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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Application of Design of Experiments and Surrogate Modeling within the NASA Advanced Concepts Office, Earth-to-Orbit Design Process

Decisions made during early conceptual design have a large impact upon the expected life-cycle cost (LCC) of a new program. It is widely accepted that up to 80% of such cost is committed during these early design phases. Therefore, to help minimize LCC, decisions made during conceptual design must be based upon as much information as possible. To aid in the decision making for new launch vehicle programs, the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) provides rapid turnaround pre-phase A and phase A concept definition studies. The ACO team utilizes a proven set of tools to provide customers with a full vehicle mass breakdown to tertiary subsystems, preliminary structural sizing based upon worst-case flight loads, and trajectory optimization to quantify integrated vehicle performance for a given mission. Although the team provides rapid turnaround for single vehicle concepts, the scope of the trade space can be limited due to analyst availability and the manpower requirements for manual execution of the analysis tools. In order to enable exploration of a broader design space, the ACO team has implemented an advanced design methods (ADM) based approach. This approach applies the concepts of design of experiments (DOE) and surrogate modeling to more exhaustively explore the trade space and provide the customer with additional design information to inform decision making. This paper will first discuss the automation of the ACO tool set, which represents a majority of the development effort. In order to fit a surrogate model within tolerable error bounds a number of DOE cases are needed. This number will scale with the number of variable parameters desired and the complexity of the system's response to those variables. For all but the smallest design spaces, the number of cases required cannot be produced within an acceptable timeframe using a manual process. Therefore, automation of the tools was a key enabler for the successful application of an ADM approach to an ACO design study. Following the overview of the tool set automation, an example problem will be given to illustrate the implementation of the ADM approach. The example problem will first cover the inclusion of ground rules and assumptions (GR&A) for a study. The GR&A are very important to the study as they determine the constraints within which a trade study can be conducted. These trades must ultimately reconcile with the customer's desired output and any anticipated "what if" questions. The example problem will then illustrate the setup and execution of a DOE through the automated ACO tools. This process is accomplished more efficiently in this work by splitting the tools into two separate environments. The first environment encompasses the structural optimization and mass estimation tools, while the second is focused on trajectory optimization. Surrogate models are fit to the outputs of each environment and are "integrated" via connection of the surrogate equations. Throughout this process, checks are implemented to compare the output of the surrogates to the output of manually run cases to ensure that the error of the final surrogates is at an acceptable level. The conclusion of the example problem demonstrates the utility of the ADM based approach. Using surrogate models gives the ACO team the ability to visualize vehicle sensitivities to various design parameters and identify regions of interest within the design space. The ADM approach can thus be used to inform concept down selection and isolate promising vehicle configurations to be explored in more detail through the manual design process. In addition it provides the customer with an almost instantaneous turnaround on any ''what if" questions that may arise within the bounds of the surrogate model. This approach ultimately expands the ability of the ACO team to provide its customer with broad and rapid turnaround trade studies for launch vehicle conceptual design. The ability to identify a selection of designs which can meet the customer requirements will help ensure lower LCC of launch vehicle designs originating from ACO.

Zwack, Mathew R.↗
NASA NTRS2017

Atmospheric Capture On Mars (and Processing)

The ultimate destination of NASA's human exploration program is Mars. In Situ Resource Utilization (ISRU) is a key technology required to enable such missions, as first proposed by Prof. Robert Ash in 1976. This presentation will review progress in the systems required to produce rocket propellant, oxygen, and other consumables on Mars using the carbon dioxide atmosphere and other potential resources. For many years, NASA, commercial companies, and academia have been developing, and demonstrating techniques to capture and purify Martian atmospheric gases for their utilization for the production of hydrocarbons, oxygen, and water in ISRU systems. Other gases will be required to be separated from Martian atmospheric gases to provide pure CO2 for processing elements. Significant progress has been demonstrated in CO2 collection via adsorption by molecular sieves, freezing, and direct compression. Early stage work in adsorption in Ionic Liquids followed by electrolysis to oxygen is also underway. In addition, other Martian gases, such as nitrogen and argon, occur in concentrations high enough to be useful as buffer gas and could be captured as well. Gas separation requirements include, but are not limited to the selective separation of: (1) methane and water from unreacted carbon oxides (CO2-CO) and hydrogen typical of a Sabatier-type process, (2) carbon oxides and water from unreacted hydrogen from a Reverse Water-Gas Shift process, and (3) carbon oxides from oxygen from a trash/waste processing reaction.

propellant production↗
NASA NTRS2016

Synthesis and Review: African Environmental Processes and Water-Cycle Dynamics

Africa's vast landmass harbors a variety of physical processes that affect the environment and the water cycle. This focus issue on the "African Environmental Processes and Water-Cycle Dynamics" contains eight articles that address these phenomena from different but complementary perspectives. Fires used for agricultural and related purposes play a major role in land-cover change, surface albedo modifications, and smoke emission; all of which affect the environment and the water cycle in different ways. However, emissions of aerosols and trace gases are not restricted to fires, but also emanate from other natural and human activities. The African water cycle undergoes significant perturbations that are attributable to several factors, including the aforesaid environmental processes. These changes in the water cycle have produced severe drought and flooding events in recent decades that affect societal wellbeing across sub-Saharan Africa. The combined effects of the environmental processes and water-cycle dynamics affect and are affected by climate variability and can be propagated beyond the continent. Future studies should utilize the wealth of observations and modeling tools that are constantly improving to clearly elucidate the interrelationships between all of these phenomena for the benefit of society.

Water cycle dynamics↗
NASA NTRS2017

Framework for Processing Citizens Science Data for Applications to NASA Earth Science Missions

Citizen science (or crowdsourcing) has drawn much high-level recent and ongoing interest and support. It is poised to be applied, beyond the by-now fairly familiar use of, e.g., Twitter for natural hazards monitoring, to science research, such as augmenting the validation of NASA earth science mission data. This interest and support is seen in the 2014 National Plan for Civil Earth Observations, the 2015 White House forum on citizen science and crowdsourcing, the ongoing Senate Bill 2013 (Crowdsourcing and Citizen Science Act of 2015), the recent (August 2016) Open Geospatial Consortium (OGC) call for public participation in its newly-established Citizen Science Domain Working Group, and NASA's initiation of a new Citizen Science for Earth Systems Program (along with its first citizen science-focused solicitation for proposals). Over the past several years, we have been exploring the feasibility of extracting from the Twitter data stream useful information for application to NASA precipitation research, with both "passive" and "active" participation by the twitterers. The Twitter database, which recently passed its tenth anniversary, is potentially a rich source of real-time and historical global information for science applications. The time-varying set of "precipitation" tweets can be thought of as an organic network of rain gauges, potentially providing a widespread view of precipitation occurrence. The validation of satellite precipitation estimates is challenging, because many regions lack data or access to data, especially outside of the U.S. and in remote and developing areas. Mining the Twitter stream could augment these validation programs and, potentially, help tune existing algorithms. Our ongoing work, though exploratory, has resulted in key components for processing and managing tweets, including the capabilities to filter the Twitter stream in real time, to extract location information, to filter for exact phrases, and to plot tweet distributions. The key step is to process the "precipitation" tweets to be compatible with satellite-retrieved precipitation data. These key components for processing and managing "precipitation" tweets (and additional ones to be developed) are not limited to precipitation, nor are they limited to the Twitter social medium. Indeed, to maximize the value of our work for NASA earth science programs, these components should be generalized and be part of an overall framework for processing citizen science data for science research. In this paper, we outline such a framework.

earth science satellite data↗
NASA NTRS2016

A Spatiotemporal Indexing Approach for Efficient Processing of Big Array-Based Climate Data with MapReduce

Climate observations and model simulations are producing vast amounts of array-based spatiotemporal data. Efficient processing of these data is essential for assessing global challenges such as climate change, natural disasters, and diseases. This is challenging not only because of the large data volume, but also because of the intrinsic high-dimensional nature of geoscience data. To tackle this challenge, we propose a spatiotemporal indexing approach to efficiently manage and process big climate data with MapReduce in a highly scalable environment. Using this approach, big climate data are directly stored in a Hadoop Distributed File System in its original, native file format. A spatiotemporal index is built to bridge the logical array-based data model and the physical data layout, which enables fast data retrieval when performing spatiotemporal queries. Based on the index, a data-partitioning algorithm is applied to enable MapReduce to achieve high data locality, as well as balancing the workload. The proposed indexing approach is evaluated using the National Aeronautics and Space Administration (NASA) Modern-Era Retrospective Analysis for Research and Applications (MERRA) climate reanalysis dataset. The experimental results show that the index can significantly accelerate querying and processing (10 speedup compared to the baseline test using the same computing cluster), while keeping the index-to-data ratio small (0.0328). The applicability of the indexing approach is demonstrated by a climate anomaly detection deployed on a NASA Hadoop cluster. This approach is also able to support efficient processing of general array-based spatiotemporal data in various geoscience domains without special configuration on a Hadoop cluster.

big data↗
NASA NTRS2016

Normalized Temperature Contrast Processing in Infrared Flash Thermography

The paper presents further development in normalized contrast processing used in flash infrared thermography method. Method of computing normalized image or pixel intensity contrast, and normalized temperature contrast are provided. Methods of converting image contrast to temperature contrast and vice versa are provided. Normalized contrast processing in flash thermography is useful in quantitative analysis of flash thermography data including flaw characterization and comparison of experimental results with simulation. Computation of normalized temperature contrast involves use of flash thermography data acquisition set-up with high reflectivity foil and high emissivity tape such that the foil, tape and test object are imaged simultaneously. Methods of assessing other quantitative parameters such as emissivity of object, afterglow heat flux, reflection temperature change and surface temperature during flash thermography are also provided. Temperature imaging and normalized temperature contrast processing provide certain advantages over normalized image contrast processing by reducing effect of reflected energy in images and measurements, therefore providing better quantitative data. Examples of incorporating afterglow heat-flux and reflection temperature evolution in flash thermography simulation are also discussed.

Koshti, Ajay M.↗
NASA NTRS2017

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

Prater, Tracie↗
NASA NTRS2017

Evaluation of a Candidate Trace Contaminant Control Subsystem Architecture: The High Velocity, Low Aspect Ratio (HVLA) Adsorption Process

Traditional gas-phase trace contaminant control adsorption process flow is constrained as required to maintain high contaminant single-pass adsorption efficiency. Specifically, the bed superficial velocity is controlled to limit the adsorption mass-transfer zone length relative to the physical adsorption bed; this is aided by traditional high-aspect ratio bed design. Through operation in this manner, most contaminants, including those with relatively high potential energy are readily adsorbed. A consequence of this operational approach, however, is a limited available operational flow margin. By considering a paradigm shift in adsorption architecture design and operations, in which flows of high superficial velocity are treated by low-aspect ratio sorbent beds, the range of well-adsorbed contaminants becomes limited, but the process flow is increased such that contaminant leaks or emerging contaminants of interest may be effectively controlled. To this end, the high velocity, low aspect ratio (HVLA) adsorption process architecture was demonstrated against a trace contaminant load representative of the International Space Station atmosphere. Two HVLA concept packaging designs (linear flow and radial flow) were tested. The performance of each design was evaluated and compared against computer simulation. Utilizing the HVLA process, long and sustained control of heavy organic contaminants was demonstrated.

Kayatin, Matthew J.↗
NASA NTRS2017

Trajectory Dispersed Vehicle Process for Space Launch System

The Space Launch System (SLS) vehicle is part of NASA's deep space exploration plans that includes manned missions to Mars. Manufacturing uncertainties in design parameters are key considerations throughout SLS development as they have significant effects on focus parameters such as lift-off-thrust-to-weight, vehicle payload, maximum dynamic pressure, and compression loads. This presentation discusses how the SLS program captures these uncertainties by utilizing a 3 degree of freedom (DOF) process called Trajectory Dispersed (TD) analysis. This analysis biases nominal trajectories to identify extremes in the design parameters for various potential SLS configurations and missions. This process utilizes a Design of Experiments (DOE) and response surface methodologies (RSM) to statistically sample uncertainties, and develop resulting vehicles using a Maximum Likelihood Estimate (MLE) process for targeting uncertainties bias. These vehicles represent various missions and configurations which are used as key inputs into a variety of analyses in the SLS design process, including 6 DOF dispersions, separation clearances, and engine out failure studies.

Statham, Tamara↗
NASA NTRS2010

Application of Ensemble Detection and Analysis to Modeling Uncertainty in Non Stationary Process

Characterization of non stationary and nonlinear processes is a challenge in many engineering and scientific disciplines. Climate change modeling and projection, retrieving information from Doppler measurements of hydrometeors, and modeling calibration architectures and algorithms in microwave radiometers are example applications that can benefit from improvements in the modeling and analysis of non stationary processes. Analyses of measured signals have traditionally been limited to a single measurement series. Ensemble Detection is a technique whereby mixing calibrated noise produces an ensemble measurement set. The collection of ensemble data sets enables new methods for analyzing random signals and offers powerful new approaches to studying and analyzing non stationary processes. Derived information contained in the dynamic stochastic moments of a process will enable many novel applications.

Racette, Paul↗
NASA NTRS2010

Analyzing Non Stationary Processes in Radiometers

The lack of well-developed techniques for modeling changing statistical moments in our observations has stymied the application of stochastic process theory for many scientific and engineering applications. Non linear effects of the observation methodology is one of the most perplexing aspects to modeling non stationary processes. This perplexing problem was encountered when modeling the effect of non stationary receiver fluctuations on the performance of radiometer calibration architectures. Existing modeling approaches were found not applicable; particularly problematic is modeling processes across scales over which they begin to exhibit non stationary behavior within the time interval of the calibration algorithm. Alternatively, the radiometer output is modeled as samples from a sequence random variables; the random variables are treated using a conditional probability distribution function conditioned on the use of the variable in the calibration algorithm. This approach of treating a process as a sequence of random variables with non stationary stochastic moments produce sensible predictions of temporal effects of calibration algorithms. To test these model predictions, an experiment using the Millimeter wave Imaging Radiometer (MIR) was conducted. The MIR with its two black body calibration references was configured in a laboratory setting to observe a third ultra-stable reference (CryoTarget). The MIR was programmed to sequentially sample each of the three references in approximately a 1 second cycle. Data were collected over a six-hour interval. The sequence of reference measurements form an ensemble sample set comprised of a series of three reference measurements. Two references are required to estimate the receiver response. A third reference is used to estimate the uncertainty in the estimate. Typically, calibration algorithms are designed to suppress the non stationary effects of receiver fluctuations. By treating the data sequence as an ensemble collection, it is possible to apply temporal algorithms which exacerbate the non stationary effects. By varying the algorithm, information about the properties of the non stationary receiver fluctuations is obtained. Comparisons of analytical calculations and statistical analysis of data demonstrate impressive agreement.

Racette, Paul↗
NASA NTRS2013

Using Giovanni in Investigating the Links between Environmental Processes and Drought in Northern sub-Saharan Africa

The northern sub-Saharan African (NSSA) region, bounded on the north and south by the Sahara and the Equator, respectively, and stretching East-West across Africa, is very vulnerable because of the highly active environmental and meteorological processes associated with its unique location and human activities that adversely impact the regional water cycle. Over the years, this region has suffered frequent severe droughts that have caused tremendous hardship and loss of life to millions of its inhabitants due to the rapid depletion of the regional water resources, as exemplified by the dramatic drying of Lake Chad. On the other hand, the NSSA region shows one of the highest biomass-burning rates per unit land area among all regions of the world. Because of the high concentration and frequency of fires in this region, with the associated abundance of heat release and gaseous and particulate smoke emissions, biomass-burning activity is believed to be one of the drivers of the regional carbon and energy cycles, with serious implications for the water cycle. An interdisciplinary research effort funded by NASA is presently being focused on the NSSA region, to better understand possible connections between the intense biomass burning observed from satellite year after year across the region and the water cycle, through associated changes in land-cover, surface albedo, emissions, atmospheric processes, precipitation, soil moisture, surface evaporation and runoff, and groundwater recharge. A combination of remote sensing and modeling approaches is being utilized to investigate these multiple processes to clarify possible links between them. However, by using Giovanni, we are able to extract and jointly analyze some of the important relevant parameters to obtain a first insight into their relationships. In this presentation, we will discuss these preliminary results as well as the path toward improved understanding of the interrelationships and feedbacks between the water cycle components and the environmental change dynamics due to biomass burning and related processes in the NSSA region.

water resources↗
NASA NTRS2018

A Single Thread to Fortran Coarray Transition Process for the Control Algorithm in the Space Radiation Code HZETRN

Exa-scale computing is the direction by industry and government are going to generate solutions to problems they deem necessary. Computing hardware is being developed to achieve the transition from Peta-scale to Exa-scale with more CPUs (Central Processing Units) that have more cores per CPU and more accelerators (GPGPUs (General Purpose Graphics Processing Units) and MICs (Many Integrated Cores)) per node. To fully utilize the hardware available now and in the future, algorithms must become multi-threaded. There are a few methods to generate multi-threaded software such as MPI (Message Passing Interface) and OpenMP (Multi-Processing) / OpenACC (ACCelerator). This paper concentrates on using Coarray Fortran to convert the Fortran 95 based HZETRN (High Z and Energy TRaNsport) code's control algorithm from a single threaded code to a multithreaded code. The resultant Coarray code was 32.5 times faster (with a theoretical speed-up of 74.5 times) than the single threaded version on the hardware tested, as reliable as the Fortran 95 version, and, as it uses native Fortran, was as maintainable as the Fortran 95 version. The Coarray code can be maintained by the same project engineers and scientists who created the original single threaded code. This transition process can be utilized on a C language based code with a compiler that has the UPC (Universal Parallel C) extensions to C.

Singleterry, Robert C., Jr.↗
NASA NTRS2019

Valuing Rigor in the Risk Management Process

NASA, as an organization, takes risk management (RM) seriously, and for most projects, the risk management process is exemplar. There can be challenges, though, with defining RM processes. For example, many different risk analysis methodologies are available, they can be applied with varying degrees of rigor, and they can have different value depending on how projects use them. In particular, risk analysis methodologies vary considerably in the level of quantitative detail, with more probabilistic techniques encouraged in some situations. We discussed these processes and methodologies with ten project managers (PM) at the NASA Goddard Space Flight Center (GSFC). Our intent was not to prove with some level of statistical significance that some are more helpful than others, but rather to obtain a general understanding of how projects are identifying, and thinking, about risks. This paper describes some of the available risk processes and methodologies, and provides some insights about the benefits that can gained from their use. We provide an in-depth discussion of one quantitative methodology, Probabilistic Risk Assessments (PRAs), and conclude with a few insights from observed best practices.

Dillon, Robin L.↗
NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗
NASA NTRS2014

Landform Evolution Modeling of Sedimentary Processes on Icy Worlds: the Cases of Hyperion and Helene

Sedimentary activity (erosion, transportation and deposition) is a major landscape-shaping process on many icy worlds of the outer solar system for which an understanding of this process is central to their geologic characterizations. Several recent studies, lead by the authors, have identified the effects of sedimentary activity on icy satellite landforms and recognized the role of mass wasting and volatile loss and redistribution in the evolution of these features. We apply state of the art, physics based, landform evolution modeling to icy satellite sedimentary landforms in order to fully quantitatively characterize how their morphologies change with time, and what their present appearances imply for the initial abundance and distribution of loose material, volatiles, and refractories in original pristine landforms. We will present results of our landform evolution modeling to the development of the landscapes of the Saturnian moons of Hyperion and Helene. Our current conclusions for Hyperion are that its unique appearance can be explained in part by the loss to space of ballistic ejecta during impact events. In order to create the smooth surfaces and the reticulate, honeycomb pattern of narrow divides between old craters, appreciable subsequent modification of crater morphology must occur through mass-wasting processes accompanied by sublimation, probably facilitated by the loss of CO2 as a component of the relief-supporting matrix of the bedrock. This mass wasting effectively destroys small craters, at least in part accounting for the paucity of sub-kilometer craters on Hyperion. Helene’s unusual morphology consists of broad depressions (modified large craters) and a generally smooth surface patterned with streaks and grooves. The streaks appear to be oriented down-gradient, as are the grooves. This pattern suggests intensive mass-wasting as a dominant process. Our initial modeling of this surface suggests a Bingham-like rheological behavior for the loose down-slope moving material. Interestingly, as a Bingham flow, the models indicate that aperiodic "intermittent" behavior to be present, suggesting that periods of quiet steady landform evolution are punctuated short periods of active surface readjustment.

Saturnian moons↗
NASA NTRS2019

Low-Loss Microstrip Transmission Line Fabricated with Improved Liftoff Process

The µ-Spec integrated spectrometer operating at ~500 GHz, employs thin film superconducting Nb microstrip transmission lines deposited directly on a thin (450 nm) single-crystal silicon dielectric. This single-crystal silicon layer is chosen as the dielectric layer due to its low intrinsic loss, with the goal of achieving both high- efficiency and precise phase control in a compact spectrometer architecture. To avoid roughening or etching through the thin single-crystal silicon dielectric a liftoff technique was developed for patterning these microstrip transmission lines and ground plane structures. This two- layer liftoff process was designed for use with sputter deposition and resulted in a US patent. Although this original technique provided precise control of linewidth, results of initial prototype spectrometer devices and separate diagnostic co-planer waveguide resonator devices showed that unexpected loss was being introduced due to the lift-off process. This extra loss was believed to be due to the “tails” (thin tapered regions) at the edge of the metal traces resulting from the sputtering process, as well as an amorphous oxide layer at the Nb-Si interface. We have since demonstrated an improved lift-off technique, which provides a clean metal-Si interface and removes the loss-inducing tails by a two-step selective etching method. This results in a decrease in microwave loss by more than an order of magnitude when measured in co-planar waveguide microwave resonator structures. We present these microwave test results and also SEM and TEM images of the microstrip interfaces and edge profiles before and after application of the improved process.

Hess, Larry A.↗
NASA NTRS2019

Manufacturing Process Development for Adhesively Bonded Joints in Large-Scale Space Structures

In order to take full advantage of the weight savings and performance gains offered by the use of composite materials in large-scale space structures, adhesively bonded joints must be considered. While bonded joint manufacturing at laboratory scale can be straightforward, the same manufacturing processes are not trivial at full scale. Surface preparation becomes particularly challenging (a viable process must yield consistent results over a large application area and be repeatable for multiple application sites), as does the application of heat to cure the doublers and/or bond them to the primary structure (the nature and scale of assembled or partially assembled aerospace structures often necessitates an out-of-oven/out-of-autoclave approach). In this work, bonded joint manufacturing processes are adapted for a full-scale (approximately 30 feet in diameter at the aft end) composite payload adapter at the NASA Marshall Space Flight Center. By iterating across a range of variables, process parameters for adhesively bonded joints on a large-scale composite structure have been developed. Primary findings are presented with respect to overarching bonded joint manufacturing concepts so as to maximize the applicability of this work to similar material systems and structures.

Guin, William E.↗