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NASA NTRS2010

Product Lifecycle Management and the Quest for Sustainable Space Explorations

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decision-making. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful concept to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting.

Caruso, Pamela W.↗

NASA NTRS2010

Product Lifecycle Management and the Quest for Sustainable Space Exploration Solutions

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decisionmaking. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful tool to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting. Sustainable space exploration solutions demand that all lifecycle phases be optimized. Adopting PLM, which has been used by the automotive industry for many years, for aerospace applications provides a foundation for strong, disciplined systems engineering and accountable return on investment by making lifecycle considerations variables in an iterative decision-making process. This paper combines the perspectives of the founding father of PLM, along with the experience of Engineering leaders who are implementing these processes and practices real-time. As the nation moves from an industrial-based society to one where information is a valued commodity, future NASA programs and projects will benefit from the experience being gained today for the exploration missions of tomorrow.

Caruso, Pamela W.↗

NASA NTRS2011

Product Lifecycle Management and the Quest for Sustainable Space Exploration Solutions

Caruso, Pamela W.↗

NASA NTRS1994

A new material for removing heavy metals from water

The NASA Lewis Research Center developed and is patenting a new high capacity ion exchange material (IEM) that removes toxic metals from contaminated water in laboratory tests. The IEM can be made into many forms, such as thin films, coatings, pellets, and fibers. As a result, it can be adapted to many applications to purify contaminated water wherever it is found, be it in waste water treatment systems, lakes, ponds, industrial plants, or in homes. Laboratory tests have been conducted on aqueous solutions containing only one of the following metal cations: lead, copper, mercury, cadmium, silver, chromium (III), nickel, zinc, and yttrium. Tests were also conducted with: (1) calcium present to determine its effects on the uptake of cadmium and copper, and (2) uranium and lanthanides which are stand-ins for other radioactive elements, (3) drinking water for the removal of copper and lead, and (3) others compositions. The results revealed that the IEM removes all these cations, even in the presence of the calcium. Of particular interest are the results of the tests with the drinking water: the lead concentration was reduced from 142 ppb down to 2.8 ppb (well below the accepted EPA standard).

Philipp, Warren H., Jr.↗

NASA NTRS1997

Developing a Graphical User Interface for the ALSS Crop Planning Tool

The goal of my project was to create a graphical user interface for a prototype crop scheduler. The crop scheduler was developed by Dr. Jorge Leon and Laura Whitaker for the ALSS (Advanced Life Support System) program. The addition of a system-independent graphical user interface to the crop planning tool will make the application more accessible to a wider range of users and enhance its value as an analysis, design, and planning tool. My presentation will demonstrate the form and functionality of this interface. This graphical user interface allows users to edit system parameters stored in the file system. Data on the interaction of the crew, crops, and waste processing system with the available system resources is organized and labeled. Program output, which is stored in the file system, is also presented to the user in performance-time plots and organized charts. The menu system is designed to guide the user through analysis and decision making tasks, providing some help if necessary. The Java programming language was used to develop this interface in hopes of providing portability and remote operation.

Koehlert, Erik↗

NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

NASA NTRS1981

Martian channels and valleys - Their characteristics, distribution, and age

The distribution and ages of Martian channels and valleys, which are generally believed to have been cut by running water, are examined with particular emphasis on the small branching networks referred to as runoff channels or valley networks. Valleys at latitudes from 65 deg S to 65 deg N were surveyed on Viking images at resolutions between 125 and 300 m. Almost all of the valleys are found in the old cratered terrain, in areas characterized by high elevations, low albedos and low violet/red ratios. The networks are deduced to have formed early in the history of the planet, with a formation rate declining rapidly shortly after the decline of the cratering rate 3.9 billion years ago. Two types of outflow channels are distinguished: unconfined, in which broad swaths of terrain are scoured, and confined, in which flow is restricted to discrete channels. Both types start at local sources, and have formed episodically throughout Martian history. Fretted channels, found mainly in two latitude belts characterized by relatively rapid erosion along escarpments, are explained by the lateral enlargement of other channels by mass wasting.

Carr, M. H.↗

NASA NTRS2005

Analyzing MER Uplink Reports

The MER project includes two rovers working simultaneously on opposite sides of Mars each receiving commands only once a day. Creating this uplink is critical, since a failed uplink means a lost day and a waste of money. Examining the process of creating this uplink, I tracked the use of the system developed for requesting observations as well as the development, from stage to stage, in forming an activity plan. I found the system for requesting observations was commonly misused, if used at all. There are half a dozen reports to document the creation of the uplink plan and often there are discrepancies among them. Despite this, the uplink process worked very well and MER has been one of the most successful missions for NASA in recent memory. Still it is clear there is room for improvement.

Savin, Stephen C.↗

NASA NTRS2013

The Pinnacles of Callisto

Many regions of Callisto feature an unusual landscape consisting of rolling dark plains with interspersed bright knobs (pinnacles) and ridges. In earlier work we interpreted the dark plains as dusty, mass-wasted residue from sublimation from volatile-rich bedrock and the bright knobs (often crater rims) as water ice accumulations at locations sheltered from thermal reradiation from the dusty residue. We simulated evolution of Callisto's craters as a combination of bedrock volatile sublimation, mass wasting of the dark, non-coherent residue, and redeposition of ice, and concluded that the ice pinnacles and ridges might be underlain by tens to hundreds of meters of ice. Here we report the initial work of a new study of pinnacles addressing additional questions: 1) Is there an evolutionary sequence starting, e.g., from a cratered initial surface through growth and formation of a dust mantle and pinnacles, to eventual loss of ice to sublimation resulting in just a dark, dusty surface? 2) What determines the areal density and spatial scale of pinnacles - volatile content of bedrock, crater density, surface age, broad-scale topographic setting? 3) Are pinnacles still forming? Several observations address these questions. In a few places scattered high-albedo blocks approx. 25-60 m in diameter occur in the vicinity of large icy pinnacles. We interpret these blocks to be remnants from the collapse of tall pinnacles that were undermined by mass wasting. Some high-relief icy knobs have developed a skeletonized planform due to mass wasting by avalanching, or perhaps to seeding of new sites of ice deposition on mass-wasted ice blocks. Some areas nearly lack fresh craters with well-defined ejecta and ice-free rims. This may imply rapid transformation of fresh craters by sublimation, mass wasting, and ice reprecipitation. In other areas small sharp-rimmed craters occur which lack ice pinnacles, but the craters nonetheless lack visible ejecta sheets. Our preliminary interpretation is that mass wasting is very efficient on Callisto, or alternatively the dust cover is very thick and lacks competent coarse materials.

bedrock volatile sublimation↗

NASA NTRS1974

Raw Liquid Waste Treatment System and Process

A raw sewage treatment process is disclosed in which substantially all the non-dissolved matter, suspended in the sewage water is first separated from the water, in which at least organic matter remains dissolved. The non-dissolved material is pyrolyzed to form an activated carbon and ash material without the addition of any conditioning agents. The activated carbon and ash material is added to the water from which the non-dissolved matter was removed. The activated carbon and ash material adsorbs the organic matter dissolved in the water and is thereafter supplied in a counter flow direction and combined with the incoming raw sewage to at least facilitate the separation of the non-dissolved settleable materials from the sewage water. Carbon and ash material together with the non-dissolved matter which was separated from the sewage water are pyrolyzed to form the activated carbon and ash material.

Humphrey, M. F.↗

NASA NTRS1980

Raw liquid waste treatment process

A raw sewage treatment process is disclosed in which substantially all the non-dissolved matter, which is suspended in the sewage water is first separated from the water, in which at least organic matter is dissolved. The non-dissolved material is pyrolyzed to form an activated carbon and ash material without the addition of any conditioning agents. The activated carbon and ash material is added to the water from which the non-dissolved matter was removed. The activated carbon and ash material absorbs organic matter and heavy metal ions, it is believed, are dissolved in the water and is thereafter supplied in a counter current flow direction and combined with the incoming raw sewage to facilitate the separation of the non-dissolved settleable materials from the sewage water. The used carbon and ash material together with the non-dissolved matter which was separated from the sewage water are pyrolyzed to form the activated carbon and ash material.

Humphrey, Marshall F.↗

NASA NTRS1989

Logistics resupply and emergency crew return system for Space Station Freedom

Sometime in the late 1990's, if all goes according to plan, Space Station Freedom will allow the United States and its cooperating partners to maintain a permanent presence in space. Acting as a scientific base of operations, it will also serve as a way station for future explorations of the Moon and perhaps even Mars. Systems onboard the station will have longer lifetimes, higher reliability, and lower maintenance requirements than seen on any previous space flight vehicle. Accordingly, the station will have to be resupplied with consumables (air, water, food, etc.) and other equipment changeouts (experiments, etc.) on a periodic basis. Waste materials and other products will also be removed from the station for return to Earth. The availability of a Logistics Resupply Module (LRM), akin to the Soviet's Progress vehicle, would help to accomplish these tasks. Riding into orbit on an expendable launch vehicle, the LRM would be configured to rendezvous autonomously and dock with the space station. After the module is emptied of its cargo, waste material from the space station would be loaded back into it. The module would then begin its descent to a recovery point on Earth. Logistics Resupply Modules could be configured in a variety of forms depending on the type of cargo being transferred. If the LRM's were cycled to the space station in such a way that at least one vehicle remained parked at the station at all times, the modules could serve double duty as crew emergency return capsules. A pressurized LRM could then bring two or more crew-persons requiring immediate return (because of health problems, system failure, or unavoidable catastrophes) back to Earth. Large cost savings would be accrued by combining the crew return function with a logistics resupply system.

Ahne, D.↗

NASA NTRS1999

Review of historical monitoring data on Techa River contamination

The Mayak Production Association was the first Russian site for the production and separation of plutonium. The extensive increase in plutonium production during 1948-1955, as well as the absence of reliable waste-management technology, resulted in significant releases of liquid radioactive effluent into the rather small Techa River. This resulted in chronic external and internal exposure of about 30,000 residents of riverside communities; these residents form the cohort of an epidemiologic investigation. Analysis of the available historical monitoring data indicates that the following reliable data sets can be used for reconstruction of doses received during the early periods of operation of the Mayak Production Association: Temporal pattern of specific beta activity of river water for several sites in the upper Techa region since July 1951; average annual values of specific beta activity of river water and bottom sediments as a function of downstream distance for the whole river since 1951; external gamma-exposure rates near the shoreline as a function of downstream distance for the whole Techa River since 1952; and external gamma-exposure rate as a function of distance from the shoreline for several sites in the upper and middle Techa since 1951.

NASA Discipline Radiation Health↗

NASA NTRS2000

Catalytic Decomposition of Propellant Hydrazines, N-Nitrosodimethylamine, and N-Nitrodimethylamine

Remediation of propellant hydrazine spills, waste treatment, or cleanup of water contaminated with these propellants and/or their oxidation products is a subject of great concern for safety and the environment. Current remediation technologies typically employ oxidative methods, such as chlorination or ozonation. Methylated hydrazines, in particular 1,1-dimethythydrazine (UDMH) and to some degree monomethy1hydrazine (MMH), form N-Nitrosodimethylamine (NDMA) and N-Nitrodimethylamine (DMNM) during oxidation. These compounds are highly toxic and may persist if oxidative conditions are not sufficiently harsh. Since NDMA and DMNM may also be formed from exposure of MMH or UDMH to air, a need exists for a method that will remediate hydrazine, MMH, UDMH, NDMA, and DMNM. In this work, aqueous solutions of propellant hydrazines, NDMA, and DMNM were found to degrade by catalytic reduction with nickel-aluminum (Ni-Al) alloy under basic conditions. The reaction is based upon dissolution of At from Ni-Al alloy in aqueous media to form aluminum ion and hydrogen gas; and the resultant finely divided nickel catalyzes reduction of the hydrazine, nitrosoamine, or nitroamine by the hydrogen produced. Greater than 99 percent of hydrazine, MMH, UDMH, NDMA, and DMNM in aqueous solutions were degraded under laboratory conditions when reacted with Ni-Al alloy. UDMH was identified as an intermediate reduction product of NDMA and DNNM. NDMA and UDMH were identified as intermediate reduction products of DMNM. Control experiments without nickel showed no degradation of hydrazine, MMH or UDMH, while NDMA and DMNM were reduced to UDMH. Spill pillows containing Ni-Al alloy and solid sodium hydroxide were also found effective in absorption and degradation of UDMH. The application of chemical reduction as a means to propellant hydrazines, NDMA, and DMNM spill remediation, waste treatment, and water decontamination appears highly attractive.

Greene, Ben↗

NASA NTRSDate not supplied

Alternative Treatment of Crew Wastewater Using a Hybrid Membrane Technology

Environmental Control and Life Support Systems (ECLSS) of future long-duration, deep-space human exploration missions should treat all “waste” streams for recovery and ideally by near closed-loop. Onboard the International Space Station (ISS), the Water Recovery System (WRS) does not treat urine and gray water to recover elements beyond water and utilizes physical-chemical technologies that operate with single-use and hazardous consumables. Urine offers a renewable source of nitrogen and other trace elements that can support sustainable crop production. In response to the lack of flight ready technologies capable of treating urine and gray water for water and nutrient recovery, a Suspended Aerobic Membrane Bioreactor (SAMBR) is under development between the University of South Florida and Kennedy Space Center. SAMBR is optimized for an early planetary base/partial gravity habitat and serves as a hybrid alternative to currently utilized urine treatment technologies and support closing the resource recovery loop. With its ECLSS minded form factor and modular design, SAMBR’s operation can be customized to suit the treatment objectives (i.e., nitrogen conversion) at that time. This proceeding presents preliminary research pertaining to: 1) design challenges in maximizing hydraulic throughput while minimizing mass and volume of the assembly; 2) capabilities for treating high nitrogen waste under steady and non-steady state conditions; and 3) measured performance parameters such chemical oxygen demand (COD), nitrogen conversion, nutrients, turbidity, and system throughput. Future research and development pertaining to further optimization on system safety, reliability, and expanded treatment capabilities will also be presented.

Membrane Filtration↗

NASA NTRS1980

Regenerator matrix physical property data

Among several cellular ceramic structures manufactured by various suppliers for regenerator application in a gas turbine engine, three have the best potential for achieving durability and performance objectives for use in gas turbines, Stirling engines, and waste heat recovery systems: (1) an aluminum-silicate sinusoidal flow passage made from a corrugated wate paper process; (2) an extruded isosceles triangle flow passage; and (3) a second generation matrix incorporating a square flow passage formed by an embossing process. Key physical and thermal property data for these configurations presented include: heat transfer and pressure drop characteristics, compressive strength, tensile strength and elasticity, thermal expansion characteristics, chanical attack, and thermal stability.

Fucinari, C. A.↗

NASA NTRS1989

Importance of helium-3 for the future

Relevant plasma physics principles of thermonuclear research; the state of plasma physics as it pertains to the D-He(3) cycle; the technological benefits of the D-He(3) fuel cycle; the availability of He(3); and its location, methods of extraction and cost are discussed. A perspective on the rate of progress toward the goal of heating the confined plasma fuel to sufficiently high temperatures at high enough densities and for long enough times to cause substantial fusion of the atoms to take place is given in graphical form. The main technological advantages resulting from the D-He(3) fuel cycle, when compared with the DT cycle, are as follows: (1) increased electrical conversion efficiency; (2) reduced radiation damage to reactors; (3) reduced radioactive waste; (4) an increased level of safety in case of an accident; (5) the lower cost of electricity; and (6) the shorter time to commercialization. An account is given of mining He(3) on the Moon.

Kulcinski, Gerald L.↗

NASA NTRS1978

Disposal of radioactive iodine in space

The possibility of space disposal of iodine waste from nuclear power reactors is investigated. The space transportation system utilized relies upon the space shuttle, a liquid hydrogen/liquid oxygen orbit transfer vehicle, and a solid propellant final stage. The iodine is assumed to be in the form of either an iodide or an iodate, and calculations assume that the final destination is either solar orbit or solar system escape. It is concluded that space disposal of iodine is feasible.

Burns, R. E.↗