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NASA NTRS2021

Investigation of Ionic Liquids Isolated Iron for Ductile Iron Castings

As research continues for missions beyond low-Earth orbit, in-situ resource utilization (ISRU) methods are critical. For Lunar and Martian colonization, the ability to manufacture mechanical and structural components with local resources is essential. Ionic liquids (IL) are being studied at NASA Marshall Space Flight Center (MSFC) to harvest elemental metals from meteorites and regolith oxides. In this investigation, the viability of casting ductile iron using ionic liquids sourced iron and nickel was explored given ductile iron’s range of applications and performance as an as-cast alloy. Ingots were produced using commercial elements to simulate the use of IL iron with carbon sourced from the by-products of a life support system currently tested at MSFC. Samples were cast and compared to commercial ductile iron with phase transformation diagrams,microstructures, and hardness. Results showed ionic liquids sourced elements are a viable source of elemental alloying materials for a range of ductile iron alloys.

Ionic Liquids↗
NASA NTRSDate not supplied

Hail Storm Risk Assessment Using Space-Borne Remote Sensing Observations and Reanalyses

Much of the world is impacted by severe thunderstorms, but whether they become disasters depends upon resilience--our capacity to prepare, mitigate, respond, and recover. Hail is the costliest severe weather hazard for the insurance industry, generating ~70% of severe convective storm losses due to damage to assets such as homes, businesses, agriculture, and infrastructure. Most insurance companies do not reserve enough capital to cover catastrophes, so they acquire reinsurance. The reinsurance industry uses catastrophe models (CatModels) to statistically estimate risk to an insurer’s portfolio. Hail CatModels are developed with climatologies that define hailstorm frequency and severity. Hail-prone areas can be defined using hail reports from trained spotters, the media, and the general public. Extremely severe hail (2+ inch diameter) occurs nearly every day across the world. Weather radars can detect hail because hailstones strongly reflect microwave signals that they emit. However, hail climatologies are difficult to derive because hail covers small areas and there are neither hail reporting mechanisms (e.g. website or mobile app) nor radar networks in most places outside the US and Europe. This lack of ground truth on severe hail puts society and economies at risk. Hail is generated within storms by strong updrafts. These updrafts exhibit unique signatures in NASA and other agency satellite observations, offering new opportunities for hailstorm analysis. Geostationary (GEO) visible and infrared imagery has been collected for ~15-25 years across the world (region dependent) and methods have been developed at NASA Langley Research Center (LaRC) to detect hailstorm updrafts using GEO imagery. Climatological GEO updraft data has been used by Willis Towers Watson (WTW), a leader in catastrophe risk assessment for the insurance industry, and Karlsruhe Institute of Technology to develop CatModels over Europe and Australia. Hail can also be inferred with passive microwave imagery collected by low-Earth-orbiting sensors such as the GPM GMI, TRMM TMI, AMSR-E, AMSR-2, SSM/I, and SSMIS over the last 20+ years using methods developed at the Marshall Space Flight Center (MSFC). Hailstorms generate enhanced lightning flash rates that can be tracked using new GOES-R series GEO Lightning Mapping (GLM) imagery. Atmospheric reanalyses can be used to define favorable hailstorm environments for combination with the satellite-based storm detections. This presentation will describe a framework for developing continental to global hail climatologies and CatModels based on NASA satellite data and capabilities. This is a collaboration between LaRC and MSFC, WTW, and partners in Brazil, Argentina, and South Africa. This project seeks to mitigate hail disasters by aiding development of new satellite-based severe storm nowcasting tools by regional partners and developing climatologies to improve societal understanding of hail frequency. GEOO visible and infrared metrics of storm intensity, environmental conditions based on reanalyses, spotter hail reports and radar MESH observations are intercompared to quantify the detectability of hailstorms, and our ability to discriminate hailstorms from other severe storms. We are also maturing methods using land surface imaging satellite data (e.g. MODIS, Landsat, Sentinel 1 and 2) to identify hail damage to agriculture. Work with WTW will improve socioeconomic resilience through development of new CatModels. Southern Brazil, Uruguay, Paraguay, and Argentina feature some of the most intense thunderstorms on Earth. South America and South Africa are developing insurance markets of interest to WTW clients, and is similar to other regions routinely impacted by hail that do not have comprehensive hail reporting or radars to assess hailstorm frequency. Project datasets will be made available via online GIS-enabled tools developed at the LaRC Atmospheric Science Data Center (ASDC) which will visualize data and provide it in multiple formats for use in a wide range of open source and commercial tools.

Kristopher Michael Bedka↗
NASA NTRSDate not supplied

In-Space Manufacturing and Planetary Surface Construction: A "Make It, Don't Take It" Approach to Long Duration Human Exploration

This presentation will focus on technology development efforts at NASA Marshall Space Flight Center (MSFC) related to the long term sustainability of human spaceflight operations. NASA’s in-space manufacturing (ISM) project is developing approaches for on-demand manufacturing of metals, printed electronics, and recycling. These technologies will be demonstrated onboard the International Space Station (ISS) before transitioning to more logistically remote platforms such as Gateway or a foundational lunar surface habitat. Based on quantitative analyses, the operations and logistics approach used for ISS (which relies on storage of a large volume of spares and frequent cargo resupply), will not be transferrable to long duration, long endurance missions beyond low earth orbit. The deployment of manufacturing and recycling technologies on crewed platforms will enable on-demand manufacturing of spares at the point of use and conversion of nuisance materials to manufacturing feedstock, reducing both launch mass and waste material. This talk will also include information on NASA’s 3D Printed Habitat Centennial Challenge, which concluded in 2019 and served to advance the state of the art for large scale 3D printing with indigenous materials similar to those which would be available on a planetary surface. MSFC also recently began work on the Moon-to-Mars Planetary Autonomous Construction Technologies (MMPACT) project, which seeks to demonstrate capabilities for the creation of infrastructure on the lunar surface via construction of landing pads and habitats with lunar regolith based materials.

materials↗
NASA NTRSDate not supplied

Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Lunar Surface Construction Activity at NASA Marshall Space Flight Center

Introduction: The goal of the Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Project at NASA Marshall Space Flight Center (MSFC) is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure elements on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms, and blast shields using lunar regolith-based materials. MSFC has strong collaborations with industry, academia, and other NASA Centers to accomplish this goal. The MMPACT project consists of three elements. The first focuses on the development of an autonomous construction system. The second focuses on construction feedstock materials development. The third element focuses on the development of a microwave sintering construction capability. The team plans to demonstrate construction on a small Commercial Lunar Payload Services (CLPS) lander in the 2025 timeframe, with a future goal of constructing a subscale landing pad in 2028-2029.The MMPACT project is funded through the Lunar Surface Innovation Initiative, which is part of the Space Technology Mission Directorate. Technology Development: The MMPACT team will evaluate multiple autonomous construction and microwave construction technologies, materials, and construction element forms. Selected technologies will be matured; processes and operations will be defined for the two flight missions. Evaluations of materials, as well as the technology itself, will be demonstrated in simulated lunar environments as part of the technology maturation process. The team is keenly aware of the properties of the lunar environment. Its temperature swings, negligible exosphere, and unprepared site foundations factor into the materials for both construction and hardware, the concept of operations, and the technology’s interdependencies. Materials: The team is looking at materials that can be produced from in-situ resources in an effort to make lunar construction cost-effective. The particular focus of the materials team is cementitious materials, metals, and sintered and melted regolith. These materials will be studied for tensile, compressive, and flexural strength. They will also be tested for their ability to handle thermal swings and vacuum. They will be fully characterized using various microscopy techniques to examine micro-structures, chemistry, and crystal formation. Interdependencies: There are many interdependencies that MMPACT has already identified. These include: •Excavation interface •Regolith feedstock beneficiation •Regolith feedstock storage and provision •Requirements for structures •Site-to-site mobility systems •Availability of lunar simulant •Lander off-loading capabilities •Navigation systems •Power •Regolith composition and mineralogy •Lander specifications •Communication protocols Technology developments in these additional areas would be beneficial to MMPACT.

Moon to Mars Planetary Autonomous Construction Tec↗
NASA NTRSDate not supplied

ISS Payload Operations Training During the COVID-19 Pandemic: Impacts and Solutions

Introduction: The onset and the protracted duration of the COVID-19 pandemic brought a dramatic and rapid transformation to almost every aspect of humanity in 2020. The world’s space agencies and their missions were not immune to the unpredictable and wide-sweeping changes. One discipline principally affected was mission operations and the various groups supporting that critical function. Mission support teams, especially for complex and crewed missions like the International Space Station (ISS) were forced to rapidly rethink how and where control center staff performed their vital work. Operations training – an essential element to mission ops, had unique hurdles to overcome. Operations training is responsible for preparing astronaut crews for their scientific missions, providing recurring proficiency and currency material to flight controllers, as well as ensuring new team members are ready to join their colleagues on console. Every element of training was impacted by COVID restrictions. From orientation and introductory classes for new controllers, training for scientists and payload developers, to simulations and advanced lessons, critical On the Job Training (OJT) and final evaluations; all aspects faced new challenges. Operations trainers at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama, were forced to rethink, retool, and become more efficient with trainees and training resources in order to continue supporting payload operations on the ISS. Impacts and Barriers to Operations Training: The pandemic started in the United States in early March 2020. Immediately, NASA mandated that the support for ISS real-time operations was critical. As a result, physical access to the ISS Payload Operations Center was restricted to only those people supporting console operations. Thus, use of on-site NASA facilities and any trainer to trainee face-to-face interaction was not authorized. Trainers and trainees had to quickly shift to 100% remote learning. In the short term, this was not a problem since NASA had already prepared Information Technology (IT) resources that facilitated remote access to mission resources like classes, documents and teleconferences. However, instructors quickly discovered the classes that they were accustomed to delivering in a large classroom environment did not translate well to remote teaching. The lack of non-verbal communication with the class became a major barrier to instruction. Another significant hurdle to operations training was the mandate that all simulations could only be held remotely. The logistics of planning and executing even small simulations proved to be challenging, almost impossible, due to IT technology and public internet limitations. With simulations essentially stopped, as well as the restrictions on most OJT training, trainees were essentially stopped in their advancement towards certification. An additional barrier that had to be overcome was the formal documentation of the curriculum objectives. Even though NASA had been deliberately transitioning to electronic documents for years, some organizations were still relying on “pen and ink” documents to formalize training completion. The logistics of implementing secure and controlled e-signature documents in a standardized, NASA approved format had to be addressed. Lesson Learned and Efficiencies: Once the various limitations were identified, ISS trainers at MSFC discussed, proposed, and prioritized new options and techniques. Transitioning to all electronic learning materials and certifications was a relevantly easy fix. Teaching courses to large and diverse groups took additional shifts in the NASA training paradigm. Likewise, methods and procedures for preparing astronauts for their missions were forced to be revised. Simulation supervisors and their teams were also forced to find more efficient techniques to provide realistic training experience. Communication and approvals from management was essential. In every case, the ISS payload operations instructors found novel and efficient solutions to all functions listed above. This paper will discuss the factors and solutions payloads operations trainers found to keep scientific research on the ISS flying forward to mission success.

ISS Operations↗
NASA NTRS2021

Performance Assessment of the Eastern Range Titusville-Cocoa 915-MHz Doppler Radar Wind Profiler

The United States Space Force (USSF) is responsible for space vehicle launches at its Eastern Range (ER), which includes the Cape Canaveral Space Force Station (CCSFS). Multiple systems are used to measure the atmosphere at the ER, including suites of Doppler Radar Wind Profilers (DRWPs)that operate at 915MHz and measure winds within the lowest few kilometers of the atmosphere. Observations of boundary layer winds can be used for multiple applications, including serving as input to toxic dispersion models and characterizing winds for low-level aborts. The USSF upgraded the Titusville-Cocoa(TICO)DRWP, which collected data during the spring and summer of 2020. The USSF also requested NASA’s Marshall Space Flight Center (MSFC) Natural Environments Branch (NE) to evaluate wind output from this DRWP system. This report describes the system and the analyses that MSFC NE conducted to demonstrate the system’s wind accuracy relative to balloons from the Automated Meteorological Profiling System (AMPS), data availability, and effective vertical resolution (EVR).

B. J. Barbre↗
NASA NTRSDate not supplied

Modeling Electrolytic O2 Recovery from Metabolic CO2 for Advanced Closed Loop Life Support Systems in Extraterrestrial Human Missions

The International Space Station (ISS) is currently equipped with a complex, heavy, and power consuming system that recovers approximately 50% of O2 from metabolic CO2. Future long duration human missions to the Moon and Mars will necessitate a sustainable and highly efficient metabolic oxygen recovery system capable of yielding a minimum of 75% O2 recovery. A Macrofluidic Electrochemical Reactor (MFECR) technology development effort is currently underway at NASA Marshall Space Flight Center (MSFC) to significantly increase current metabolic O2 recovery efficiency, expand mission sustainability, and reduce complexity of the system. The novel design combines CO2 conversion to O2 along with C2H4 as byproduct and water electrolysis (currently conducted in two separate units) into a single compact unit that runs at standard conditions and is theoretically capable of generating O2 with a theoretical maximum metabolic CO2 conversion of 73% while consuming less than metabolic water. This paper presents a comprehensive multi-physic 3D model developed at MSFC on CO2 conversion to O2 and C2H4 at standard conditions via MFECR. The 3D spatial domain of the model is a replica of the actual MFECR’s 3D drawing generated for the MFECR fabrication and operated to recover O2 from CO2 yielding C2H4 as byproduct. Electrochemical (EC) physics that includes EC multicomponent reaction mechanisms, mass transport, and electrical current density distributions is coupled in the model with all the other physics phenomena involved in the MFECR’s process, such as two-phase flow, free and porous fluid regimes, multicomponent mass transfer, heat transfer, and DC electrical current generation along with Joule heating effect. The EC reaction sections of the MFECR consists of two porous gas diffusion electrodes (GDE) and an electrolyte serpentine channel sandwiched in the middle. The CO2 feeds the cathode serpentine channel and part of the O2 product is fed back to the anode serpentine chamber. An alkaline solution feeds the electrolyte serpentine chamber wetting the GDEs of both, the anode and cathode allowing the OH- ionic transport between them. The EC reactions in the cathode’s GDE yield C2H4 from CO2 and H2 from water while the EC reaction in the anode’s GDE yields O2. The authors will present in this paper the validation of the model using experimental data and the utilization of the validated model in building a reliable simulator that will not only assist the authors on the MFECR design but also the optimization of its operation in the ISS and future spatial human missions.

Jesus A Dominguez↗
NASA NTRS2021

Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

Carbon-carbon (C-C) composite and ceramic matrix composite (CMC) nozzle extensions are being considered and developed for use with a variety of cryogenic liquid rocket engine systems. Some of the potential applications include in-space, lunar lander, and launch vehicle upper stage propulsion systems. Composite material systems of interest include C-C and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Nozzle extension materials and fabrication methods under development by industry support both National Aeronautics and Space Administration (NASA) and Department of Defense (DOD) requirements, as well as those of the broader Commercial Space industry. Marshall Space Flight Center (MSFC) efforts are aimed at both (a) assisting industry with the development of composite nozzle extensions for cryogenic liquid rocket engines, and (b) developing and demonstrating capabilities for characterizing, testing, and qualifying such nozzle extensions. Results of recent MSFC nozzle-extension characterization efforts and engine firing demonstrations will be presented.

carbon-carbon↗
NASA NTRS2021

Performance Assessment of the Eastern Range False Cape 915-MHz Doppler Radar Wind Profiler

The United States Space Force (USSF) is responsible for space vehicle launches at its Eastern Range (ER), which includes the Cape Canaveral Space Force Station (CCSFS). Multiple systems are used to measure the atmosphere at the ER, including suites of Doppler Radar Wind Profilers (DRWPs) operating at 915 MHz that measure winds within the lowest few kilometers of the atmosphere. Observations of boundary layer winds can be used for multiple applications, including serving as input to toxic dispersion models and characterizing winds for low-level aborts. The USSF upgraded the False Cape DRWP, which collected data during the autumn of 2020. The USSF also requested NASA’s Marshall Space Flight Center (MSFC) Natural Environments Branch (NE) to evaluate wind output from this DRWP system. This report describes the system and the analyses that MSFC NE conducted to demonstrate the system’s wind accuracy relative to balloons from the Automated Meteorological Profiling System (AMPS), data availability, and effective vertical resolution (EVR).

BJ Barbre↗
NASA NTRSDate not supplied

Development of Electrolytic Oxygen Recovery System for Advanced Life Support

The oxygen (O2) recovery system for the International Space Station (ISS) can recover approximately 50 percent of O2 from metabolic carbon dioxide (CO2). Increasing the O2 recovery rate and closing the open loop for future long duration crewed missions in space beyond Low Earth Orbit (LEO) is essential. There are several developmental efforts underway to increase the recovery rate. However, most of these technologies result in a complex, heavy, and power consuming system. The desired exploration O2 recovery system would be reliable and efficient with maximum O2 recovery. Marshall Space Flight Center (MSFC) is currently investigating an electrolytic O2 recovery approach that will increase the O2 recovery to greater than 70 percent as well as lowering the complexity, mass, and power consumption than most other technologies currently under development. The electrolytic O2 recovery system consists of a Microfluidic Electrochemical Reactor (MFECR) that is based on the electrochemical reduction of CO2 to O2 and ethylene (C2H4) using water (H2O) as precursor and operates at standard condition with a theoretical recovery rate of 73 percent. In 2016, NASA’s Game Changing Development Program awarded the University of Texas Arlington (UTA) a grant to initiate the development of the MFECR. Since 2019, MSFC and UTA have been collaborating with the current goals of increasing the O2 recovery efficiency, advancing the technology readiness to a Technology Readiness Level (TRL) 4, and maturing the system to process CO2 of one crew-member. Based on the results from UTA’s initial efforts, the following were identified as key areas of improvement in order to maximize O2 recovery for the system: further development of the anode material and cathode catalyst, model-based cell design optimization, and the addition of a separation system and fuel cell. This paper will present the current developmental efforts of the electrolytic system including MFECR design and overall system enhancements as well as results from single cell stack testing.

Brittany R Brown↗
NASA NTRS2021

Post-Flight Assessment Review (PFAR): Advanced Colloids Experiment (ACE) ACE-T7-1,2

The objective of this PFAR is to: • Provide closure to ZIN DO-237 ACE-T7work and close NASA NPR 7123.1 requirements as listed in the SpaceDOC-II (S2) contract (the S2 CDRL DID No. PM-09 calls for a SEMP which refers backto NPR 7123.1) • Provide closure of SEMP (ZIN’s P40025) requirements for Technical Reviews • Provide plan to complete Informatics requirements. • Provide milestone closure to sponsoring organization. • Document property re-use and transfer decisions. • Transfer raw science data to the designated repository at MSFC. • Transfer required documents to Informatics • Opens an Informatics folder at MSFC to officially receive ACE-T7 information. • Capture open action items. • Create a formal presentation in configuration control. • Provide directions (in a Project Manager Report) how to contact the Project and Science teams through NASA when follow-on grants are awarded by Informatics.

microgravity↗
NASA NTRSDate not supplied

Extreme Environment Hot Fire Durability of Post-Processed Additively Manufactured GRCop-Alloy Combustion Chambers in LOX/Hydrogen and LOX/Methane

Extreme environment survivability of metal additive manufactured (AM) GRCop-alloy thrust chambers has been demonstrated in different bi-propellants at near stoichiometric and even oxygen rich combustion. GRCop-alloy chambers tested at NASA Marshall Space Flight Center (MSFC) have accumulated over 26,000 seconds of hot fire duration and over 500 starts. These chambers are produced using an AM process called laser powder bed fusion (L-PBF). A major feature of this process is high wall surface roughness which can be customized in post processing to leverage various performance advantages. Post-processing can include heat treatment, final machining, polishing, and welding and is key to hardware survivability in extreme environments. Surface finish enhancement techniques were applied to the hot wall and coolant channels to reduce the overall total heat load to the chamber walls. Performance optimization of various thrust class TCA’s is a strategic technology goal of NASA MSFC. Three different chamber geometries using cryogenic methane and de-ionized water as coolants were hot fire tested to obtain their life cycle, pressure drop, and heat load performances. Several 1.2K lbf LOX/H2 chambers, 1K lbf LOX/CH4 chambers, and 7K lbf LOX/CH4 chambers were tested. All post-processed configurations performed remarkably well when subjected to extreme hot fire test conditions. Streaking and blanching due to localized oxygen rich conditions were observed on some test articles in their as-built surface finish state. However, this is actually a function of the injector mixing and only serves to further establish the durability of L-PBF GRCop-alloy thrust chambers. Several different polishing techniques were applied to the hot wall and integrated coolant channels prior to hot fire testing and their performances assessed. Overall, AM produced GRCop chambers are extremely reliable, durable, and customizable to the desired performance metrics.

grcop↗
NASA NTRSDate not supplied

Extreme Dimensional Stability Thermal Control Test

Two observatories under consideration in the 2020 decadal survey include coronagraphs for characterizing the atmospheric composition of exoplanets. The telescope in those observatories must provide a wavefront that is stable to the picometer level for the coronagraph to provide enough starlight rejection to capture light reflected off of an Earth-like exoplanet. Therefore, picometer dimensional stability and control are required for these missions. Analysis indicates the thermal environment around the primary mirror must be stable to milliKelvin for the primary mirror’s thermally induced wavefront error to be stable to picometers. Marshall Space Flight Center (MSFC) partnered with L3-Harris Corporation to design and build a 1.5mthermal control system capable of milliKelvin stability. MSFC tested this thermal control system in the X-Ray and Cryogenic Facility’s large chamber to characterize how well the system controlled a 1.5m ULE® mirror.

optomechanical↗
NASA NTRS2020

Lunar Flashlight Propulsion System Fracture Control Plan

This document is intended to replace a previously approved Fracture Control Plan (VACCO X16029-10-FCP1) for the Lunar Flashlight Propulsion System (LFPS). The current LFPS is a new design and therefore requires a new plan; however, the spacecraft interfaces have remained the same. This document describes the elements of the Marshall Space Flight Center (MSFC)Fracture Control Program and the responsibilities for managing these elements for the LFPS for the Lunar Flashlight CubeSat mission that will launch as a secondary payload on the Space Launch System (SLS). The purpose of this document is to establish a plan for the fracture control activities for MSFC’s LFPS that will be used on the Lunar Flashlight CubeSat. This plan lists all the specific activities that will be performed to satisfy fracture control for this program. The provisions of this plan shall be met to demonstrate that the parts are in compliance with NASA’s fracture control requirements for space flight hardware.

Cubesat↗
NASA NTRSDate not supplied

Venus Global Reference Atmospheric Model (Venus-GRAM) Upgrades

Introduction: The Venus Global Reference Atmospheric Model (Venus-GRAM) is one of the most widely used engineering models of Venus’ atmosphere. The Venus-GRAM upgrades are being developed by NASA Marshall Space Flight Center (MSFC) and NASA Langley Research Center (LaRC). This presentation will provide details regarding the upgrades that have been made to Venus-GRAM and the ongoing objectives, tasks, and milestones related to the GRAM upgrades funded by the NASA Science Mission Directorate (SMD). Venus-GRAM: Venus-GRAM is an engineering-oriented atmospheric model that estimates mean values and statistical variations of the atmospheric properties of Venus. Venus-GRAM provides mean values and variability for any point in the atmosphere as well as seasonal, geographic, and altitude variations. Venus-GRAM outputs include atmospheric density, temperature, pressure, winds, and chemical composition along a user-defined path. It is extensively used by the engineering community because of its ability to create realistic dispersions. GRAMs have been integrated into high fidelity flight dynamic simulations of launch, entry, descent and landing (EDL), aerobraking and aerocapture. GRAMs are currently available for Earth, Mars, Venus, Neptune, Titan, and Uranus. The lower atmosphere model in Venus-GRAM (up to 250 km) is based on the Venus International Reference Atmosphere (VIRA) [1]. The Venus-GRAM thermosphere (250 to 1000 km) is based on a MSFC-developed model [2] which assumes an isothermal temperature profile initialized using VIRA conditions at 250 km [3]. The VIRA version included in Venus-GRAM includes Pioneer Venus Orbiter and Probe data as well as Venera probe data, but it does not include a solid planet model or a high-resolution gravity model [4]. Venus-GRAM Upgrade Status: Code Modernization. Venus-GRAM has been rearchitected from Fortran to a common object-oriented C++ framework called the GRAM Suite. This new architecture creates a common GRAM library of data models and utilities. The first C++ release of the rearchitected Venus-GRAM is a straight conversion from the latest Fortran version. Model Upgrades. The focus of the model upgrade task is to improve the atmosphere models in the existing GRAMs and to establish a foundation for developing GRAMs for additional destinations. The GRAM ephemeris has been upgraded to the NASA Navigation and Ancillary Information Facility (NAIF) SPICE toolkit (version N0066). The calculation of the speed of sound has also been improved in the GRAMs. In FY20, the GRAM project established contracts to improve the model data within Venus-GRAM. Hampton University is developing an empirical global model for Venus. The University of Wisconsin is reanalyzing the Venus Express radio occultation observations and analyzing the Akatsuki thermal imaging data. Upgraded Venus-GRAM Release. GRAM Suite Version 1.3 will be released in September 2021 and will contain the rearchitected Venus-GRAM, including the common GRAM framework and planet–specific code. A User Guide and Programmer’s Manual are released with all GRAMs. Conclusions: GRAMs are frequently used toolsets and vital in assessing effects of atmospheres on interplanetary spacecraft during the program life cycle process. Releases of the GRAM Suite, upgrades of the existing planetary GRAMs, and development of new planetary GRAMs are ongoing. Venus-GRAM atmosphere model upgrades will be included in the next phase of GRAM tasks. References: [1] Kliore, A. J. et al. (1985) ASR, 5, 11, 1-304. [2] Justh, H. L. et al. (2006) AIAA/AAS Astrodynamics Specialist Conference & Exhibit, Abstract AIAA-2006-6394. [3] Guide to Reference and Standard Atmosphere Models, BSR/AIAA G-003-2010. [4] Limaye, S. S. (2012), LPSC VEXAG Townhall Meeting. Acknowledgments: The authors gratefully acknowledge support from the NASA SMD.

atmospheric models↗
NASA NTRSDate not supplied

An Advanced Thermal Radiator for Global Lunar Heat Rejection

An advanced thermal radiator innovation to provide global heat rejection for Lunar exploration is described in this paper. Infrared background radiation from Lunar terrain can seriously compromise the performance of conventional thermal radiators, especially at lower latitudes. The Apollo missions boiled consumable H2O for heat rejection which would be unsustainable for long duration Lunar exploration where temperatures may exceed 250°F at the equator. The proposed innovation would provide indefinite, sustainable heat rejection for orbiting assets, rovers, landers and habitats over the entire surface of the Moon. The advanced radiator concept introduces a semi-transparent cover-glass to transmit and reflect both incident infrared radiation and solar irradiation to facilitate improved heat rejection. With sponsorship from MSFC Center Innovation Funding (CIF), two advanced radiator concepts were fabricated and evaluated inside the High Intensity Solar Environment Test (HISET) facility thermal vacuum chamber at MSFC. Using custom designed and fabricated test stands in the HISET chamber, the tests simulated both the Lunar terrestrial (inside a crater under full sun) and orbital thermal environments. A conventional radiator was also fabricated and tested under identical conditions for comparison. Test results indicate improved radiator performance (relative to conventional) in the Lunar orbital environment but the advanced radiators did not perform as well as expected in the surface environment. Correlation to thermal math models is presented and future research may consider alternate materials or designs to improve the terrestrial performance.

Thermal Control System↗
NASA NTRSDate not supplied

Beyond Gravity Single Launch Payload Accommodations Shock Testing

The Vulcan Centaur launch vehicle is purpose-built to meet all the U.S. government’s National Security Space Launch (NSSL) needs. A shock test for the Centaur V’s payload accommodations (PLA), single launch (SL) configuration was successfully conducted at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama, in May 2021. This test was a joint effort between MSFC, Beyond Gravity and United Launch Alliance. The primary purpose of the shock test was to characterize the shock environment induced by the separation event on components attached to the PLA and its interfaces. Additional test requirements included: (1) verifying the payload fairing (PLF) did not contact the flight hardware during the mechanical separation of the PLF horizontal separation system (HSS) and (2) evaluating the performance of the HSS spring packages during jettison. The data acquired during the PLF SL shock test will be used to validate the shock predictions from pre-test analysis of the launch vehicle and the PLF separation analysis. This paper provides an overview of the PLA SL shock test planning and execution as well as the required catch system, instrumentation and results.

separation↗
NASA NTRSDate not supplied

Weldability Investigation of Crack Resistant Aluminum Filler Metals Developed for Large Scale Additive Manufacturing and Industrial Welding Applications

In this study the NASA MSFC welding and manufacturing team investigated a new-age aluminum filler wire designed for welding and additive manufacturing (AM) of high strength aluminum alloys. High strength aluminum alloys are known to exhibit hot cracking and hot tearing issues during fusion welding operations. The goal of this investigation was to determine whether this new-age family of alloys can suppress the hot cracking and hot tearing issues exhibited during welding of high strength aluminum alloys and to do an initial characterization of the mechanical performance of welds created using these filler wires. This study focuses on fusion welding of aluminum alloy 6061 and compares the weldability characteristics of five aluminum filler metals and two forms of 6061 base material. The MSFC team utilized manual gas tungsten arc welding (GTAW) to conduct all welding operations and carried out metallographic analysis accompanied with mechanical testing to evaluate the performance of the welds created during this study. During the study it was observed that the new-age filler wires facilitated grain refinement in the weld fusion zone and were capable of creating crack free welds in aluminum alloy 6061 while exhibiting properties that met or exceeded conventional off the shelf aluminum filler metals.

Welding↗