard bioassay: Swab or wipe samples of cleanroom surfaces processed for colony forming unity (viable or spore selected); Rapid bioassay: Adenosine triphosphate (ATP) or Limulus amebocyte lysate (LAL) for a bioburden snapshot. High levels can signal an immediate re-cleaning before standard bioassay samples are taken. Airborne monitoring: Active (pulling air through a filter) or passive (particle fallout) for bioburden. Verify bioburden levels just before aseptic operation. Test hardware and cleanroom surfaces and air 3 days before the planned aseptic operation. Rapid bioburden just before aseptic operation to ensure room was not re-contaminated. Preparing personnel and tools: Personnel training. Everyone in the cleanroom: Standard cleanroom certification Everyone on the team: 1 day Planetary Protection overview. Aseptic operators only: Half-day aseptic operations training. Covers sterile garmenting/gloves, Sterile handling with a focus on contact transfer risk, tool/GSE preparation, and two-operator system for opening sterilized tools/components. Tool sterilization: All tools to be used during an aseptic operation need to be identified. Compatible tools are sterilized by DHMR or Autoclave. Double wrapped so that the exterior bag can be handled by a non-sterile operator, and the sterile. Tools that are not compatible with high heat do not come in contact with sensitive surfaces: either substitutes are found, or tools are isolated by wrapping in sterile foil. During an aseptic operation. Pre-task to make sure everyone understands the operations, who is handling what, and when the most critical surfaces will be exposed. Monitoring during the operation. Bioburden: active and passive airborne bioburden sampling, glove-tip dabs onto a plate after completion of operation (3 days for results). Particles: real time particle counter constantly running, with alarm for exceeding ISO 5 conditions.

aseptic processing↗
NASA NTRS2018

Puffer: Pop-Up Flat Folding Explorer Robot

A repeatably reconfigurable robot, comprising at least two printed circuit board (PCB) rigid sections, at least one PCB flexible section coupled to the at least two PCB rigid sections, at least one wheel, hybrid wheel propeller, wheel and propeller, or hybrid wheel screw propeller rotatably coupled to at least one of the at least two PCB rigid sections and at least one actuator coupled to the at least two PCB rigid sections, wherein the at least one actuator folds and unfolds the repeatably reconfigurable robot.

Karras, Jaakko T.↗
NASA NTRS2018

Dynamic Modeling using Output-Error Parameter Estimation based on Frequency Responses Estimated with Multisine Inputs

A method is developed for estimating model parameters, such as nondimensional stability and control derivatives, by fitting transfer function or state-space models to empirical frequency response data using the output-error approach. The frequency response data were computed using Fourier transforms of measured input and output data. The control surfaces were excited with periodic multisine inputs which facilitated time-ecient estimation of multiple-input multiple-output frequency responses. The method was applied to lateral data from a nonlinear flight dynamics simulation of the F-16 aircraft, and to longitudinal data from multiple repeated flight test maneuvers of the NASA T-2 subscale aircraft. Results using simulation data showed the frequency response method compared well to other standard methods for parameter estimation. In addition to including all the available inputs, outputs, and harmonic frequencies in the estimation, relatively small subsets of the measured data could also be used to focus on identifying specific parts of the model. Results from flight test data showed that parameter estimates and uncertainties determined from repeated maneuvers were accurate and in statistical agreement with each other.

Grauer, Jared A.↗
NASA NTRS2018

Snowballs in Euclid and WFIRST Detectors

Snowballs are transient events observed in HgCdTe detectors with a sudden increase of charge in a few pixels. They appear between consecutive reads of the detector, after which the affected pixels return to their normal behavior. The origin of the snowballs is unknown, but it was speculated that they could be the result of alpha decay of naturally radioactive contaminants in the detectors, but a cosmic ray origin cannot be ruled out. Even though previous studies predicted a low rate of occurrence of these events, and consequently, a minimal impact on science, it is interesting to investigate the cause or causes that may generate snowballs and their impact in detectors designed for future missions. We searched for the presence of snowballs in the dark current data in Euclid and Wide Field Infrared Survey Telescope (WFIRST) detectors tested in the Detector Characterization Laboratory at Goddard Space Flight Center. Our investigation shows that for Euclid and WFIRST detectors, there are snowballs that appear only one time, and others that repeat in the same spatial localization. For Euclid detectors, there is a correlation between the snowballs that repeat and bad pixels in the operational masks (pixels that do not fulfill the requirements to pass spectroscopy noise, photometry noise, quantum efficiency, and/or linearity). The rate of occurrence for a snowball event is about 0.9 snowballs/hr. in Euclid detectors (for the ones that do not have associated bad pixels in the mask), and about 0.7 snowballs/hr. in PV3 Full Array Lot WFIRST detectors.

Astronomy↗
NASA NTRS2020

Verification of Prognostic Algorithms to Predict Remaining Flying Time for Electric Unmanned Vehicles

This paper addresses the problem of building trust in the online prediction of a eUAV’s remaining available flying time powered by lithium-ion polymer batteries. A series of ground tests are described that make use of an electric unmanned aerial vehicle (eUAV) to verify the performance of remaining flying time predictions. The algorithm verification procedure described is implemented on a fully functional vehicle that is restrained to a platform for repeated run-to-functional-failure (charge depletion) experiments. The vehicle under test is commanded to follow a predefined propeller RPM profile in order to create battery demand profiles similar to those expected during flight. The eUAV is repeatedly operated until the charge stored in powertrain batteries falls below a specified limit threshold. The time at which the limit threshold on battery charge is crossed is then used to measure the accuracy of the remaining flying time prediction. In our earlier work battery aging was not included. In this work we take into account aging of the batteries where the parameters were updated to make predictions. Accuracy requirements are considered for an alarm that warns operators when remaining flying time is estimated to fall below the specified limit threshold.

Edward F. Hogge↗
NASA NTRS2017

S-band Smallsat InSAR Constellation for Surface Deformation Science

Surface deformation studies using repeat-pass interferometric SAR have evolved into a powerful tool for geophysicists studying earthquake fault zones, volcanoes, ice sheet motion, and subterranean aquifers. Longer wavelengths (S-Band and L-Band) are preferred because they do not decorrelate as quickly as shorter wavelengths. Rapid revisit (1-3 days) is preferred because it allows the study of these phenomena at the timescales at which they commonly occur. Global access on such timescales is also required. Vector surface deformation measurements, taken from more than one direction, are a desired feature. This paper describes the conceptual architecture of a longer wave length, Smallsat SAR constellation of up to 12 satellites for rapid revisit surface deformation studies. The key to making such a constellation affordable is to lower launch costs, spacecraft costs, and instrument (SAR) costs. The first two objectives can be achieved using an ESPA-ring class, or Smallsat spacecraft. The third objective requires a SAR instrument sized to fit the mass and volume constraints imposed by such a spacecraft. Current state-of-the-art in miniaturization of electronics means that the radar transmit, receive and data handling functions can easily be implemented in a compact, low mass solution. The most significant challenge in designing a SAR to fit the Smallsat paradigm is in the dimensions of the antenna. The antenna sizing problem is addressed by adopting a smaller antenna than allowed by conventional SAR design rules. The baseline antenna design is simple, requiring no electronic beam-steering or beam-forming capability. Both reflectarray and microstrip patch antenna solutions are considered. The antenna structure is dual-purpose, to limit the overall system mass, with solar panels on the backplane providing power for the radar and spacecraft. The proposed solution easily accommodates radar squint angles of +/-30 degrees for repeat-pass interferometry measurements from multiple direct

Freeman, Anthony↗
NASA NTRS2019

Oro-Nasal Mask Versus Two-Way Non-Rebreathing Valves for Maximal Aerobic Capacity Testing in Astronauts

Astronauts complete maximal aerobic capacity (VO2pk) testing as part of their annual fitness assessment (AFA) as well as several times once assigned to an International Space Station mission. Historically, the 2-Way T-Shape Non-Rebreathing valve with a mouthpiece and nose clip (“Mouthpiece”) has been used in these tests. The testing procedure was updated to use the oro-nasal mask (“Mask”) for the AFA starting in June 2017. Astronauts who used the mask during their AFA requested it be certified to be used for all mission associated tests. Considering the criticality of the data and the schedule constraints of astronauts, it is imperative that the requested hardware change provide data with equivalent reliability and repeatability as provided by the mouthpiece. PURPOSE: To assess the reliability and validity of mask vs. mouthpiece by comparing submaximal and VO2pkdata within subjects (approximately 1 year apart). METHODS: Each of 17 active astronauts completed a VO (sub 2pk) test with the mouthpiece (first) and the mask (second) for their AFA. The VO (sub 2pk) test was conducted on a cycle ergometer with a metabolic cart. The nominal protocol started with a 3-minute warm-up at 50 Watts (W) and increased 25W every minute until volitional fatigue (Light: 45W start; 15W increase). The VO (sub 2pk)s were compared between tests and the expected day-to-day variation (plus or minus 5 percent) was used as the threshold for determining agreement between tests. Submaximal values were plotted and evaluated visually for deviations between mask and mouthpiece. RESULTS: VO (sub 2pk) values were more than 5 percent different, despite similar test times, between mouthpiece and mask in 6 of 17 comparisons, 3 of which were higher with the mask (9.0 plus or minus 5.9 percent) while 3 were lower (minus10.8 plus or minus 2.0 percent) with the mask. The submaximal data did not indicate a leak in either apparatus during these tests. An Astronaut Strength & Conditioning Rehabilitation specialist confirmed that the measured differences in VO (sub 2pk) of these 6 astronauts was consistent with observed changes in exercise habits during the year that separated the two tests. CONCLUSION: After being presented with the results of this data mining effort the mask was accepted for use in all tests, excepting that, if a leak is detected without resolve, the test will be repeated (if schedule allows) and remaining tests will be completed with the mouthpiece.

Buxton, R.↗
NASA NTRS2016

Comparison of RTA Vibratory Loading in the 40- by 80-Foot Wind Tunnel and 80- by 120-Foot Wind Tunnel at the National Full-Scale Aerodynamics Complex

This paper presents data taken in the 80- by 120-Foot Wind Tunnel in 1992 to data taken in the 40- by 80-Foot Wind Tunnel in 2016 at the NFAC. In both sets of data, the RTA was equipped with an identical set of S-76 helicopter blades. These data sets were compared to determine the repeatability of the RTA as a testing device, and to quantify differences in 40- by 80-Foot Wind Tunnel vs. 80- by 120-Foot Wind Tunnel results. The contents include an overview of the RTA and test facility, as well as a discussion of the methodology used. Vibratory load data is presented for a variety of wind and RPM conditions in various test section configurations. Data presented in this report quantifies the repeatability of the RTA.

NFAC↗
NASA NTRS2018

Restore-L Satellite Servicing Internship Final Report

An experiment was conducted to determine whether a sample of shorter flexible metal hoses could sustain tensile loads of up to 200 lbf and continue to meet the minimum mission requirements. The purpose of this experiment was to determine if tension loads during the processing of the hoses compromise performance. With this information, it will be decided whether the flight flex-hose manufacturer should proceed with the testing of the full-scale flex-hoses. To reduce the time and funding required for this test, a test fixture was designed and assembled in the Engineering Development & Operations (EDO) test facility. In this test fixture, two Engineering Development Unit (EDU) flex-hoses were loaded with free floating weights up to 350 lbf. A load of 200 lbf equates to the maximum expected loading with a margin of safety, thus all data recorded after 200 lbf was purely for reference. Measurements were taken using a tape measure and a custom datum measurement system to record the loaded and unloaded length of each flex-hose at various loads. Any permanent stretching beyond a 1/8th of an inch was indicative of inelastic yielding. The loading of each flex-hose was done with an initial weight 80 lbf and was increased to 100 lbf. Additional loading up to 350 lbf was done by 50 lbf increments thereafter. During the performance of the test, slippage occurred in the mounting of the flex-hoses in the test fixture. The first slippage occurred during the testing of the first flex-hose due to the collar of the flex-hose slipping within the collet of the top Kellem. As a result, the first flex-hose test was terminated early to modify the fixture. Due to the flex-hose not inelastically yielding, the test was repeated on the first flex hose. This test resulted in another instance of slippage in the upper collar of the Kellem due to tape interfering with the securing of a collet around the collar of the flex-hose. The test was then continued with one more slippage of the flex-hose within the collet of the bottom Kellem. Preventive measures were taken for future slippage, and the second hose remained secure during testing.Once the tests were concluded, the elongation of each hose was analyzed for inelastic yielding. Both flex-hoses stretched a measurable and repeatable amount under loading, however, this stretching was recovered once each hose was unloaded. As a result, both EDU flex-hoses did not experience any inelastic yielding during the tension testing. Once received, one additional flex-hose will be tested for yielding, but at the time of this paper, the recommendation is to proceed with testing of the full-scale flex-hoses at the flex-hose manufacturer.

Dziekan, Joseph↗
NASA NTRS2017

Low Excess Speed Triple Cyclers of Venus, Earth, and Mars

Ballistic cycler trajectories which repeatedly encounter Earth and Mars may be invaluable to a future transportation architecture ferrying humans to and from Mars. Such trajectories which also involve at least one flyby of Venus are computed here for the first time. The so-called triple cyclers are constructed to exhibit low excess speed on Earth-Mars transit legs, and thereby reduce the cost of hyperbolic rendezvous. Numerous solutions are identified with average transit leg excess speed below 5 kilometers per second, independent of encounter epoch. The energy characteristics are lower than previously documented cyclers not involving Venus, but the repeat periods are generally longer.

Jones, Drew Ryan↗
NASA NTRS2019

Evolving Management Strategies to Improve NASA Flagship's Cost and Schedule Performance: LUVOIR as a Case Study

The LUVOIR study process has brought to fruition an extremely exciting scientific mission concept. The 3.5 year LUVOIR study duration enabled an unprecedented level of scientific, engineering, and technology thoroughness prior to the Astro2020 Decadal. This detail also shed light on many technical and programmatic challenges for efficiently developing a mission of this scale. While NASA's flagships perform exquisitely once on-orbit, there is understandable growing frustration in their development cost and schedule overruns. We felt it incumbent upon ourselves to ask how we could improve on delivering LUVOIR (or any of NASA's future flagships) on schedule and on budget, not just for the next mission, but for all NASA large strategic missions to come. We researched past and current NASA flagship's lessons learned publications and other large government projects that pointed to some systemic challenges that will only grow with larger and more complex strategic missions. Our findings pointed us to some ways that could potentially evolve NASA's current flagship management practices to help improve on their development cost and schedule performance despite their growing complexity.. This paper briefly comments on the science motivation for NASA's flagships and on the science motivation for a LUVOIR-like mission. We argue the motivation for improving NASA's flagships development cost and schedule performance. We review the specific challenges of NASA's flagships to acknowledge their specific issues. We then examine the most repeated systemic challenges we found from previous NASA flagship and other large government project lessons learned/observed. Lastly, we offer recommendations to tackle these repeated systemic challenges facing NASA's flagships. The recommendations culminate into a proactive integrated development and funding framework to enable improving the execution of NASA's future flagship's cost and schedule performance.

Crooke, Julie A.↗
NASA NTRS2019

Evolving Management Strategies to Improve NASA Flagship's Cost and Schedule Performance: LUVOIR as a Case Study

The large ultraviolet optical infrared surveyor (LUVOIR) study process has brought to fruition an extremely exciting scientific mission concept. The 3.5 year LUVOIR study duration enabled an unprecedented level of scientific, engineering, and technology thoroughness prior to the Astro2020 Decadal. This detail also shed light on many technical and programmatic challenges for efficiently developing a mission of this scale within the context of NASA’s flagships cost and schedule performances to date. While NASA’s flagships perform exquisitely once on orbit, there is understandable growing frustration in their development cost and schedule overruns. We felt it incumbent upon ourselves to ask how we could improve on delivering LUVOIR (or any of NASA’s future flagships) on schedule and on budget, not just for the next mission, but for all NASA large strategic missions to come. We researched past and current NASA flagship’s lessons learned publications and other large government projects that pointed to some systemic challenges that will only grow with larger and more complex strategic missions. Our findings pointed us to some ways that could potentially evolve NASA’s current flagship management practices to help improve on their development cost and schedule performance despite their growing complexity. This paper briefly comments on the motivations for NASA’s flagships and on the science motivations for a LUVOIR-like mission. We argue the incentives for improving NASA’s flagships development cost and schedule performance. We review the specific additional challenges of NASA’s flagships to acknowledge their specific issues. We then examine the most repeated systemic challenges we found from previous NASA flagships and other large government projects lessons learned/observed. Lastly, we offer recommendations to tackle these repeated systemic challenges facing NASA’s flagships. The recommendations culminate into a proactive integrated development and funding framework to enable improving the execution of NASA’s future flagship’s cost and schedule performance.

Crooke, Julie A.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-16988-DND

There has been renewed interest to uniformly recalibrate historical geostationary (GEO) data records to aid in climate monitoring. GEO sensors have annual repeatable angular sampling over a given location. The view angle is fixed and the imaging schedule is usually constant through its lifetime. Given the fact that colocated GEOs are always share the same sub-satellite point and maintain their imaging schedules provides repeatable angular sampling over decades. One of the biggest challenges in transferring a reference sensor calibration using invariant desert targets to another sensor is the accuracy of the bidirectional reflectance distribution function (BDRF). A well-calibrated GEO can be used to predict the daily exoatmospheric radiance model (DERM) over a desert target for a given GMT that is valid for any GEO sensor at the same location. The advantage of this method is that a BRDF is not needed. Another challenge of invariant target calibration is the unique spectra signature of the desert. However, since most GEOs are built in batches, the spectral response functions (SRF) are very similar for most historical GEOs, the spectral band adjustment factor (SBAF) between GEO sensors is much smaller than for MODIS and GEO sensors. Since the water vapor burden over the desert is seasonal, both the TOA and desert surface can be considered invariant for a given day of the year. The reference GEO can be inter-calibrated with MODIS or VIIRS, which have onboard visible calibration using solar diffusers, using other methods, such as ray-matching or deep convective clouds. Also the next generation GEOs will have onboard visible calibration, which will increase the accuracy of this method. Three Meteosats over the Libyan desert will be used to illustrate the DERM method. The reference Meteosat will be inter-calibrated against Aqua-MODIS. The reference GEO DERM will be constructed and used to calibrate the remaining Meteosats. The DERM calibration will be validated by comparing the calibration using Aqua-MODIS ray-matching. Similarly, two GOES sensors using the Sonoran desert will also be highlighted. An uncertainty analysis will also be performed with emphasis on the SBAF, derived over the desert targets using both SCIAMACHY and Hyperion hyper-spectral radiances.

David Doelling↗
NASA NTRS2020

A Framework for Understanding and Quantifying the Loss and Acceleration of Relativistic Electrons in the Outer Radiation Belt During Geomagnetic Storms

We present detailed analysis of the global relativistic electron dynamics as measured by total radiation belt content (RBC) during coronal mass ejection (CME) and corotating interaction region (CIR)-driven geomagnetic storms. Recent work has demonstrated that the response of the outer radiation belt is consistent and repeatable during geomagnetic storms. Here we build on this work to show that radiation belt dynamics can be divided into two sequential phases, which have different solar wind dependencies and which when analyzed separately reveal that the radiation belt responds more predictably than if the overall storm response is analyzed as a whole. In terms of RBC, in every storm we analyzed, a phase dominated by loss is followed by a phase dominated by acceleration. Analysis of the RBC during each of these phases demonstrates that they both respond coherently to solar wind and magnetospheric driving. However, the response is independent of whether the storm response is associated with either a CME or CIR. Our analysis shows that during the initial phase, radiation belt loss is organized by the location of the magnetopause and the strength of Dst and ultralow frequency wave power. During the second phase, radiation belt enhancements are well organized by the amplitude of ultralow frequency waves, the auroral electroject index, and solar wind energy input. Overall, our results demonstrate that storm time dynamics of the RBC is repeatable and well characterized by solar wind and geomagnetic driving, albeit with different dependencies during the two phases of a storm.

Kyle R. Murphy↗
NASA NTRSDate not supplied

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultra-fine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray micro-focus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
NASA NTRS2020

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗
NASA NTRSDate not supplied

Additive Manufacture of Ultra-Fine Lattice Structures of Green Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar Mireles↗