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All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

In Space Manufacturing and Extraterrestrial Construction: How Did We Get Here?Where Are We? Where Should We Be Going? THE CHALLENGE: Will We Be Ready?

NASA has held multiple workshops and sought inputs from a broad spectrum of sources, including international partners, other space agencies, industry, large and small businesses, academia, and private citizens to develop its Moon to Mars Strategy and Objectives. The goals and objectives set forth in the resulting documents are “designed to achieve the vision to create a blueprint for sustained human presence and exploration throughout the solar system.” The objectives were categorized into four distinct tracks: Operations, Infrastructure, Transportation and Habitation, and Science. In addition, common themes across the objectives were captured under Recurring Tenets. Within the Infrastructure category, several objectives directly address the need for manufacturing and construction on the lunar surface to support continuous human lunar presence and a robust lunar economy. In exploring the vision for creation of on-demand infrastructure on the lunar surface and beyond, this presentation will examine the development of these capabilities, starting in the late 1990’s and early 2000’s, up to the current state, and offer a perspective on the challenges facing operational implementation of these technologies. In the early 2000’s, the destination was the Moon. The International Space Station (ISS) was to be the test bed for demonstration of in space manufacturing technologies. Additive construction was in its infancy. These pioneering initiatives, having begun primarily under NASA’s Office of Biological and Physical Research In Situ Fabrication and Repair (ISFAR) Project, were short-lived. It was not until the early 2010’s that in space manufacturing and later extraterrestrial construction experienced renewed interest and support. At this time, the destination was Mars. This period saw the initial in space additive manufacturing experiments on the ISS, creation of a roadmap for development of in space manufacturing technologies, and development of additive construction systems for terrestrial use at scale. The period also included NASA’s 3D Printed Mars Habitat Centennial Challenge, which catalyzed interest in extraterrestrial construction. With NASA’s announcement of the intention to return to the Moon, and the subsequent release of the Artemis Accords in 2020, and the commensurate Moon to Mars Strategy, NASA’s Space Technology Mission Directorate initiated the Lunar Surface Innovation Initiative (LSII). The LSII has spurred technology development and maturation efforts across a spectrum of capabilities that would be needed to live on the lunar surface. The presentation will provide an overview of current technology developments in the areas of in space manufacturing and extraterrestrial construction. Looking forward from the current state, a perspective will be offered on capabilities that are still needed to “institutionalize” in space manufacturing and extraterrestrial construction to achieve the vision of NASA’s Moon to Mars Strategy. Finally, a challenge will be posed to the community to accelerate the development of these capabilities. When the explorers of the future need these enabling capabilities, will they be ready?

Raymond G Clinton Jr.↗

NASA NTRS2023

Analysis of the Solid Products from the OSCAR and the AOWG Trash Processing Systems

Two trash conversion systems that process space logistical trash for conversion into gases and liquids have minor solid product formation consisting of primarily high carbon ash, inorganic salts, and aluminum metal flakes. These solid products necessarily comprise part of the system output because the thermal degradation processes intentionally operate at temperatures below aluminum vaporization and do not convert all solid inorganics or carbon-based compounds into gaseous compounds (i.e., CO 2 or CH 4 ). The two systems included the Orbital Syngas/Commodity Augmentation Reactor (OSCAR) combustion system funded by the NASA Space Technology Mission Directorate (STMD) located at NASA’s Kennedy Space Center, and the Advanced Organic Waste Gasifier (AOWG) steam reforming system developed by Pioneer Astronautics in Lakewood, Colorado, and funded by the NASA Small Business Innovation Research (SBIR) Exploration Systems Development Mission Directorate (ESDMD). OSCAR residual solids were collected from suborbital flight and ground-based laboratory testing, while all AOWG samples were collected from ground testing. This report discusses the solid product characterization, including elemental analyses performed with scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS), and a surface chemistry performed with x-ray photoelectron spectroscopy (XPS). A particle size analysis was performed with sieves, followed by SEM analyses. These analyses were performed to elucidate what high value products can be extracted or utilized from the solid products for follow on infusion into chemical feedstocks, manufacturing additives, or in-situ construction-based material needs.

OSCAR↗

NASA NTRS1990

Factors affecting the perception of transparent motion

It is possible to create a perception of transparency by combining patterns having different motions. Two particular combination rules, have specific interpretations in terms of physical phenomena: additive (specular reflection) and multiplicative (shadow illumination). Arbitrary combination rules applied to random patterns generate percepts in which the motions of the two patterns are visible, but have super-imposed noise. It is also possible to combine the patterns (using an exclusive-OR rule) so that only noise is visible. Within a one-dimensional family of combination rules which include addition and multiplication, there is a range where smooth motions are seen with no superimposed noise; this range is centered about the additive combination. This result suggests that the motion system deals with a linear representation of luminance, and is consistent with the analysis of motion by linear sensors. This research gives tentative validation the use in beam splitters (which combine images additively) in the construction of heads-up aviation displays. Further work is needed to determine if the superiority of additive combination generalizes to the case of full-color imagery (there are results in the literature suggesting that subtractive color mixture yields the best legibility of overlapping alphanumerics).

Mulligan, Jeffrey B.↗

NASA NTRS1991

A strongly goal-directed close-range vision system for spacecraft docking

In this presentation, we will propose a strongly goal-oriented stereo vision system to establish proper docking approach motions for automated rendezvous and capture (AR&C). From an input sequence of stereo video image pairs, the system produces a current best estimate of: contact position; contact vector; contact velocity; and contact orientation. The processing demands imposed by this particular problem and its environment dictate a special case solution; such a system should necessarily be, in some sense, minimalist. By this we mean the system should construct a scene description just sufficiently rich to solve the problem at hand and should do no more processing than is absolutely necessary. In addition, the imaging resolution should be just sufficient. Extracting additional information and constructing higher level scene representations wastes energy and computational resources and injects an unnecessary degree of complexity, increasing the likelihood of malfunction. We therefore take a departure from most prior stereopsis work, including our own, and propose a system based on associative memory. The purpose of the memory is to immediately associate a set of motor commands with a set of input visual patterns in the two cameras. That is, rather than explicitly computing point correspondences and object positions in world coordinates and trying to reason forward from this information to a plan of action, we are trying to capture the essence of reflex behavior through the action of associative memory. The explicit construction of point correspondences and 3D scene descriptions, followed by online velocity and point of impact calculations, is prohibitively expensive from a computational point of view for the problem at hand. Learned patterns on the four image planes, left and right at two discrete but closely spaced instants in time, will be bused directly to infer the spacecraft reaction. This will be a continuing online process as the docking collar approaches.

Boyer, Kim L.↗

NASA NTRS1993

Capacitive Proximity Sensors With Additional Driven Shields

Improved capacitive proximity sensors constructed by incorporating one or more additional driven shield(s). Sensitivity and range of sensor altered by adjusting driving signal(s) applied to shield(s). Includes sensing electrode and driven isolating shield that correspond to sensing electrode and driven shield.

Mcconnell, Robert L.↗

NASA NTRS1985

Vegetation canopy discrimination and biomass assessment using multipolarized airborne SAR

Multipolarized airborne Synthetic Aperture Radar (SAR) data were acquired over a largely agricultural test site near Macomb, Illinois, in conjunction with the Shuttle Imaging Radar (SIR-B) experiment in October 1984. The NASA/JPL L-band SAR operating at 1.225 GHz made a series of daily overflights with azimuth view angles both parallel and orthogonal to those of SIR-B. The SAR data was digitally recorded in the quadpolarization configuration. An extensive set of ground measurements were obtained throughout the test site and include biophysical and soil measurements of approximately 400 agricultural fields. Preliminary evaluation of some of the airborne SAR imagery indicates a great potential for crop discrimination and assessment of canopy condition. False color composites constructed from the combination of three linear polarizations (HH, VV, and HV) were found to be clearly superior to any single polarization for purposes of crop classification. In addition, an image constructed using the HH return to modulate intensity and the phase difference between HH and VV returns to modulate chroma indicates a clear capability for assessment of canopy height and/or biomass. In particular, corn fields heavily damaged by infestations of corn borer are readily distinguished from noninfested fields.

Ulaby, F. T.↗

NASA NTRS2004

Research Performed within the Non-Destructive Evaluation Team at NASA Glenn Research Center

Non-destructive testing is essential in many fields of manufacturing and research in order to perform reliable examination of potentially damaged materials and parts without destroying the inherent structure of the materials. Thus, the Non-Destructive Evaluation (NDE) Team at NASA Glenn Research Center partakes in various projects to improve materials testing equipment as well as analyze materials, material defects, and material deficiencies. Due to the array of projects within the NDE Team at this time, five research aims were supplemental to some current projects. A literature survey of "DE and testing methodologies as related to rocks was performed. Also, Mars Expedition Rover technology was assessed to understand the requirements for instrumentation in harsh space environments (e.g. temperature). Potential instrumentation and technologies were also considered and documented. The literature survey provided background and potential sources for a proposal to acquire funding for ultrasonic instrumentation on board a future Mars expedition. The laboratory uses a Santec Systems AcousticScope AS200 acoustography system. Labview code was written within the current program in order to improve the current performance of the acoustography system. A sample of Reinforced Carbon/Carbon (RCC) material from the leading edge of the space shuttle underwent various non-destructive tests (guided wave scanning, thermography, computed tomography, real time x-ray, etc.) in order to characterize its structure and examine possible defects. Guided wave scan data of a ceramic matrix composite (CMC) panel was reanalyzed utilizing image correlations and signal processing variables. Additional guided wave scans and thermography were also performed on the CMC panel. These reevaluated data and images will be used in future presentations and publications. An additional axis for the guided wave scanner was designed, constructed, and implemented. This additional axis allowed incremental spacing of the previously fixed transducers for ultrasonic velocity measurements.

Burns, Erin A.↗

NASA NTRSDate not supplied

Voxel Based Three-Dimensional Topology Optimization of Heat Exchanger Fins

Increasing interest in novel aircraft propulsion systems and potential for unwanted heat generation, or capture and reuse of waste heat, may require increasingly lightweight and high performing heat exchangers. Advances in manufacturing technologies have shown potential to create complex designs, but design tools need more flexibility. This study utilizes genetic algorithm-driven topology optimization to develop high performance heat exchanger fins for critical applications such as aerospace. The solid domain is generated using voxel representation where a voxel value of 1 indicates the solid domain and a voxel value of 0 refers to the fluid domain. The use of voxel representation somewhat matches the digitization of a model that is required to fabricate using additive manufacturing, and also allows for a highly unconstrained geometry. To test the topology optimization approach, a three-dimensional(3D)baseline offset strip fin geometry in steady laminar flow(Reynolds number = 215)with conjugate heat transfer(simultaneous solution of solid and fluid temperature fields)is optimized. New designs are generated using the genetic algorithm (GA) and sent to evaluation by the CFD software OpenFOAM; then the GA sorts and selects the reproduction pool for the following generation. This process is repeated for 60 generations. The study also investigates the effect off in material on the performance of the GA and the resulting designs. The results show that the optimal designs have overall performance improvement of 18% relative to the baseline. Additionally, a fin constructed of a lower conductivity material (such as an Inconel super alloy that might be necessary for waste heat recovery applications)results in lower overall performance improvement (11%)and optimal designs with higher pressure drop relative to their baseline, and relative to optimal designs produced using higher conductivity materials.

3D Optimization↗

NASA NTRS1993

Active control of buildings during earthquakes

The objective of this report is to provide an overview of the different types of control systems used in buildings, to discuss the problems associated with current active control mechanisms, and to show the cost-effectiveness of applying active control to buildings. In addition, a small case study investigates the feasibility and benefits of using embedded actuators in buildings. Use of embedded actuators could solve many of the current problems associated with active control by providing a wider bandwidth of control, quicker speed of response, increased reliability and reduced power requirement. Though embedded actuators have not been developed for buildings, they have previously been used in space structures. Many similarities exist between large civil and aerospace structures indicating that direct transfer of concepts between the two disciplines may be possible. In particular, much of the Controls-Structures Interaction (CSI) technology currently being developed could be beneficially applied to civil structures. While several buildings with active control systems have been constructed in Japan, additional research and experimental verification are necessary before active control systems become widely accepted and implemented.

Vance, Vicki L.↗

NASA NTRS2003

Development of a Dynamically Configurable, Object-Oriented Framework for Distributed, Multi-modal Computational Aerospace Systems Simulation: Second Year Progress Report

Mesh generation has long been recognized as a bottleneck in the CFD process. While much research on automating the volume mesh generation process have been relatively successful,these methods rely on appropriate initial surface triangulation to work properly. Surface discretization has been one of the least automated steps in computational simulation due to its dependence on implicitly defined CAD surfaces and curves. Differences in CAD peometry engines manifest themselves in discrepancies in their interpretation of the same entities. This lack of "good" geometry causes significant problems for mesh generators, requiring users to "repair" the CAD geometry before mesh generation. The problem is exacerbated when CAD geometry is translated to other forms (e.g., IGES )which do not include important topological and construction information in addition to entity geometry. One technique to avoid these problems is to access the CAD geometry directly from the mesh generating software, rather than through files. By accessing the geometry model (not a discretized version) in its native environment, t h s a proach avoids translation to a format which can deplete the model of topological information. Our approach to enable models developed in the Denali software environment to directly access CAD geometry and functions is through an Application Programming Interface (API) known as CAPRI. CAPRI provides a layer of indirection through which CAD-specific data may be accessed by an application program using CAD-system neutral C and FORTRAN language function calls. CAPRI supports a general set of CAD operations such as truth testing, geometry construction and entity queries.

Afjeh, Abdollah A.↗

NASA NTRS2013

Silicon Heat Pipe Array

Improved methods of heat dissipation are required for modern, high-power density electronic systems. As increased functionality is progressively compacted into decreasing volumes, this need will be exacerbated. High-performance chip power is predicted to increase monotonically and rapidly with time. Systems utilizing these chips are currently reliant upon decades of old cooling technology. Heat pipes offer a solution to this problem. Heat pipes are passive, self-contained, two-phase heat dissipation devices. Heat conducted into the device through a wick structure converts the working fluid into a vapor, which then releases the heat via condensation after being transported away from the heat source. Heat pipes have high thermal conductivities, are inexpensive, and have been utilized in previous space missions. However, the cylindrical geometry of commercial heat pipes is a poor fit to the planar geometries of microelectronic assemblies, the copper that commercial heat pipes are typically constructed of is a poor CTE (coefficient of thermal expansion) match to the semiconductor die utilized in these assemblies, and the functionality and reliability of heat pipes in general is strongly dependent on the orientation of the assembly with respect to the gravity vector. What is needed is a planar, semiconductor-based heat pipe array that can be used for cooling of generic MCM (multichip module) assemblies that can also function in all orientations. Such a structure would not only have applications in the cooling of space electronics, but would have commercial applications as well (e.g. cooling of microprocessors and high-power laser diodes). This technology is an improvement over existing heat pipe designs due to the finer porosity of the wick, which enhances capillary pumping pressure, resulting in greater effective thermal conductivity and performance in any orientation with respect to the gravity vector. In addition, it is constructed of silicon, and thus is better suited for the cooling of semiconductor devices.

Yee, Karl Y.↗

DOE OSTI2024

Wind plant wake losses: Disconnect between turbine actuation and control of plant wakes with engineering wake models

Wake losses from neighboring plants may become a major factor in wind plant design and control as additional plants are constructed in areas with high wind resource availability. Because plant wakes span a large range of physical scales, from turbine rotor diameter to tens of kilometers, it is unclear whether conventional wake models or turbine control strategies are effective at the plant scale. Wake steering and axial induction control are evaluated in the current work as means of reducing the impact of neighboring wind plants on power and levelized cost of electricity. FLOw Redirection and Induction in Steady State (FLORIS) simulations were performed with the Gauss–Curl Hybrid and TurbOPark wake models as well as two operation and maintenance models to investigate control setpoint sensitivity to wake representation and economic factors. Both wake models estimate losses across a range of atmospheric conditions, although the wake loss magnitude is dependent on the wake model. Annual energy production and levelized cost of electricity are driven by wind direction frequency, with frequently aligned plants experiencing the greatest losses. However, both wake steering and axial induction are unable to mitigate the impact of upstream plants. Wake steering is constrained by plant geometry, since wake displacement is much less than the plant wake width, while axial induction requires curtailing the majority of turbines in upstream plants. Individual turbine strategies are limited by their effective scale and model representation. New wake models that include plant-scale physics are needed to facilitate the design of effective plant wake control strategies.

Scott, Ryan (ORCID:0000000328107574)↗

DOE OSTI2025

Fiber-optic bolometers with high-temperature tolerance and reduced time constants for fusion plasma diagnostics

Fiber-optic bolometers (FOBs) designed for plasma radiation measurement in magnetically confined fusion environments have been previously developed and tested at the DIII-D tokamak. These FOBs utilize a silicon Fabry–Perot interferometer at the fiber tip for temperature measurement and a gold disk as a radiation absorber. This paper presents recent advancements in the development of FOBs with reduced cooling time constants and enhanced temperature tolerance. We also demonstrate high-temperature operation and report findings from irradiation tests. By incorporating a copper sensor holder as a thermal sink and integrating two closely packed sensor heads into a compact design, the cooling time constants were reduced to ∼100 ms in vacuum, while minimizing uncertainties caused by temperature gradients. The FOBs were subjected to heating at 400 °C for five hours, with no observed degradation in noise performance post-heating. High-temperature operation tests were conducted at ∼220 °C using a 404 nm square-wave modulated laser to simulate the plasma radiation. In addition, four FOBs constructed from copper-coated pure-silica fibers were fabricated and underwent irradiation testing, enduring a total γ-radiation dose of 15.2 MGy and a neutron fluence of 1.6 × 10 18 n/cm 2 . As a result, the FOBs maintained their physical integrity and the optical signal shows high visibility throughout the test.

42 ENGINEERING↗

DOE OSTI2026

Faster Randomized Dynamical Decoupling

We present a randomized dynamical decoupling (DD) protocol that can substantially improve the performance of any given deterministic DD scheme for suppressing coherent noise by using no more than two additional pulses. Our construction is implemented by probabilistically applying sequences of pulses, which, when combined, effectively eliminate the error terms that scale linearly with the system-environment coupling strength. As a result, we show that a randomized protocol using a few pulses can outperform deterministic DD protocols that require considerably more pulses. Furthermore, we prove that the randomized protocol provides an improvement compared to deterministic DD sequences that aim to reduce the error in the system’s Hilbert space, such as Uhrig DD, which had been previously regarded to be optimal. To rigorously evaluate the performance, we introduce new analytical methods suitable for analyzing higher-order DD protocols that might be of independent interest. Here, we also present numerical simulations confirming the significant advantage of using randomized protocols compared to widely used deterministic protocols.

Quantum algorithms & computation↗

DOE OSTI2024

CHARACTERIZATION OF FATIGUE BEHAVIORS OF NOTCHED 316L DED AM SPECIMENS

ASME Codification of Additive Manufacturing • Integration of AM into ASME Codes and Standards • The ASME goal is to have AM requirements in ASME Code Cases preceding the 2025 Edition. • The ASME Special Committee on AM has drafted criteria for two Code Cases for Additive Manufacturing. • AM Construction of Pressure Equipment using the Direct Energy Deposition Process with Wire Feedstock. • Includes Gas Metal Arc Welding. • Time-independent material properties. • Status - Criteria endorsed by AM Committee. • AM Construction of Pressure Equipment using the Powder Bed Fusion AM Process. • Includes Laser and Electron Beam Energy Sources. • Austenitic and Nonferrous materials. • Time-independent material properties. • Status – Approval ballot circulating to the AM Committee.

Krentz, Timothy M.↗

DOE OSTI2025

Custom Equipment Development for Processing of Surplus Plutonium

Facilities and Material • Location: Savannah River Site K-Area, South Carolina • Plutonium designated as surplus is blended with adulterant material, re-packaged and shipped to WIPP in New Mexico • Currently one operational glovebox for downblending, facility modifications and construction of three additional glovebox lines in progress • Current operations are highly manual requiring full PPE and reader/worker steps

Krementz, Daniel [Savannah River National Laborato↗

DOE OSTI2024

ezAlign: A Tool for Converting Coarse-Grained Molecular Dynamics Structures to Atomistic Resolution for Multiscale Modeling

Soft condensed matter is challenging to study due to the vast time and length scales that are necessary to accurately represent complex systems and capture their underlying physics. Multiscale simulations are necessary to study processes that have disparate time and/or length scales, which abound throughout biology and other complex systems. Herein we present ezAlign, an open-source software for converting coarse-grained molecular dynamics structures to atomistic representation, allowing multiscale modeling of biomolecular systems. The ezAlign v1.1 software package is publicly available for download at github.com/LLNL/ezAlign. Its underlying methodology is based on a simple alignment of an atomistic template molecule, followed by position-restraint energy minimization, which forces the atomistic molecule to adopt a conformation consistent with the coarse-grained molecule. The molecules are then combined, solvated, minimized, and equilibrated with position restraints. Validation of the process was conducted on a pure POPC membrane and compared with other popular methods to construct atomistic membranes. Additional examples, including surfactant self-assembly, membrane proteins, and more complex bacterial and human plasma membrane models, are also presented. By providing these examples, parameter files, code, and an easy-to-follow recipe to add new molecules, this work will aid future multiscale modeling efforts.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1974

Observational constraints on model atmospheres for Uranus and Neptune

We have re-examined the visible and near-IR regions of the spectra of Uranus and Neptune to provide additional data for constructing atmospheric models. We find that a true continuum exists only at wavelengths below 4700 A, that the 6420 A absorption previously attributed to hydrogen is probably caused by methane, that there is no evidence for ammonia, ethylene or ethane absorptions in our spectra, and that the abundance of methane is probably much higher than previous estimates suggest. This last finding implies that the value of H/C in the atmospheres of both planets is much less than 1/10 the solar (or Jovian) value. Clear, Rayleigh-scattering model atmospheres are not compatible with the observations, but more work is needed to establish viable alternatives.

Encrenaz, T.↗