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NASA NTRS2011

From Paper to Production to Test: An Update on NASA's J-2X Engine for Exploration

The NASA/industry team responsible for developing the J-2X upper stage engine for the Space Launch System (SLS) Program has made significant progress toward moving beyond the design phase and into production, assembly, and test of development hardware. The J-2X engine exemplifies the SLS Program goal of using proven technology and experience from more than 50 years of United States spaceflight experience combined with modern manufacturing processes and approaches. It will power the second stage of the fully evolved SLS Program launch vehicle that will enable a return to human exploration of space beyond low earth orbit. Pratt & Whitney Rocketdyne (PWR) is under contract to develop and produce the engine, leveraging its flight-proven LH2/LOX, gas generator cycle J-2 and RS-68 engine capabilities, recent experience with the X-33 aerospike XRS-2200 engine, and development knowledge of the J-2S tap-off cycle engine. The J- 2X employs a gas generator operating cycle designed to produce 294,000 pounds of vacuum thrust in primary operating mode with its full nozzle extension. With a truncated nozzle extension suitable to support engine clustering on the stage, the nominal vacuum thrust level in primary mode is 285,000 pounds. It also has a secondary mode, during which it operates at 80 percent thrust by altering its mixture ratio. The J-2X development philosophy is based on proven hardware, an aggressive development schedule, and early risk reduction. NASA Marshall Space Flight Center (MSFC) and PWR began development of the J-2X in June 2006. The government/industry team of more than 600 people within NASA and PWR successfully completed the Critical Design Review (CDR) in November 2008, following extensive risk mitigation testing. Assembly of the first development engine was completed in May 2011 and the first engine test was conducted at the NASA Stennis Space Center (SSC), test stand A2, on 14 July 2011. Testing of the first development engine will continue through the autumn of 2011, be paused for test stand modifications to the passive diffuser, and then restart in the spring of 2012. This testing will be followed by specialized powerpack testing intended to examine the design and operating margins of the engine turbomachinery. The development plan beyond this point leads through more system-level, engine testing of several samples, analytical model validation activities, functional and performance verification, and then ultimate certification to support human spaceflight. This paper will discuss the J-2X development background, provide top-level information on design and development planning, and will explore some of the development challenges and mitigation activities pursued to date.

Kynard, Michael↗
NASA NTRS2012

Grain Refinement of Freeform Fabricated Ti-6Al-4V Alloy Using Beam/Arc Modulation

Grain refinement can significantly improve the mechanical properties of freeform-fabricated Ti-6Al-4V alloy, promoting increased strength and enhanced isotropy compared with coarser grained material. Large beta-grains can lead to a segregated microstructure, in regard to both alpha-phase morphology and alpha-lath orientation. Beam modulation, which has been used in conventional fusion welding to promote grain refinement, is explored in this study for use in additive manufacturing processes including electron beam freeform fabrication (EBF(sup 3)) and gas-tungsten arc (GTA) deposition to alter solidification behavior and produce a refined microstructure. The dynamic molten pool size induced by beam modulation causes rapid heat flow variance and results in a more competitive grain growth environment, reducing grain size. Consequently, improved isotropy and strength can be achieved with relatively small adjustments to deposition parameters.

Mitzner, Scott↗
NASA NTRS2012

Materials Research in Microgravity 2012

Reducing gravitational effects such as thermal and solutal buoyancy enables investigation of a large range of different phenomena in materials science. The Symposium on Materials Research in Microgravity involved 6 sessions composed of 39 presentations and 14 posters with contributions from more than 14 countries. The sessions concentrated on four different categories of topics related to ongoing reduced-gravity research. Highlights from this symposium will be featured in the September 2012 issue of JOM. The TMS Materials Processing and Manufacturing Division, Process Technology and Modeling Committee and Solidification Committee sponsored the symposium.

Hyers, R.↗
NASA NTRS2012

Structural Health Monitoring with Fiber Bragg Grating and Piezo Arrays

Structural health monitoring (SHM) is one of the most important tools available for the maintenance, safety, and integrity of aerospace structural systems. Lightweight, electromagnetic-interference- immune, fiber-optic sensor-based SHM will play an increasing role in more secure air transportation systems. Manufacturers and maintenance personnel have pressing needs for significantly improving safety and reliability while providing for lower inspection and maintenance costs. Undetected or untreated damage may grow and lead to catastrophic structural failure. Damage can originate from the strain/stress history of the material, imperfections of domain boundaries in metals, delamination in multi-layer materials, or the impact of machine tools in the manufacturing process. Damage can likewise develop during service life from wear and tear, or under extraordinary circumstances such as with unusual forces, temperature cycling, or impact of flying objects. Monitoring and early detection are key to preventing a catastrophic failure of structures, especially when these are expected to perform near their limit conditions.

Black, Richard J.↗
NASA NTRS2012

Manufacturing of 5.5 Meter Diameter Cryogenic Fuel Tank Domes for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration s (NASA s) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA) and the common bulkhead manufacturing development articles (CBMDA). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminum-lithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. Manufacturing solutions will be discussed including the implementation of photogrammetry, an advanced metrology technique, as well as fixtureless welding. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) will also be highlighted. Each CBMDA consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. An overview of CBMDA manufacturing processes and the effect of tooling on weld defect formation will be discussed.

Jones, Ronald E.↗
NASA NTRS2012

Compact Fuel Element Environment Test

Deep space missions with large payloads require high specific impulse (I(sub sp)) and relatively high thrust to achieve mission goals in reasonable time frames. Conventional, storable propellants produce average I(sub sp). Nuclear thermal rockets (NTRs) capable of high I(sub sp) thrust have been proposed. NTR employs heat produced by fission reaction to heat and therefore accelerate hydrogen, which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3,000 K) and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high-temperature hydrogen exposure on fuel elements are limited. The primary concern is the mechanical failure of fuel elements that employ high melting point metals, ceramics, or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. It is not necessary to include fissile material in test samples intended to explore high-temperature hydrogen exposure of the structural support matrices. A small-scale test bed designed to heat fuel element samples via noncontact radio frequency heating and expose samples to hydrogen for typical mission durations has been developed to assist in optimal material and manufacturing process selection without employing fissile material. This Technical Memorandum details the test bed design and results of testing conducted to date.

Bradley, D. E.↗
NASA NTRS2013

Advanced Materials and Manufacturing for Low-Cost, High-Performance Liquid Rocket Combustion Chambers

A document describes the low-cost manufacturing of C103 niobium alloy combustion chambers, and the use of a high-temperature, oxidation-resistant coating that is superior to the standard silicide coating. The manufacturing process involved low-temperature spray deposition of C103 on removable plastic mandrels produced by rapid prototyping. Thin, vapor-deposited platinum-indium coatings were shown to substantially improve oxidation resistance relative to the standard silicide coating. Development of different low-cost plastic thrust chamber mandrel materials and prototyping processes (selective laser sintering and stereolithography) yielded mandrels with good dimensional accuracy (within a couple of mils) for this stage of development. The feasibility of using the kinetic metallization cold-spray process for fabrication of free-standing C1O3 thrusters on removable plastic mandrels was also demonstrated. The ambient and elevated temperature mechanical properties of the material were shown to be reasonably good relative to conventionally processed C103, but the greatest potential benefit is that coldsprayed chambers require minimal post-process machining, resulting in substantially lower machining and material costs. The platinum-iridium coating was shown to provide greatly increased oxidation resistance over the silicide when evaluated through oxyacetylene torch testing to as high as 300 F (= 150 C). The iridium component minimizes reaction with the niobium alloy chamber at high temperatures, and provides the high-temperature oxidation resistance needed at the throat.

Williams, Brian E.↗
NASA NTRS2013

Pack Density Limitations of Hybrid Parachutes

The development and testing of the Orion crew capsule parachute system has provided a unique opportunity to study dense parachute packing techniques and limits, in order to establish a new baseline for future programs. The density of parachute packs has a significant influence on vibration loads, retention system stresses, and parachute mortar performance. Material compositions and pack densities of existing designs for space capsule recovery were compared, using the pack density of the Apollo main parachutes as the current baseline. The composition of parachutes has changed since Apollo, incorporating new materials such as Kevlar , Vectran , Teflon and Spectra . These materials have different specific densities than Nylon, so the densities of hybrid parachute packs cannot be directly compared to Nylon parachutes for determination of feasibility or volume allocation. Six parachute packs were evaluated in terms of weighted average solid density in order to achieve a non-dimensional comparison of packing density. Means of mitigating damage due to packing pressure and mortar firing were examined in light of the Capsule Parachute Assembly System (CPAS) and Apollo experience. Parachute design improvements including incorporation of modern materials and manufacturing processes serves to make CPAS the new knowledge base on which future spacecraft parachute systems will be built.

Zwicker, Matthew L.↗
NASA NTRS2013

Combining Through-Thickness Reinforcement and Self-Healing for Improved Damage Tolerance and Durability of Composites

A study was undertaken to develop a prototype method for adding through-thickness hollow glass tubes infused with uncured resin and hardener in a carbon Z-pin through-thickness reinforcement field embedded in a composite laminate. Two types of tube insertion techniques were attempted in an effort to ensure the glass tubes survived the panel manufacturing process. A self-healing resin was chosen with a very low viscosity, two component, liquid epoxy resin system designed to be mixed at a 2-to-1 ratio of epoxy to hardener. IM7/8552 carbon epoxy double cantilever beam (DCB) specimens were cut from the hybrid Z-pin and glass tube reinforced panels and tested. In-situ injection of resin and hardener directly into glass tubes, in a staggered pattern to allow for 2-to-1 ratio mixing, resulted in partial healing of the fracture plane, but only if the injection was performed while the specimen was held at maximum load after initial fracture. Hence, there is some potential for healing delamination via resin and hardener delivered through a network of through-thickness glass tubes, but only if the tubes are connected to a reservoir where additional material may be injected as needed.

O'Brien, T. Kevin↗
NASA NTRS2013

Enabling a Better Aft Heat Shield Solution for Future Mars Science Laboratory Class Vehicles

System studies are described that compare masses and estimated manufacturing costs of options for the as‐flown Mars Science Laboratory (MSL) aft body Thermal Light Weight Ablator (SLA) 561‐V and its thickness was not optimized using the standard TPS Sizer Tool widely used for heat shield design. Use of the TPS sizing tool suggests that optimization of the SLA thickness could reduce the aft heat shield mass by 40 percent. Analysis of the predicted aft‐shell aerothermodynamics suggests that the bulk of MSL class entry vehicle heat shields could incorporate Advanced Flexible Reusable Surface Insulation (AFRSI). AFRSI has a wellestablished record of relatively inexpensive manufacturing and flight certification based on its use on the lee side of the Space Shuttle. Runs with the TPS Sizer show that the AFRSI solution would be 60 percent lighter than the as‐flown SLA. The issue of Reaction Control System (RCS) heating on the aft shell could be addressed by locally impregnating the AFRSI with silicone to enhance its robustness to short bursts ofheating. Stagnation point arcjet testing has shown that silicone impregnated AFRSI performs well at heat rates of 115 W/cm2 and 0.1 atmospheres for a duration of 40 seconds, far beyond conditions that are expected for MSL class vehicles. The paper concludes with a discussion of manufacturing processes for AFRSI, impregnation approaches and relative cost comparisons to the SLA solution.

McGuire, Mary K.↗
NASA NTRS2013

Selection and Manufacturing of Membrane Materials for Solar Sails

Commercial metallized polyimide or polyester films and hand-assembly techniques are acceptable for small solar sail technology demonstrations, although scaling this approach to large sail areas is impractical. Opportunities now exist to use new polymeric materials specifically designed for solar sailing applications, and take advantage of integrated sail manufacturing to enable large-scale solar sail construction. This approach has, in part, been demonstrated on the JAXA IKAROS solar sail demonstrator, and NASA Langley Research Center is now developing capabilities to produce ultrathin membranes for solar sails by integrating resin synthesis with film forming and sail manufacturing processes. This paper will discuss the selection and development of polymer material systems for space, and these new processes for producing ultrathin high-performance solar sail membrane films.

Bryant, Robert G.↗
NASA NTRS2012

Follow on Researches for X-56A Aircraft at NASA Dryden Flight Research Center (Progress Report)

A lot of composite materials are used for the modern aircraft to reduce its weight. Aircraft aeroservoelastic models are typically characterized by significant levels of model parameter uncertainty due to composite manufacturing process. Small modeling errors in the finite element model will eventually induce errors in the structural flexibility and mass, thus propagating into unpredictable errors in the unsteady aerodynamics and the control law design. One of the primary objectives of X-56A aircraft is the flight demonstration of active flutter suppression, and therefore in this study, the identification of the primary and secondary modes is based on the flutter analysis of X-56A aircraft. It should be noted that for all three Mach number cases rigid body modes and mode numbers seven and nine are participated 89.1 92.4 % of the first flutter mode. Modal participation of the rigid body mode and mode numbers seven and nine for the second flutter mode are 94.6 96.4%. Rigid body mode and the first two anti-symmetric modes, eighth and tenth modes, are participated 93.2 94.6% of the third flutter mode. Therefore, rigid body modes and the first four flexible modes of X-56A aircraft are the primary modes during the model tuning procedure. The ground vibration test-validated structural dynamic finite element model of the X-56A aircraft is to obtain in this study. The structural dynamics finite element model of X-56A aircraft is improved using the parallelized big-bang big-crunch algorithm together with a hybrid optimization technique.

Structural Dynamic Model Tuning↗
NASA NTRS2013

Very-Low-Cost, Rugged Vacuum System

NASA, DoD, DHS, and commercial industry have a need for miniaturized, rugged, low-cost vacuum systems. Recent advances in sensor technology have led to the development of very small mass spectrometer detectors as well as other miniature analytical instruments. However, the vacuum systems to support these sensors remain large, heavy, and power-hungry. To meet this need, a miniaturized vacuum system was created based on a very small, rugged, and inexpensive- to-manufacture molecular drag pump (MDP). The MDP is enabled by the development of a miniature, veryhigh- speed, rugged, low-power, brushless DC motor optimized for wide temperature operation and long life. Such a pump represents an order-of-magnitude reduction in mass, volume, and cost over current, commercially available, state-ofthe- art vacuum pumps. The vacuum system consists of the MDP coupled to a ruggedized rough pump (for terrestrial applications or for planets with substantial atmospheres). The rotor in the MDP consists of a simple smooth cylinder of aluminum spinning at approximately 200,000 RPM inside an outer stator housing. The pump stator comprises a cylindrical aluminum housing with one or more specially designed grooves that serve as flow channels. To minimize the length of the pump, the gas is forced down the flow channels of the outer stator to the base of the pump. The gas is then turned and pulled toward the top through a second set of channels cut into an inner stator housing that surrounds the motor. The compressed gas then flows down channels in the motor housing to the exhaust port of the pump. The exhaust port of the pump is connected to a diaphragm or scroll pump. This pump delivers very high performance in a very small envelope. The design was simplified so that a smaller compression ratio, easier manufacturing process, and enhanced ruggedness can be achieved at the lowest possible cost. The machining of the rotor and stators is very simple compared to that necessary to fabricate TMP (turbo molecular pump) rotor and stator blades. Also, the symmetry of the rotor is such that dynamic balancing of the rotor is greatly simplified. Finally, because of the simplified design, the number of parts in the unit is cut by nearly a factor of three. In fact, there are only five parts, not counting the motor and off-the-shelf screws and O-rings. This reduces the amount of machining and also makes fit-up much simpler while allowing the maintenance of close tolerances.

Kline-Schoder, Robert↗
NASA NTRS2013

Thermal Protection and Control

During all phases of a spacecraft's mission, a Thermal Protection System (TPS) is needed to protect the vehicle and structure from extreme temperatures and heating. When designing TPS, low weight and cost while ensuring the protection of the vehicle is highly desired. There are two main types of TPS, ablative and reusable. The Apollo missions needed ablators due to the high heat loads from lunar reentry. However, when the desire for a reusable space vehicle emerged, the resultant_ Space Shuttle program propelled a push for the development of reusable TPS. With the growth of reqsable TPS, the need for ablators declined, triggering a drop off of the ablator industry. As a result, the expertise was not heavily maintained within NASA or the industry. When the Orion Program initiated a few years back, a need. for an ablator reemerged. Yet, due to of the lack of industry capability, redeveloping the ablator material took several years and came at a high cost. As NASA looks towards the future with both the Orion and Commercial Crew Programs, a need to preserve reusable, ablative, and other TPS technologies is essential. Research of the different TPS materials alongside their properties, capabilities, and manufacturing process was performed, and the benefits of the materials were analyzed alongside the future of TPS. Knowledge of the different technologies has the ability to help us know what expertise to maintain and ensure a lack in the industry does not occur again.

Greene, Effie E.↗
NASA NTRS2013

Evaluation of the Behavior of Technova Corporation Rod-Stiffened Stitched Compression Specimens

Under Space Act Agreement 1347 between NASA and Technova Corporation, Technova designed and fabricated two carbon-epoxy crippling specimens and NASA loaded them to failure in axial compression. Each specimen contained a pultruded rod stiffener which was held to the specimen skin with through-the-thickness stitches. One of these specimens was designed to be nominally the same as pultruded rod stitched specimens fabricated by Boeing under previous programs. In the other specimen, the rod was prestressed in a Technova manufacturing process to increase its ability to carrying compressive loading. Experimental results demonstrated that the specimen without prestressing carried approximately the same load as the similar Boeing specimens and that the specimen with prestressing carried significantly more load than the specimen without prestressing.

Jegley, Dawn C.↗
NASA NTRS2013

Incorporating Skew into RMS Surface Roughness Probability Distribution

The standard treatment of RMS surface roughness data is the application of a Gaussian probability distribution. This handling of surface roughness ignores the skew present in the surface and overestimates the most probable RMS of the surface, the mode. Using experimental data we confirm the Gaussian distribution overestimates the mode and application of an asymmetric distribution provides a better fit. Implementing the proposed asymmetric distribution into the optical manufacturing process would reduce the polishing time required to meet surface roughness specifications.

Stahl, Mark T.↗
NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗
NASA NTRS2014

Optical Properties of Nanosatellite Hardware

Over the last decade, a number of very small satellites have been launched into space. These have been called nanosatellites (generally of a weight between 1 and 10 kg) or picosatellites (weight <1 kg). This also includes CubeSats, which are based on 10-cm cube units. With the addition of the Japanese Experiment Module (JEM) Small Satellite Orbital Deployer (J-SSOD) to the International Space Station (ISS), CubeSats are easily cycled through the JEM airlock and deployed into space (fig. 1). The number of CubeSats launched since 2003 was approaching 100 at the time of publication, and the authors expect this trend in research to continue, particularly for high school and college flight experiments. Because these spacecraft are so small, there is usually no allowance for shielding or active heating or cooling of the avionics and other hardware. Parts that are usually ignored in the thermal analysis of larger spacecraft may contribute significantly to the heat load of a tiny satellite. In addition, many small satellites have commercial-off-the-shelf (COTS) components. To reduce costs, many providers of COTS components do not include the optical and physical parameters necessary for accurate thermal analysis. Marshall Space Flight Center participated in the development and analysis of the Space Missile Defense Command-Operational Nanosatellite Effect (SMDC-ONE) and the Edison Demonstration of Smallsat Networks (EDSN) nanosatellites. These optical property measurements are documented here in hopes that they may benefit future nanosatellite and picosatellite programs and aid thermal analysis to ensure project goals are met, with the understanding that material properties may vary by vendor, batch, manufacturing process, and preflight handling. Where possible, complementary data are provided from ground simulations of the space environment and flight experiments, such as the Materials on International Space Station Experiment (MISSE) series. NASA gives no recommendation, endorsement, or preference, either expressed or implied, concerning materials and vendors used. Solar absorptance was calculated from spectral reflectance measurements made from 250 to 2,800 nm with an AZ Technology Laboratory Portable Spectroreflectometer (LPSR) model 300. ASTM E-903 was the test method used under normal laboratory conditions, and ASTM E-490 was the solar spectral irradiance data used to calculate solar absorptance. Most of the samples were flat, but stray light was minimized as much as possible with either a blackbody or black cloth as sample background. The LPSR has repeatability of approximately +/-1%, where solar absorptance is given as range, that is, from actual measurements taken across the sample. Infrared emittance measurements were made with an AZ Technology TEMP 2000A infrared reflectometer. This instrument measures the total hemispheric reflectance averaged over 3-35 micrometer wavelengths. ASTM E-408 was the test method used under normal laboratory conditions. 3 Stray light was minimized as much as possible. The TEMP 2000A has repeatability of approximately +/-0.5%, where infrared emittance is given as a range, that is, from actual measurements taken across the sample.

Finckenor, M. M.↗