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NASA NTRS2015

Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

Werkheiser, Niki J.↗
NASA NTRS2015

On The Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

Werkheiser, Niki↗
NASA NTRS2015

SLS-SPEC-159 Cross-Program Design Specification for Natural Environments (DSNE) Revision D

This document is derived from the former National Aeronautics and Space Administration (NASA) Constellation Program (CxP) document CxP 70023, titled "The Design Specification for Natural Environments (DSNE), Revision C." The original document has been modified to represent updated Design Reference Missions (DRMs) for the NASA Exploration Systems Development (ESD) Programs. The DSNE completes environment-related specifications for architecture, system-level, and lower-tier documents by specifying the ranges of environmental conditions that must be accounted for by NASA ESD Programs. To assure clarity and consistency, and to prevent requirements documents from becoming cluttered with extensive amounts of technical material, natural environment specifications have been compiled into this document. The intent is to keep a unified specification for natural environments that each Program calls out for appropriate application. This document defines the natural environments parameter limits (maximum and minimum values, energy spectra, or precise model inputs, assumptions, model options, etc.), for all ESD Programs. These environments are developed by the NASA Marshall Space Flight Center (MSFC) Natural Environments Branch (MSFC organization code: EV44). Many of the parameter limits are based on experience with previous programs, such as the Space Shuttle Program. The parameter limits contain no margin and are meant to be evaluated individually to ensure they are reasonable (i.e., do not apply unrealistic extreme-on-extreme conditions). The natural environments specifications in this document should be accounted for by robust design of the flight vehicle and support systems. However, it is understood that in some cases the Programs will find it more effective to account for portions of the environment ranges by operational mitigation or acceptance of risk in accordance with an appropriate program risk management plan and/or hazard analysis process. The DSNE is not intended as a definition of operational models or operational constraints, nor is it adequate, alone, for ground facilities which may have additional requirements (for example, building codes and local environmental constraints). "Natural environments," as the term is used here, refers to the environments that are not the result of intended human activity or intervention. It consists of a variety of external environmental factors (most of natural origin and a few of human origin) which impose restrictions or otherwise impact the development or operation of flight vehicles and destination surface systems. These natural environments include the following types of environments: Terrestrial environments at launch, abort, and normal landing sites (winds, temperatures, pressures, surface roughness, sea conditions, etc.); Space environments (ionizing radiation, orbital debris, meteoroids, thermosphere density, plasma, solar, Earth, and lunar-emitted thermal radiation, etc.); Destination environments (Lunar surface and orbital, Mars atmosphere and surface, near Earth asteroids, etc.). Many of the environmental specifications in this document are based on models, data, and environment descriptions contained in the CxP 70044, Constellation Program Natural Environment Definition for Design (NEDD). The NEDD provides additional detailed environment data and model descriptions to support analytical studies for ESD Programs. For background information on specific environments and their effects on spacecraft design and operations, the environment models, and the data used to generate the specifications contained in the DSNE, the reader is referred to the NEDD paragraphs listed in each section of the DSNE. Also, most of the environmental specifications in this document are tied specifically to the ESD DRMs in ESD-10012, Revision B, Exploration Systems Development Concept of Operations (ConOps). Coordination between these environment specifications and the DRMs must be maintained. This document should be compatible with the current ESD DRMs, but updates to the mission definitions and variations in interpretation may require adjustments to the environment specifications.

Roberts, Barry C.↗
NASA NTRS2016

Enhancing Systems Engineering Education Through Case Study Writing

Developing and refining methods for teaching systems engineering is part of Systems Engineering grand challenges and agenda for research in the SE research community. Retention of systems engineering knowledge is a growing concern in the United States as the baby boom generation continues to retire and the faster pace of technology development does not allow for younger generations to gain experiential knowledge through years of practice. Government agencies, including the National Aeronautics and Space Administration (NASA), develop their own curricula and SE leadership development programs to "grow their own" systems engineers. Marshall Space Flight Center (MSFC) conducts its own Center-focused Marshall Systems Engineering Leadership Development Program (MSELDP), a competitive program consisting of coursework, a guest lecture series, and a rotational assignment into an unfamiliar organization engaged in systems engineering. Independently, MSFC developed two courses to address knowledge retention and sharing concerns: Real World Marshall Mission Success course and its Case Study Writers Workshop and Writers Experience. Teaching case study writing and leading students through a hands-on experience at writing a case study on an SE topic can enhance SE training and has the potential to accelerate the transfer of experiential knowledge. This paper is an overview of the pilot experiences with teaching case study writing, its application in case study-based learning, and identifies potential areas of research and application for case study writing in systems engineering education.

Stevens, Jennifer Stenger↗
NASA NTRS2015

Solar Thermal Upper Stage Liquid Hydrogen Pressure Control Testing

High-energy cryogenic propellant is an essential element in future space exploration programs. Therefore, NASA and its industrial partners are committed to an advanced development/technology program that will broaden the experience base for the entire cryogenic fluid management community. Furthermore, the high cost of microgravity experiments has motivated NASA to establish government/aerospace industry teams to aggressively explore combinations of ground testing and analytical modeling to the greatest extent possible, thereby benefitting both industry and government entities. One such team consisting of ManTech SRS, Inc., Edwards Air Force Base, and Marshall Space Flight Center (MSFC) was formed to pursue a technology project designed to demonstrate technology readiness for an SRS liquid hydrogen (LH2) in-space propellant management concept. The subject testing was cooperatively performed June 21-30, 2000, through a partially reimbursable Space Act Agreement between SRS, MSFC, and the Air Force Research Laboratory. The joint statement of work used to guide the technical activity is presented in appendix A. The key elements of the SRS concept consisted of an LH2 storage and supply system that used all of the vented H2 for solar engine thrusting, accommodated pressure control without a thermodynamic vent system (TVS), and minimized or eliminated the need for a capillary liquid acquisition device (LAD). The strategy was to balance the LH2 storage tank pressure control requirements with the engine thrusting requirements to selectively provide either liquid or vapor H2 at a controlled rate to a solar thermal engine in the low-gravity environment of space operations. The overall test objective was to verify that the proposed concept could enable simultaneous control of LH2 tank pressure and feed system flow to the thruster without necessitating a TVS and a capillary LAD. The primary program objectives were designed to demonstrate technology readiness of the SRS concept at a system level as a first step toward actual flight vehicle demonstrations. More specific objectives included testing the pressure and feed control system concept hardware for functionality, operability, and performance. Valuable LH2 thermodynamic and fluid dynamics data were obtained for application to both the SRS concept and to future missions requiring space-based cryogen propellant management.

Moore, J. D.↗
NASA NTRS2016

Micrometeorite Impact Test of Flex Solar Array Coupon

Spacecraft with solar arrays operate throughout the near earth environment and are planned for outer planet missions. An often overlooked test condition for solar arrays that is applicable to these missions is micrometeoroid impacts and possibly electrostatic discharge (ESD) events resulting from these impacts. NASA Marshall Space Flight Center (MSFC) is partnering with Space Systems/Loral, LLC (SSL) to examine the results of simulated micrometeoroid impacts on the electrical performance of an advanced, lightweight flexible solar array design. The test is performed at MSFC's Micro Light Gas Gun Facility with SSL-provided coupons. Multiple impacts were induced at various locations on a powered test coupon under different string voltage (0V-150V) and string current (1.1A - 1.65A) conditions. The setup, checkout, and results from the impact testing are discussed.

Wright, K. H.↗
NASA NTRS2016

Micrometeorite Impact Test of Flex Solar Array Coupon

Spacecraft with solar arrays operate throughout the near earth environment and are increasingly planned for outer planet missions. An often overlooked test condition for solar arrays that is applicable to these missions is micrometeorite impacts and possibly electrostatic discharge (ESD) events resulting from these impacts. The Marshall Space Flight Center (MSFC) is partnering with Space Systems/Loral, LLC (SSL) to examine the results of simulated micrometeorite impacts on the electrical performance of an advanced, lightweight flexible solar array design. The test is performed at NASA MSFC's Microlight Gas Gun Facility. The SSL-provided coupons consist of three strings, each string with two solar cells in series. Five impacts will be induced at various locations on a powered test coupon under different string voltage (0 volts - 150 volts) and string current (1.1 amperes - 1.65 amperes) conditions. The maximum specified test voltage and current represent margins of 1.5 times for both voltage and current. The test parameters are chosen to demonstrate new array design robustness to any ESD event caused by plasma plumes resulting from a simulated micrometeorite impact. A second unpowered coupon will undergo two impacts: one impact on the front side and one impact on the back side. Following the impact testing, the second coupon will be exposed to a thermal cycle test to determine possible damage propagation and further electrical degradation due to thermally-induced stress. The setup, checkout, and results from the impact testing are discussed. The challenges for impact testing include precise coupon alignment to control impact location; pressure management during the impact process; and measurement of the true transient electrical response during impact on the powered coupon. Results from pre- and post-test visual and electrical functional testing are also discussed.

Wright, K. H.↗
NASA NTRS2016

Results of the Test Program for Replacement of AK-225G Solvent for Cleaning NASA Propulsion Oxygen Systems

Since the 1990's, when the Class I Ozone Depleting Substance (ODS) chlorofluorocarbon-113 (CFC-113) was banned, NASA's propulsion test facilities at Marshall Space Flight Center (MSFC) and Stennis Space Center (SSC) have relied upon the solvent AsahiKlin AK-225 (hydrochlorofluorocarbon-225ca/cb or HCFC-225ca/cb) and, more recently AK-225G (the single isomer form, HCFC-225cb) to safely clean and verify the cleanliness of large scale propulsion oxygen systems. Effective January 1, 2015, the production, import, export, and new use of Class II Ozone Depleting Substances, including AK-225G, was prohibited in the United States by the Clean Air Act. In 2012 through 2014, NASA test labs at MSFC, SSC, and Johnson Space Center's White Sands Test Facility (WSTF) collaborated to seek out, test, and qualify a solvent replacement for AK-225G that is both an effective cleaner and safe for use with oxygen systems. This paper summarizes the tests performed, results, and lessons learned.

Lowrey, Nikki M.↗
NASA NTRS2015

Near-Earth Asteroid Scout

Near-Earth asteroids (NEAs) are easily accessible objects in Earth's vicinity. As NASA continues to refine its plans to possibly explore NEAs with humans, initial reconnaissance with comparatively inexpensive robotic precursors is necessary. Obtaining and analyzing relevant data about these bodies via robotic precursors before committing a crew to visit an NEA will significantly minimize crew and mission risk, as well as maximize exploration return potential. The NASA Marshall Space Flight Center (MSFC) and NASA Jet Propulsion Laboratory are jointly developing the Near-Earth Asteroid Scout (NEAS) utilizing a low-cost CubeSat platform in response to the current needs for affordable missions with exploration science value. The mission is enabled by the use of an 85-sq m solar sail being developed by MSFC (figs. 1 and 2).

Walden, Amy↗
NASA NTRS2015

Lunar Flashlight

The Lunar Flashlight is a Jet Propulsion Laboratory project, with NASA Marshall Space Flight Center (MSFC) serving as the principal investigator and providing the solar sail propulsion system. The goal of Lunar Flashlight is to determine the presence and abundance of exposed lunar water ice within permanently shadowed regions (PSRs) at the lunar south pole, and to map its concentration at the 1-2 kilometer scale to support future exploration and use. After being ejected in cis-lunar space by the launch vehicle, Lunar Flashlight deploys solar panels and an 85-square-meter solar sail and maneuvers into a low-energy transfer to lunar orbit. The solar sail and attitude control system work to bring the satellite into an elliptical polar orbit, spiraling down over a period of 18 months to a perilune of 30-10 kilometers above the south pole for data collection. Lunar Flashlight uses its solar sail to shine reflected sunlight onto the lunar surface, measuring surface reflectance with a four-filter point spectrometer. The spectrometer measures water ice absorption features (1.5, 1.95 microns) and the continuum between them (1.1, 1.9 microns). The ratios of water ice bands to the continuum will provide a measure of the abundance of surface frost and its variability across PSRs. Water ice abundance will be correlated with other data from previous missions, such as the Lunar Reconnaissance Orbiter and Lunar Crater Observation and Sensing Satellite, to provide future human and robotic explorers with a map of potential resources. The mission is enabled by the use of an 85-square-meter solar sail being developed by MSFC.

Baker, John↗
NASA NTRS2015

Nanoelectric Materials Laboratory Development

The Ultracapacitor Research and Development project is a collaborative effort between the NASA Marshall Space Flight Center's (MSFC's) ES43 Parts, Packaging, and Fabrication Branch and the EM41 Nonmetallic Materials Branch. NASA's Ultracapacitor Research is an effort to develop solid-state energy storage devices through processing of ceramic materials into printable dielectric inks, which can be formed and treated to produce solid state ultracapacitor cells capable of exceeding lithium-ion battery energy density at a fraction of the weight. Research and development efforts into solid state ultracapacitors have highlighted a series of technical challenges such as understanding as-received nature of ceramic powders, treatment and optimization of ceramic powders, dielectric and conductor ink formulation, and firing of printed (green) ultracapacitor cells. Two facilities have been continually developed since project inception: the Additive Electronics Lab in Bldg. 4487 and the Nanoelectric Materials Lab in Bldg. 4602. The Nanoelectric Materials Lab has become a unique facility at MSFC, capable of custom processing a wide range of media for additive electronics. As research has progressed, it was discovered that additional in-house processing was necessary to achieve smaller, more uniform particle diameters. A vibratory mill was obtained that can agitate powder and media in three directions, which has shown to be much more effective than ball milling. However, in order to understand the effects of milling, a particle size analysis system has been installed to characterize as-received and milled materials Continued research into the ultracapacitor technology included advanced milling and optimization of ceramic nanoparticles, fluidized bed treatment of atomic-layer deposition- (ALD-) coated ceramic particles, custom development of dielectric and conductor inks, as well as custom ink precursors such as polyvinylidene diflouride- (PVDF-) loaded vehicles. Experiments with graphene-based inks were also conducted.

Allen, Lee↗
NASA NTRS2015

Fast Light Optical Gyroscopes

Next-generation space missions are currently constrained by existing spacecraft navigation systems which are not fully autonomous. These systems suffer from accumulated dead-reckoning errors and must therefore rely on periodic corrections provided by supplementary technologies that depend on line-of-sight signals from Earth, satellites, or other celestial bodies for absolute attitude and position determination, which can be spoofed, incorrectly identified, occluded, obscured, attenuated, or insufficiently available. These dead-reckoning errors originate in the ring laser gyros themselves, which constitute inertial measurement units. Increasing the time for standalone spacecraft navigation therefore requires fundamental improvements in gyroscope technologies. One promising solution to enhance gyro sensitivity is to place an anomalous dispersion or fast light material inside the gyro cavity. The fast light essentially provides a positive feedback to the gyro response, resulting in a larger measured beat frequency for a given rotation rate as shown in figure 1. Game Changing Development has been investing in this idea through the Fast Light Optical Gyros (FLOG) project, a collaborative effort which began in FY 2013 between NASA Marshall Space Flight Center (MSFC), the U.S. Army Aviation and Missile Research, Development, and Engineering Center (AMRDEC), and Northwestern University. MSFC and AMRDEC are working on the development of a passive FLOG (PFLOG), while Northwestern is developing an active FLOG (AFLOG). The project has demonstrated new benchmarks in the state of the art for scale factor sensitivity enhancement. Recent results show cavity scale factor enhancements of approx.100 for passive cavities.

Smith, David D.↗
NASA NTRS2015

Space Synthetic Biology Project

Synthetic biology is an effort to make genetic engineering more useful by standardizing sections of genetic code. By standardizing genetic components, biological engineering will become much more similar to traditional fields of engineering, in which well-defined components and subsystems are readily available in markets. Specifications of the behavior of those components and subsystems can be used to model a system which incorporates them. Then, the behavior of the novel system can be simulated and optimized. Finally, the components and subsystems can be purchased and assembled to create the optimized system, which most often will exhibit behavior similar to that indicated by the model. The Space Synthetic Biology project began in 2012 as a multi-Center effort. The purpose of this project was to harness Synthetic Biology principals to enable NASA's missions. A central target for application was to Environmental Control & Life Support (ECLS). Engineers from NASA Marshall Space Flight Center's (MSFC's) ECLS Systems Development Branch (ES62) were brought into the project to contribute expertise in operational ECLS systems. Project lead scientists chose to pursue the development of bioelectrochemical technologies to spacecraft life support. Therefore, the ECLS element of the project became essentially an effort to develop a bioelectrochemical ECLS subsystem. Bioelectrochemical systems exploit the ability of many microorganisms to drive their metabolisms by direct or indirect utilization of electrical potential gradients. Whereas many microorganisms are capable of deriving the energy required for the processes of interest (such as carbon dioxide (CO2) fixation) from sunlight, it is believed that subsystems utilizing electrotrophs will exhibit smaller mass, volume, and power requirements than those that derive their energy from sunlight. In the first 2 years of the project, MSFC personnel conducted modeling, simulation, and conceptual design efforts to assist the project in selecting the best approaches to the application of bioelectrochemical technologies to ECLS. Figure 1 shows results of simulation of charge transport in an experimental system. Figure 2 shows one of five conceptual designs for ECLS subsystems based on bioelectrochemical reactors. Also during the first 2 years, some work was undertaken to gather fundamental data (conductivities, overpotentials) relevant to the modeling efforts.

Howard, David↗
NASA NTRS2015

A Magnetron Sputter Deposition System for the Development of X-Ray Multilayer Optics

The project objective is to establish the capability to deposit multilayer structures for x-ray, neutron, and extreme ultraviolet (EUV) optic applications through the development of a magnetron sputtering deposition system. A specific goal of this endeavor is to combine multilayer deposition technology with the replication process in order to enhance NASA Marshall Space Flight Center's (MSFC's) position as a world leader in the design of innovative x-ray instrumentation through the development of full shell replicated multilayer optics. The development of multilayer structures are absolutely necessary in order to advance the field of x-ray astronomy by pushing the limit for observing the universe to ever-increasing photon energies (i.e., up to 200 keV or higher), well beyond Chandra's (approx.10 keV) and NuStar's (approx.75 keV) capability. The addition of multilayer technology would significantly enhance the x-ray optics capability at MSFC and allow NASA to maintain its world leadership position in the development, fabrication, and design of innovative x-ray instrumentation, which would be the first of its kind by combining multilayer technology with the mirror replication process. This marriage of these technologies would allow astronomers to see the universe in a new light by pushing to higher energies that are out of reach with today's instruments. To this aim, a magnetron vacuum sputter deposition system for the deposition of novel multilayer thin film x-ray optics is proposed. A significant secondary use of the vacuum deposition system includes the capability to fabricate multilayers for applications in the field of EUV optics for solar physics, neutron optics, and x-ray optics for a broad range of applications including medical imaging.

Broadway, David↗
NASA NTRS2015

High Thermal Conductivity NARloy-Z-Diamond Composite Liner for Advanced Rocket Engines

NARloy-Z (Cu-3Ag-0.5Zr) alloy is state-of-the-art combustion chamber liner material used in liquid propulsion engines such as the RS-68 and RS-25. The performance of future liquid propulsion systems can be improved significantly by increasing the heat transfer through the combustion chamber liner. Prior work1 done at NASA Marshall Space Flight Center (MSFC) has shown that the thermal conductivity of NARloy-Z alloy can be improved significantly by embedding high thermal conductivity diamond particles in the alloy matrix to form NARloy-Z-diamond composite (fig. 1). NARloy-Z-diamond composite containing 40vol% diamond showed 69% higher thermal conductivity than NARloy-Z. It is 24% lighter than NARloy-Z and hence the density normalized thermal conductivity is 120% better. These attributes will improve the performance and life of the advanced rocket engines significantly. The research work consists of (a) developing design properties (thermal and mechanical) of NARloy-Z-D composite, (b) fabrication of net shape subscale combustion chamber liner, and (c) hot-fire testing of the liner to test performance. Initially, NARloy-Z-D composite slabs were made using the Field Assisted Sintering Technology (FAST) for the purpose of determining design properties. In the next step, a cylindrical shape was fabricated to demonstrate feasibility (fig. 3). The liner consists of six cylinders which are sintered separately and then stacked and diffusion bonded to make the liner (fig. 4). The liner will be heat treated, finish-machined, and assembled into a combustion chamber and hot-fire tested in the MSFC test facility (TF 115) to determine perform.

Bhat, Biliyar↗
NASA NTRS2015

Laser Imaging Detection and Ranging Performance in a High-Fidelity Lunar Terrain Field

The prime objective of this project is to evaluate Laser Imaging Detection and Ranging (LIDAR) systems and compare their performance for hazard avoidance when tested at the NASA Marshall Space Flight Center's (MSFC's) lunar high-fidelity terrain field (see fig. 1). Hazard avoidance is the ability to avoid boulders, holes, or slopes that would jeopardize a safe landing and the deployment of scientific payloads. This capability is critical for any sample return mission intending to land in challenging terrain. Since challenging terrain is frequently where the most scientifically attractive targets are, hazard avoidance will be among the highest priorities for future robotic exploration missions. The maturation of hazard avoidance sensing addressed in this project directly supports the MSFC Tier I priority of sample return.

Chuang, Jason↗
NASA NTRS2015

Grazing Incidence Optics Technology

This project is to demonstrate the capability to directly fabricate lightweight, high-resolution, grazing-incidence x-ray optics using a commercially available robotic polishing machine. Typical x-ray optics production at NASA Marshall Space Flight Center (MSFC) uses a replication process in which metal mirrors are electroformed on to figured and polished mandrels from which they are later removed. The attraction of this process is that multiple copies can be made from a single master. The drawback is that the replication process limits the angular resolution that can be attained. By directly fabricating each shell, errors inherent in the replication process are removed. The principal challenge now becomes how to support the mirror shell during all aspects of fabrication, including the necessary metrology to converge on the required mirror performance specifications. This program makes use of a Zeeko seven-axis computer-controlled polishing machine (see fig. 1) and supporting fabrication, metrology, and test equipment at MSFC. The overall development plan calls for proof-of-concept demonstration with relatively thick mirror shells (5-6 mm, fig. 2) which are straightforward to support and then a transition to much thinner shells (2-3 mm), which are an order of magnitude thinner than those used for Chandra. Both glass and metal substrates are being investigated. Currently, a thick glass shell is being figured. This has enabled experience to be gained with programming and operating the polishing machine without worrying about shell distortions or breakage. It has also allowed time for more complex support mechanisms for figuring/ polishing and metrology to be designed for the more challenging thinner shells. These are now in fabrication. Figure 1: Zeeko polishing machine.

Ramsey, Brian↗
NASA NTRS2016

The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

Bagg, Stacey D.↗