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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7

Optical to optical interface device

The development, fabrication, and testing of a preliminary model of an optical-to-optical (noncoherent-to-coherent) interface device for use in coherent optical parallel processing systems are described. The developed device demonstrates a capability for accepting as an input a scene illuminated by a noncoherent radiation source and providing as an output a coherent light beam spatially modulated to represent the original noncoherent scene. The converter device developed under this contract employs a Pockels readout optical modulator (PROM). This is a photosensitive electro-optic element which can sense and electrostatically store optical images. The stored images can be simultaneously or subsequently readout optically by utilizing the electrostatic storage pattern to control an electro-optic light modulating property of the PROM. The readout process is parallel as no scanning mechanism is required. The PROM provides the functions of optical image sensing, modulation, and storage in a single active material.

Oliver, D. S.↗

Description of Selected Algorithms and Implementation Details of a Concept-Demonstration Aircraft VOrtex Spacing System (AVOSS)

A ground-based system has been developed to demonstrate the feasibility of automating the process of collecting relevant weather data, predicting wake vortex behavior from a data base of aircraft, prescribing safe wake vortex spacing criteria, estimating system benefit, and comparing predicted and observed wake vortex behavior. This report describes many of the system algorithms, features, limitations, and lessons learned, as well as suggested system improvements. The system has demonstrated concept feasibility and the potential for airport benefit. Significant opportunities exist however for improved system robustness and optimization. A condensed version of the development lab book is provided along with samples of key input and output file types. This report is intended to document the technical development process and system architecture, and to augment archived internal documents that provide detailed descriptions of software and file formats.

Hinton, David A.↗

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

A Module Experimental Process System Development Unit (MEPSDU)

Restructuring research objectives from a technical readiness demonstration program to an investigation of high risk, high payoff activities associated with producing photovoltaic modules using non-CZ sheet material is reported. Deletion of the module frame in favor of a frameless design, and modification in cell series parallel electrical interconnect configuration are reviewed. A baseline process sequence was identified for the fabrication of modules using the selected dendritic web sheet material, and economic evaluations of the sequence were completed.

Source record↗

Revisiting Building-Block Approaches for Structures

The building-block approach is a method for building confidence in designs, working from lower-level components to more complex assemblies, using knowledge gained at each step to inform higher fidelity representations. The goals of this paper are to revisit the basic techniques of the building-block approach as it applies to structural design and analysis and illustrate some best practices that should be considered when developing structural analysis models. The paper demonstrates the process of leveraging existing information to build confidence in the design/development of analysis models, followed by examples of how the building-block approach for analysis was used in NASA hardware and spacecraft development efforts. The paper will also discuss virtual testing and hybrid simulation techniques, which are showing promise for more efficient/cost-effective verification of aerospace structures.

Kenneth R. Hamm Jr.↗

Adaptation of Metal Additive Manufacturing Processes for the International Space Station

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center, in a partnership with the company, Made in Space, has previously investigated 3D printing of polymer materials on-orbit. In recent years, the project has begun exploring the potential for metal additive manufacturing (AM) on future space missions to reduce logistics and enable point-of-use manufacturing for sparing and repair. This paper provides an overview of constraints for demonstrating a manufacturing process on the International Space Station (ISS) as well as information on previous trades of available metal AM processes and their potential for in-space use. There are currently two processes in development as payloads for an ISS technology demonstration: wire+arc additive manufacturing (the Vulcan payload from Made in Space, Inc.) and bound metal additive manufacturing (the Fabrication Laboratory from Techshot, Inc). An update on both of these systems, key results to date, and future development efforts will be presented. Relevant modeling work, performed by NASA Ames Research Center, to evaluate operation of certain aspects of the bound metal AM process in a microgravity environment will also be summarized.

in-space manufacturing↗

Manufacturing and Metal Extraction Lunar Technology (MMELT)

Extraction processes of oxygen from regolith under development include carbothermal, molten regolith electrolysis (MRE), ionic liquids, and others, all of which result in a metal slag byproduct. The separation of some of these metals from the slag byproduct have been accomplished on small scales. However, no system currently exists that can extract aluminum, from these processes at scale, to create suitable feedstocks for manufacturing. Funding for MMELT will be used to develop a demonstration of the first end-to-end process to additively manufacture aluminum wire from lunar regolith in a simulated environment.

Manufacturing↗

Solar Concentrator Demonstrator for Lunar Regolith Processing

NASA at the Marshall Space Flight Center (MSFC) is building a portable inflatable solar concentrator ground demonstrator for use in testing in-situ resource utilization (ISRU) lunar regolith processing methods. Of primary interest is the production of oxygen as a propellant oxidizer and for life support. There are various processes being proposed for the in-situ reduction of the lunar regolith, the leading processes are hydrogen reduction, carbothermal reduction and vapor phase pyrolysis. The concentrator system being built at MSFC could support demonstrations of all of these processes. The system consists of a light inflatable concentrator that will capture sunlight and focus it onto a receiver inside a vacuum chamber. Inflatable concentrators are good for space based applications due to their low weight and dense packaging at launch. The hexapod design allows the spot size to be increased to reduce the power density if needed for the process being demonstrated. In addition to the hardware development, a comprehensive simulation model is being developed and will be verified and validated using the system hardware. The model will allow for the evaluation of different lunar locations and operational scenarios for the lunar regolith processing with a high confidence in the predicted results.

Fikes, John C.↗

AVOSS Development Approach

A concept is presented for development and implementation of prototype Aircraft Vortex Spacing System (AVOSS). The purpose of the AVOSS is to provide dynamical, weather dependent wake vortex separation criteria to ATC facilities with adequate stability and lead time for use in establishing arrival scheduling. This current paper discusses AVOSS development approach. The discussion includes: system model, AVOSS R&D effort scope, major development issues, concept system development process, AVOSS system testing, and concept demonstration.

Hinton, David A.↗

Streamling the Change Management with Business Rules

Will discuss how their organization is trying to streamline workflows and the change management process with business rules. In looking for ways to make things more efficient and save money one way is to reduce the work the workflow task approvers have to do when reviewing affected items. Will share the technical details of the business rules, how to implement them, how to speed up the development process by using the API to demonstrate the rules in action.

Basic Rules↗

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Soendker, Erich↗

Power Processing and Flow Control for a 100 kW Hall Thruster System

Aerojet Rocketdyne's NextSTEP program is developing and demonstrating a 100 kW Electric Propulsion (EP) system, the XR-100, which includes a modular power processing unit and modular xenon feed system to operate a Nested Hall Thruster (NHT) designed for powers up to 200 kW. The NextSTEP system is intended for use on large scale cargo transportation to support human missions to the Moon and Mars, which require very high-power Solar Electric Propulsion (SEP) systems operating between 200 and 400 kW. The three-year program objective is to operate the integrated EP system continuously at 100 kW for 100 hours, advancing this very high-power EP system to Technology Readiness Level (TRL) 5. In order to process the power and control propellant flow for this high-power system, Aerojet Rocketdyne has developed a modular concept for the Power Processing Units (PPUs) and Xenon feed system. The program has completed testing of critical elements of the PPU and feed system with a thruster simulator. Design upgrades to demonstrate the TRL 5 capabilities are underway. This paper will present an overview of the program and system design approach, the high power XR-100 capabilities of the PPU and feed system, and the latest test results for the 100 kW EP system demonstration program. In order to successfully execute this contract, there is a close collaboration between the teammates at Aerojet Rocketdyne (AR), the University of Michigan (UM), the NASA Jet Propulsion Laboratory (JPL), and the NASA Glenn Research Center (GRC).

Hablitzel, Sam↗

VIPER Lunar Rover Agile Mission Systems

Agile development methods, which have gone from outlier to mainstream in software development, are poised to expand into all aspects of space mission development. Modern software development operates on a principle of continuous deployment, where progress is verified not with conventional metrics, but with a continuous build, available to key stakeholders, enabling direct examination of the state of the code base, and assessment of progress through demonstration of capability. Delivery times are measured in weeks, not months. Stakeholders are part of the process on an ongoing basis. The cost of change is comparatively low and requirements, which often are not precisely defined at the start of a project, may be iteratively refined in a series of agile development cycles. Agile methods are compatible with traditional system engineering methods and may be tailored to the space operations environment. The low cost of change and iterative development cycles of agile enable requirements to be defined as outcomes and constraints, with design details to be refined during the development cycle. We are now at a point where agile methods may be extended beyond software, to Mission Systems, including the Mission Operations System and the Ground Data System. For NASA’s VIPER Lunar Rover Mission, scheduled to land at a lunar pole in late 2023, we are developing the Mission System using agile methods. As in agile software, where the measure of progress is working code, in agile mission system development, the measure of capability is what we can demonstrate. Demonstrations over presentations. We demonstrate mission system capability using simulations. The concept of operations, from commanding, to driving the rover, to how we downlink images for evaluation for a near-real time command cycle, will be tested and proven in simulation, years before we begin the traditional simulation cycle for training. “Say it then simulate it.” We develop and refine our designs using simulations, with an emphasis on new components of the system that are not well known early. For example, the required duration of a mission planning cycle for a lunar surface asset such as VIPER, that operates twenty-four hours a day, seven days a week, with continuous communications and a unique set of constraints based on the physics of the lunar poles and the line of site to Earth, is a unique problem in mission planning that is unlikely to be solved in a series of meetings. A small number of requirements specifying the outcomes may serve as the jumping off point to an agile development cycle, with demonstration in simulations. We have already demonstrated this process with simulations of rover driver decision time. VIPER is driven using near-real time command and control to waypoints. The driver decision time between waypoints is a fundamental enabling unit of productivity to accomplish the mission timeline. We have validated driver decision time in simulations of rover driving at the lunar South Pole, using the prototype mission tools for driving, command and control. The capability to develop and refine designs using simulations as part of agile Mission System development cycle changes the nature of team interactions, creating a focus on doing, rather than analyzing and documenting. Waterfall development cycles were, in part, a product of the significant cost of change in the early days of spaceflight. When the cost of change is high, it is vital to get your requirements right at the outset, because the system will be built to those specifications, and, when change is expensive, you better get it right early. However, modern technology has greatly lowered the cost of change, enabling iterative, rapid development cycles, in which key operations concepts may be tested and refined during development. Extending agile development to the Mission System for VIPER is a significant step in moving agile development methods for space operations beyond software, to the Mission System.

Agile↗

A Methodology for Multiple Rule System Integration and Resolution Within a Singular Knowledge Base

Expert Systems which support knowledge representation by qualitative modeling techniques experience problems, when called upon to support integrated views embodying description and explanation, especially when other factors such as multiple causality, competing rule model resolution, and multiple uses of knowledge representation are included. A series of prototypes are being developed to demonstrate the feasibility of automating the process of systems engineering, design and configuration, and diagnosis and fault management. A study involves not only a generic knowledge representation; it must also support multiple views at varying levels of description and interaction between physical elements, systems, and subsystems. Moreover, it will involve models of description and explanation for each level. This multiple model feature requires the development of control methods between rule systems and heuristics on a meta-level for each expert system involved in an integrated and larger class of expert system. The broadest possible category of interacting expert systems is described along with a general methodology for the knowledge representation and control of mutually exclusive rule systems.

Kautzmann, Frank N., III↗

Summary Report on Phase I and Phase II Results From the 3D Printing in Zero-G Technology Demonstration Mission

In-space manufacturing seeks to develop the processes, skill sets, and certification architecture needed to provide a rapid response manufacturing capability on long-duration exploration missions. The first 3D printer on the Space Station was developed by Made in Space, Inc. and completed two rounds of operation on orbit as part of the 3D Printing in Zero-G Technology Demonstration Mission. This Technical Publication provides a comprehensive overview of the technical objections of the mission, the two phases of hardware operation conducted on orbit, and the subsequent detailed analysis of specimens produced. No engineering significant evidence of microgravity effects on material outcomes was noted. This technology demonstration mission represents the first step in developing a suite of manufacturing capabilities to meet future mission needs.

Prater, T. J.↗

High resolution, low cost solar cell contact development

The MIDFILM cell fabrication and encapsulation processes were demonstrated as a means of applying low-cost solar cell collector metallization. The average cell efficiency of 12.0 percent (AM1, 28 C) was achieved with fritted silver metallization with a demonstration run of 500 starting wafers. A 98 percent mechanical yield and 80 percent electrical yield were achieved through the MIDFILM process. High series resistance was responsible for over 90 percent of the electrical failures and was the major factor causing the low average cell efficiency. Environmental evaluations suggest that the MIDFILM cells do not degrade. A slight degradation in power was experienced in the MIDFILM minimodules when the AMP Solarlok connector delaminated during the environmental testing.

Mardesich, N.↗

Model-Based Engineering Design for Trade Space Exploration throughout the Design Cycle

This paper presents ongoing work to standardize model-based system engineering as a complement to point design development in the conceptual design phase of deep space missions. It summarizes two first steps towards practical application of this capability within the framework of concurrent engineering design teams and their customers. The first step is standard generation of system sensitivities models as the output of concurrent engineering design sessions, representing the local trade space around a point design. A review of the chosen model development process, and the results of three case study examples, demonstrate that a simple update to the concurrent engineering design process can easily capture sensitivities to key requirements. It can serve as a valuable tool to analyze design drivers and uncover breakpoints in the design. The second step is development of rough-order- of-magnitude, broad-range-of-validity design models for rapid exploration of the trade space, before selection of a point design. At least one case study demonstrated the feasibility to generate such models in a concurrent engineering session. The experiment indicated that such a capability could yield valid system-level conclusions for a trade space composed of understood elements. Ongoing efforts are assessing the practicality of developing end-to-end system-level design models for use before even convening the first concurrent engineering session, starting with modeling an end-to-end Mars architecture.

models↗

Development of metallization process: FSA project, cella and module formation research area

The optimization, evaluation, and demonstration of a novel metallization applied by a screen printing process is examined. Based on previous results of High Resolution, Low Cost Solar Cell Contact Development, a paste consisting of molybdenum, tin, and titanium hydride was selected as the promising composition. No satisfactory cells were made using any of the molybdenum/tin pastes used as a complete replacement for conventional silver pastes. The major problem is the inability to form a bond between the pastes and silicon that withstands soldering.

Garcia, A., III↗