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NASA NTRS2012

Method to Enhance the Operation of an Optical Inspection Instrument Using Spatial Light Modulators

For many aspheric and freeform optical components, existing interferometric solutions require a custom computer-generated hologram (CGH) to characterize the part. The overall objective of this research is to develop hardware and a procedure to produce a combined, dynamic, Hartmann/ Digital Holographic interferometry inspection system for a wide range of advanced optical components, including aspheric and freeform optics. This new instrument would have greater versatility and dynamic range than currently available measurement systems. The method uses a spatial light modulator to pre-condition wavefronts for imaging, interferometry, and data processing to improve the resolution and versatility of an optical inspection instrument. Existing interferometers and Hartmann inspection systems have either too small a dynamic range or insufficient resolution to characterize conveniently unusual optical surfaces like aspherical and freeform optics. For interferometers, a specially produced, computer-generated holographic optical element is needed to transform the wavefront to within the range of the interferometer. A new hybrid wavefront sensor employs newly available spatial light modulators (SLMs) as programmable holographic optical elements (HOEs). The HOE is programmed to enable the same instrument to inspect an optical element in stages, first by a Hartmann measurement, which has a very large dynamic range but less resolution. The first measurement provides the information required to precondition a reference wave that avails the measurement process to the more precise phase shifting interferometry. The SLM preconditions a wavefront before it is used to inspect an optical component. This adds important features to an optical inspection system, enabling not just wavefront conditioning for null testing and dynamic range extension, but also the creation of hybrid measurement procedures. This, for example, allows the combination of dynamic digital holography and Hartmann sensing procedures to cover a virtually unlimited dynamic range with high resolution. Digital holography technology brings all of the power and benefits of digital holographic interferometry to the requirement, while Hartmann-type wavefront sensors bring deflectometry technologies to the solution. The SLM can be used to generate arbitrary wavefronts in one leg of the interferometer, thereby greatly simplifying its use and extending its range. The SLM can also be used to modify the system into a dynamic Shack-Hartmann system, which is useful for optical components with large amounts of slope. By integrating these capabilities into a single instrument, the system will have tremendous flexibility to measure a variety of optical shapes accurately.

Trolinger, James↗

NASA NTRS2011

GPM Avionics Module Heat Pipes Design and Performance Test Results

The Global Precipitation Measurement (GPM) mission is an international network of satellites that provide the next-generation global observations of rain and snow. The GPM core satellite carries an advanced radar / radiometer system to measure precipitation from space and serve as a reference standard to unify precipitation measurements from a constellation of research and operational satellites. Through improved measurements of precipitation globally, the GPM mission will help to advance our understanding of Earth's water and energy cycle, improve forecasting of extreme events that cause natural hazards and disasters, and extend current capabilities in using accurate and timely information of precipitation to directly benefit society. The avionics module on the core satellite contains a number of electronics boxes which are cooled by a network of aluminum/ammonia heat pipes and a honeycomb radiator which contains thirteen embedded aluminum/ammonia heat pipes. All heat pipes were individually tested by the vendor (Advanced Cooling Technologies, Inc.) prior to delivery. Following delivery to NASA, the flight avionics radiator and the flight spare transport heat pipes were mounted to flight-like test structure and a system level thermal vacuum test was performed. This test, which used simulators in place of all electronics boxes, was done to verify the operation of the thermal control system as a whole. This presentation will discuss the design of the avionics module heat pipes, and then discuss performance tests results for the individual heat pipes prior to delivery and for the system level thermal vacuum test. All heat pipes met their performance requirements. However, it was found that the power was too low in some instances to start all of the smaller radiator spreader heat pipes when they were tested in a reflux configuration (which is the nominal test configuration). Although this lowered the efficiency of the radiator somewhat, it did not impact the operating temperatures of the electronics boxes.

Ottenstein, Laura↗

NASA NTRS2012

Orion MPCV Service Module Avionics Ring Pallet Testing, Correlation, and Analysis

The NASA Orion Multi-Purpose Crew Vehicle (MPCV) is being designed to replace the Space Shuttle as the main manned spacecraft for the agency. Based on the predicted environments in the Service Module avionics ring, an isolation system was deemed necessary to protect the avionics packages carried by the spacecraft. Impact, sinusoidal, and random vibration testing were conducted on a prototype Orion Service Module avionics pallet in March 2010 at the NASA Glenn Research Center Structural Dynamics Laboratory (SDL). The pallet design utilized wire rope isolators to reduce the vibration levels seen by the avionics packages. The current pallet design utilizes the same wire rope isolators (M6-120-10) that were tested in March 2010. In an effort to save cost and schedule, the Finite Element Models of the prototype pallet tested in March 2010 were correlated. Frequency Response Function (FRF) comparisons, mode shape and frequency were all part of the correlation process. The non-linear behavior and the modeling the wire rope isolators proved to be the most difficult part of the correlation process. The correlated models of the wire rope isolators were taken from the prototype design and integrated into the current design for future frequency response analysis and component environment specification.

Staab, Lucas↗

NASA NTRS2012

The Single Habitat Module Concept a Streamlined Way to Explore

Many concepts have been proposed for exploring space. In early 2010 presidential direction called for reconsidering the approach to address changes in exploration destinations, use of new technologies and development of new capabilities to support exploration of space. Considering the proposed new technologies and capabilities that NASA was directed to pursue, the Single Habitathabitat module (SHMSHM) concept for a more streamlined approach to the infrastructure and conduct of exploration missions was developed. The SHM concept combines many of the new promising technologies with a central concept of mission architectures that uses a single habitat module for all phases of an exploration mission. Integrating mission elements near Earth and fully fueling them prior to departure of the vicinity of Earth provides the capability of using the single habitat both in transit to an exploration destination and while exploring the destination. The concept employs the capability to return the habitat and interplanetary propulsion system to Earth vicinity so that those elements can be reused on subsequent exploration missions. This paper describes the SHM concept, and the advantages it provides to accomplish exploration objectives.

Chambliss, Joe↗

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

The Marshall Space Flight Center Development of Mirror Modules for the ART-XC Ins1rument Aboard the Spectrum-Roentgen-Gamma Mission

The Spectrum-Rontgen-Gamma (SRG) mission is a Russian-German X-ray astrophysical observatory that carries two co-aligned and complementary X-ray telescope systems. The primary instrument is the German-led extended ROentgen Survey with an Imaging Telescope Array (eROSITA), a 7-module X-ray telescope system that covers the energy range from 0.2-12 keV. The complementary instrument is the Russian-led Astronomical Roentgen Telescope -- X-ray Concentrator (ART-XC or ART), a 7-module X-ray telescope system that provides higher energy coverage, up to 30 keV (with limited sensitivity above 12 keV).

Gubarev, M.↗

NASA NTRS2012

Creation of a Rapid High-Fidelity Aerodynamics Module for a Multidisciplinary Design Environment

In the traditional aerospace vehicle design process, each successive design phase is accompanied by an increment in the modeling fidelity of the disciplinary analyses being performed. This trend follows a corresponding shrinking of the design space as more and more design decisions are locked in. The correlated increase in knowledge about the design and decrease in design freedom occurs partly because increases in modeling fidelity are usually accompanied by significant increases in the computational expense of performing the analyses. When running high fidelity analyses, it is not usually feasible to explore a large number of variations, and so design space exploration is reserved for conceptual design, and higher fidelity analyses are run only once a specific point design has been selected to carry forward. The designs produced by this traditional process have been recognized as being limited by the uncertainty that is present early on due to the use of lower fidelity analyses. For example, uncertainty in aerodynamics predictions produces uncertainty in trajectory optimization, which can impact overall vehicle sizing. This effect can become more significant when trajectories are being shaped by active constraints. For example, if an optimal trajectory is running up against a normal load factor constraint, inaccuracies in the aerodynamic coefficient predictions can cause a feasible trajectory to be considered infeasible, or vice versa. For this reason, a trade must always be performed between the desired fidelity and the resources available. Apart from this trade between fidelity and computational expense, it is very desirable to use higher fidelity analyses earlier in the design process. A large body of work has been performed to this end, led by efforts in the area of surrogate modeling. In surrogate modeling, an up-front investment is made by running a high fidelity code over a Design of Experiments (DOE); once completed, the DOE data is used to create a surrogate model, which captures the relationships between input variables and responses into regression equations. Depending on the dimensionality of the problem and the fidelity of the code for which a surrogate model is being created, the initial DOE can itself be computationally prohibitive to run. Cokriging, a modeling approach from the field of geostatistics, provides a desirable compromise between computational expense and fidelity. To do this, cokriging leverages a large body of data generated by a low fidelity analysis, combines it with a smaller set of data from a higher fidelity analysis, and creates a kriging surrogate model with prediction fidelity approaching that of the higher fidelity analysis. When integrated into a multidisciplinary environment, a disciplinary analysis module employing cokriging can raise the analysis fidelity without drastically impacting the expense of design iterations. This is demonstrated through the creation of an aerodynamics analysis module in NASA’s OpenMDAO framework. Aerodynamic analyses including Missile DATCOM, APAS, and USM3D are leveraged to create high fidelity aerodynamics decks for parametric vehicle geometries, which are created in NASA’s Vehicle Sketch Pad (VSP). Several trade studies are performed to examine the achieved level of model fidelity, and the overall impact to vehicle design is quantified.

Aerodynamic Properties↗

NASA NTRS2012

Modulating Retro-Reflectors: Technology, Link Budgets and Applications

Satellite communications systems today -- usually radio frequency (RF) -- tend to have low data rates and use a lot of on-board power. For CubeSats, communications often dominate the power budget. We investigate the use of modulating retro-reflectors (MRRs), previously demonstrated on the ground, for high data-rate communication downlinks from small satellites. A laser ground station would illuminate a retro-reflector on-board the satellite while an element in the retro-reflector modulates the intensity of the reflected signal, thereby encoding a data stream on the returning beam. A detector on the ground receives the data, keeping the complex systems and the vast majority of power consumption on the ground. Reducing the power consumption while increasing data rates would relax constraints on power budgets for small satellites, leaving more power available for payloads. In the future, this could enable the use of constellations of nano-satellites for a variety of missions, possibly leading to a paradigm shift in small satellite applications.

Salas, Alberto Guillen↗

NASA NTRS2012

Design and Analysis of Modules for Segmented X-Ray Optics

Future X-ray astronomy missions demand thin, light, and closely packed optics which lend themselves to segmentation of the annular mirrors and, in turn, a modular approach to the mirror design. The modular approach to X-ray Flight Mirror Assembly (FMA) design allows excellent scalability of the mirror technology to support a variety of mission sizes and science objectives. This paper describes FMA designs using slumped glass mirror segments for several X-ray astrophysics missions studied by NASA and explores the driving requirements and subsequent verification tests necessary to qualify a slumped glass mirror module for space-flight. A rigorous testing program is outlined allowing Technical Development Modules to reach technical readiness for mission implementation while reducing mission cost and schedule risk.

McClelland, Ryan S.↗

NASA NTRS2012

The Single Habitat Module Concept for Exploration - Mission Planning and Mass Estimates

The Single Habitat Module (SHM) concept approach to the infrastructure and conduct of exploration missions combines many of the new promising technologies with a central concept of mission architectures that use a single habitat module for all phases of an exploration mission. Integrating mission elements near Earth and fully fueling them prior to departure of the vicinity of Earth provides the capability of using the single habitat both in transit to an exploration destination and while exploring the destination. The concept employs the capability to return the habitat and interplanetary propulsion system to Earth vicinity so that those elements can be reused on subsequent exploration missions. This paper provides a review of the SHM concept, the advantages it provides, trajectory assessments related to use of a high specific impulse space based propulsion system, advances in mission planning and new mass estimates.

Chambliss, Joe↗

NASA NTRS2013

The Single Habitat Module Concept for Exploration - Mission Planning and Mass Estimates

The Single Habitat Module (SHM) concept approach to the infrastructure and conduct of exploration missions combines many of new promising technologies with a central concept of mission architectures that use a single habitat module for all phases of an exploration mission. Integrating mission elements near Earth and fully fueling them prior to departure of the vicinity of Earth provides the capability of using the single habitat both in transit to/from an exploration destination and while exploring the destination. The concept employs the capability to return the habitat and interplanetary propulsion system to Earth vicinity so that those elements can be reused on subsequent exploration missions. This paper provides an overview of the SHM concept and the advantages it provides. A summary of calculations of the mass of the habitat propulsion system (HPS) needed to get the habitat from Low Mars Orbit (LMO) to the surface and back to LMO and an overview of trajectory and mission mass assessments related to use of a high specific impulse space based propulsion system is provided. Those calculations lead to the conclusion that the SHM concept can significantly reduce the mass required and streamline mission operations to explore Mars (and thus all exploration destinations).

Chambliss, Joe↗

NASA NTRS2012

NASA AND ESA Partnership on the Multi-Purpose Crew Vehicle Service Module

In March 2011, NASA and ESA made a decision to partially offset the European obligations deriving from the extension of the ISS Program until the end of 2020 with different means than ATVs, following the ATV-5 mission foreseen in mid-2014. NASA and ESA considered a number of barter options, and concluded that the provision by ESA of the Service Module and Spacecraft Adaptor for the NASA Multi-Purpose Crew Vehicle (MPCV) was the barter element with the most interest. A joint ESA - NASA working group was established to assess the feasibility of Europe developing this Module based on ATV heritage. The working group was supported by European and US industry namely Astrium, TAS-I and Lockheed-Martin. This paper gives an overview of the results of the on-going study as well as its projected utilization for the global space exploration endeavour.

Free, James M.↗

NASA NTRS2013

Ballistics Analysis of Orion Crew Module Separation Bolt Cover

NASA is currently developing a new crew module to replace capabilities of the retired Space Shuttles and to provide a crewed vehicle for exploring beyond low earth orbit. The crew module is a capsule-type design, which is designed to separate from the launch vehicle during launch ascent once the launch vehicle fuel is expended. The separation is achieved using pyrotechnic separation bolts, wherein a section of the bolt is propelled clear of the joint at high velocity by an explosive charge. The resulting projectile must be contained within the fairing structure by a containment plate. This paper describes an analytical effort completed to augment testing of various containment plate materials and thicknesses. The results help guide the design and have potential benefit for future similar applications.

Howard, Samuel A.↗

NASA NTRS2009

Developing NDE Techniques for Orion Crew Module

Project: The Orion Crew Module (CM) and Service Module (SM) subsystems will require approximately 870 tube welds to be fabricated onsite at KSC O&C High Bay. A quick and reliable NDE technique is required to ensure efficient assembly and superior weld quality.

Parker, Don↗

NASA NTRS2013

Investigation of Abnormal Grain Growth in a Friction Stir Welded and Spin-Formed Al-Li Alloy 2195 Crew Module

In order to improve manufacturing efficiency and reduce structural mass and costs in the production of launch vehicle structures, NASA is pursuing a wide-range of innovative, near-net shape manufacturing technologies. A technology that combines friction stir welding (FSW) and spin-forming has been applied to manufacture a single-piece crew module using Aluminum-Lithium (AL-Li) Alloy 2195. Plate size limitations for Al-Li alloy 2195 require that two plates be FSW together to produce a spin-forming blank of sufficient size to form the crew module. Subsequent forming of the FSW results in abnormal grain growth (AGG) within the weld region upon solution heat treatment (SHT), which detrimentally impacts strength, ductility, and fracture toughness. The current study seeks to identify microstructural factors that contribute to the development of AGG. Electron backscatter diffraction (EBSD) was used to correlate driving forces for AGG, such as stored energy, texture, and grain size distributions, with the propensity for AGG. Additionally, developmental annealing treatments prior to SHT are examined to reduce or eliminate the occurrence of AGG by promoting continuous, or uniform, grain growth

Tayon, Wesley A.↗

NASA NTRS2013

Atmospheric CO2 Column Measurements with an Airborne Intensity-Modulated Continuous-Wave 1.57-micron Fiber Laser Lidar

The 2007 National Research Council (NRC) Decadal Survey on Earth Science and Applications from Space recommended Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) as a mid-term, Tier II, NASA space mission. ITT Exelis, formerly ITT Corp., and NASA Langley Research Center have been working together since 2004 to develop and demonstrate a prototype Laser Absorption Spectrometer for making high-precision, column CO2 mixing ratio measurements needed for the ASCENDS mission. This instrument, called the Multifunctional Fiber Laser Lidar (MFLL), operates in an intensity-modulated, continuous-wave mode in the 1.57- micron CO2 absorption band. Flight experiments have been conducted with the MFLL on a Lear-25, UC-12, and DC-8 aircraft over a variety of different surfaces and under a wide range of atmospheric conditions. Very high-precision CO2 column measurements resulting from high signal-to-noise (great than 1300) column optical depth measurements for a 10-s (approximately 1 km) averaging interval have been achieved. In situ measurements of atmospheric CO2 profiles were used to derive the expected CO2 column values, and when compared to the MFLL measurements over desert and vegetated surfaces, the MFLL measurements were found to agree with the in situ-derived CO2 columns to within an average of 0.17% or approximately 0.65 ppmv with a standard deviation of 0.44% or approximately 1.7 ppmv. Initial results demonstrating ranging capability using a swept modulation technique are also presented.

Dobler, Jeremy T.↗

NASA NTRS2013

The Single Habitat Module Concept for Exploration - Mission Planning and Mass Estimates

Chambliss, Joe↗

NASA NTRS2013

Development of Advanced Seed Laser Modules for Lidar and Spectroscopy Applications

We report on recent progress made in the development of highly compact, single mode, distributed feedback laser (DFB) seed laser modules for lidar and spectroscopy applications from space based platforms. One of the intended application of this technology is in the NASA's Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) mission. The DFB laser modules operating at 1571 nm and 1262 nm have advanced current and temperature drivers built into them. A combination of temperature and current tuning allows coarse and fine adjustment of the diode wavelengths.

Prasad, Narasimha S.↗