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Research and Technology at the John F. Kennedy Space Center 1993

As the NASA Center responsible for assembly, checkout, servicing, launch, recovery, and operational support of Space Transportation System elements and payloads, the John F. Kennedy Space Center is placing increasing emphasis on its advanced technology development program. This program encompasses the efforts of the Engineering Development Directorate laboratories, most of the KSC operations contractors, academia, and selected commercial industries - all working in a team effort within their own areas of expertise. This edition of the Kennedy Space Center Research and Technology 1993 Annual Report covers efforts of all these contributors to the KSC advanced technology development program, as well as our technology transfer activities. Major areas of research include material science, advanced software, industrial engineering, nondestructive evaluation, life sciences, atmospheric sciences, environmental technology, robotics, and electronics and instrumentation.

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WSTF Pyrovalve Test Program Status: 2000

Extensive propulsion and pyrotechnic testing has been in progress at NASA/JSC White Sands Test Facility (WSTF) since 1995, starting with the Mars Observer Propulsion and Pyrotechnics Corrective Action Test Program (MOCATP). The MOCATP has been concluded, but extensive pyrovalve testing plus research and development continues at WSTF. Our capability to accurately characterize pyrovalve combustion product blow-by into propellant systems, evaluate hydrazine and monomethylhydrazine (MMH) thermal decomposition initiated by blow-by, and characterize valve actuation operation, continues to be used and refined. Data from this and several low blow-by pyrovalves manufactured by Conax and other corporations continues to be evaluated as a potential corrective measure for blow-by induced propellant explosions. Additionally, new measurement techniques are being developed, advanced pyrovalve development is under-way, and nondestructive examination (NDE) methods are being developed to help ensure pyrovalve safety. Starting in 2000 these data are being formatted into a pyrovalve application and testing handbook. Near-term testing includes evaluation of 3/8-in. Conax pyrovalves and other commercially available valves; development of advanced pyrovalve subcomponent technology; investigation of NDE techniques to evaluate pyrovalve ram seals and real-time measurement of housing deformation; and investigation of pyrotechnically induced explosive hydrazine decomposition both through testing and modeling. Evaluation of 3/8-in. Conax valves is to include operational margin testing to be accomplished at the NASA Langley Research Center.

Saulsberry, Regor L.↗

Tech House

The members of the Swain family- Dr. Charles "Bill" Swain, wife Elaine, daughter Carol, 17, son "Chuck", 12, and dog Susie have an interesting assignment. They are active participants in an important NASA research program involving the application of space-age technology to home construction. b' Transplanted Floridians, the Swains now reside in NASA's Tech House, lo~atedat Langley Research Center, Hampton, Virginia. Their job is to use and help evaluate the variety of advanced technology systems in Tech House. A contemporary three-bedroom home, Tech House incorporates NASA technology, the latest commercial building techniques and other innovations, all designed to reduce energy and water consumption and to provide new levels of comfort, convenience, security and fire safety. Tech House equipment performed well in initial tests, but a house is not a home until it has people. That's where the Swains come in. NASA wants to see how the various systems work under actual living conditions, to confirm the effectiveness of the innovations or to determine necessary modifications for improvement. The Swains are occupying the house for a year, during which NASA engineers are computer monitoring the equipment and assembling a record of day-to-day performance. . Tech House is a laboratory rather than a mass production prototype, but its many benefits may influence home design and construction. In a period of sharply rising utility costs, widespread adoption of Tech House features could provide large-scale savings to homeowners and potentially enormous national benefit in resources conservation. Most innovations are aerospace spinoffs: Some of the equipment is now commercially available; other systems are expected to be in production within a few years. Around 1980, a Tech House-type of home could be built for $45-50,000 (1 976 dollars). It is estimated that the homeowner would save well over $20,000 (again 1976 dollars) in utility costs over the average mortgage span of 20 years.

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Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems

In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.

Kurt A Polzin↗

Virtual reality for automotive design evaluation

A general description of Virtual Reality technology and possible applications was given from publicly available material. A video tape was shown demonstrating the use of multiple large-screen stereoscopic displays, configured in a 10' x 10' x 10' room, to allow a person to evaluate and interact with a vehicle which exists only as mathematical data, and is made only of light. The correct viewpoint of the vehicle is maintained by tracking special glasses worn by the subject. Interior illumination was changed by moving a virtual light around by hand; interior colors are changed by pointing at a color on a color palette, then pointing at the desired surface to change. We concluded by discussing research needed to move this technology forward.

Dodd, George G.↗

Milestone 4: Thrust structure concepts and IHM screening Graphite Composite Primary Structure (GCPS)

The first part of the task was to select up to three promising thrust structure constructions and to select materials for screening tests. Part of the nondestructive evaluation and inspection (NDE/I) and integrated health management (IHM) task is to acquire and develop NDE/I sensor technologies and to integrate those sensors into the full scale test articles which will be produced under the TA2 program. Review of the anticipated fault modes and the available sensor technology data indicates that three sensor technologies should be assessed for the in-situ monitoring of the composite primary structure elements. These are: ultrasonics (dry contact), acoustic emissions, and fiber optics (embedded or attached). In fact, a combination of sensor technologies will be needed to detect and evaluate the fault modes; not only do sensor technology have specific capabilities and applicability, but the three Gr/Ep primary structures being demonstrated under the TA2 effort have differing requirements based on their respective failure modes and designs.

Greenberg, H. S.↗

Combustor liner durability analysis

An 18 month combustor liner durability analysis program was conducted to evaluate the use of advanced three dimensional transient heat transfer and nonlinear stress-strain analyses for modeling the cyclic thermomechanical response of a simulated combustor liner specimen. Cyclic life prediction technology for creep/fatigue interaction is evaluated for a variety of state-of-the-art tools for crack initiation and propagation. The sensitivity of the initiation models to a change in the operating conditions is also assessed.

Moreno, V.↗

2.5/3D Daisy Chain Reliability Evaluation

The objective of this task is to evaluate thermal cycle behavior of advanced 2.5/3D electronics — commercial-off the-shelf (COTS) —packages of different configurations assembled onto printed circuit boards (PCBs). Three key approaches were considered for evaluation. The first approach focused on the through-mold via (TMV™) technology at assembly level. The second approach focused on evaluation of 2.5D (also known as, System in Package (SiP)) in fine pitch ball grid array (FPGA). The third approach focused on evaluation of through-silicone-via (TSV) technologies. This report presents the test results for TMV™ and SiP packaging technologies and reliability, and it also provides lessons learned on quality assurance methods. Specifically, the report presents the test matrix for various 3D TMV™ packaging assembly configurations and reliability characterizations performed under two accelerated thermal cycling (ATC) and accelerated thermal shock cycling (ATSC) conditions. The ATC and ATSC were performed in the range of –55°C to 125°C and –100°C to 100°C, respectively. The report also includes assembly of a SiP— a 60-mm fine-pitch ball-grid array (FPGA) interposer with an IC at the center and six chip-scale package (CSP) daisy chains at the periphery—with package assembly characterizations. After assembly, the daisy chains were subjected to ATCs in the range of –40°C to 125°C for reliability evaluation. Finally, for both TMV™ and SiP packaging configurations, characterizations results by X-ray, optical imaging, and daisy-chain resistance evaluations were also presented.

Ghaffarian, Reza↗

Updating the Default Anaerobic Digester Technology for Wastewater Sludge Anaerobic Digestion Pathways in R&D GREET 2025 Rev.1

The Greenhouse Gases, Regulated Emissions and Energy Use in Technologies model (R&D GREET) evaluates the life cycle impacts of renewable fuels and materials, including renewable natural gas (RNG) produced from wastewater (WW) sludge. In the sludge-to-RNG pathway, the assumed anaerobic digestion (AD) technology impacts results, such as energy use, greenhouse gases (GHG), and air pollutant emissions. Prior versions assumed sludge was fed through a thermal hydrolysis stage preceding the mesophilic AD (Thermohydrolysis). Such a process is expected to yield biosolids with sufficiently reduced pathogens to qualify for U.S Environmental Protection Agency (EPA) Class A designation. Other technologies, such as mesophilic AD without any advanced pretreatments, typically produce lower quality Class B biosolids but requires a lower energy burden and infrastructure investment. Table 1 displays the available AD technologies and the assumed resulting EPA biosolids class type from each technology. Full descriptions of each technology and their performance differences can be found in previous work.

09 BIOMASS FUELS↗

The De-Icing Comparison Experiment (D-ICE): a study of broadband radiometric measurements under icing conditions in the Arctic

Abstract. Surface-based measurements of broadband shortwave (solar) and longwave (infrared) radiative fluxes using thermopile radiometers are made regularly around the globe for scientific and operational environmental monitoring. The occurrence of ice on sensor windows in cold environments – whether snow, rime, or frost – is a common problem that is difficult to prevent as well as difficult to correct in post-processing. The Baseline Surface Radiation Network (BSRN) community recognizes radiometer icing as a major outstanding measurement uncertainty. Towards constraining this uncertainty, the De-Icing Comparison Experiment (D-ICE) was carried out at the NOAA Atmospheric Baseline Observatory in Utqiaġvik (formerly Barrow), Alaska, from August 2017 to July 2018. The purpose of D-ICE was to evaluate existing ventilation and heating technologies developed to mitigate radiometer icing. D-ICE consisted of 20 pyranometers and 5 pyrgeometers operating in various ventilator housings alongside operational systems that are part of NOAA's Barrow BSRN station and the US Department of Energy Atmospheric Radiation Measurement (ARM) program North Slope of Alaska and Oliktok Point observatories. To detect icing, radiometers were monitored continuously using cameras, with a total of more than 1 million images of radiometer domes archived. Ventilator and ventilator–heater performance overall was skillful with the average of the systems mitigating ice formation 77 % (many >90 %) of the time during which icing conditions were present. Ventilators without heating elements were also effective and capable of providing heat through roughly equal contributions of waste energy from the ventilator fan and adiabatic heating downstream of the fan. This provided ∼0.6 ∘C of warming, enough to subsaturate the air up to a relative humidity (with respect to ice) of ∼105 %. Because the mitigation technologies performed well, a near complete record of verified ice-free radiometric fluxes was assembled for the duration of the campaign. This well-characterized data set is suitable for model evaluation, in particular for the Year of Polar Prediction (YOPP) first Special Observing Period (SOP1). We used the data set to calculate short- and long-term biases in iced sensors, finding that biases can be up to +60 W m−2 (longwave) and −211 to +188 W m−2 (shortwave). However, because of the frequency of icing, mitigation of ice by ventilators, cloud conditions, and the timing of icing relative to available sunlight, the biases in the monthly means were generally less than the aggregate uncertainty attributed to other conventional sources in both the shortwave and longwave.

54 ENVIRONMENTAL SCIENCES↗

Subsonic Ultra Green Aircraft Research

This Final Report summarizes the work accomplished by the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team in Phase 1, which includes the time period of October 2008 through March 2010. The team consisted of Boeing Research and Technology, Boeing Commercial Airplanes, General Electric, and Georgia Tech. The team completed the development of a comprehensive future scenario for world-wide commercial aviation, selected baseline and advanced configurations for detailed study, generated technology suites for each configuration, conducted detailed performance analysis, calculated noise and emissions, assessed technology risks, and developed technology roadmaps. Five concepts were evaluated in detail: 2008 baseline, N+3 reference, N+3 high span strut braced wing, N+3 gas turbine battery electric concept, and N+3 hybrid wing body. A wide portfolio of technologies was identified to address the NASA N+3 goals. Significant improvements in air traffic management, aerodynamics, materials and structures, aircraft systems, propulsion, and acoustics are needed. Recommendations for Phase 2 concept and technology projects have been identified.

Bradley, Marty K.↗

New Observing Strategy (NOS) for Future Earth Science Missions

One of the new thrusts of the Earth Science Technology Office (ESTO) Advanced Information Systems Technology (AIST) Program is the New Observing Strategy (NOS) thrust. Its goal is to provide a framework for identifying technology advances needed to exploit newly available observational capabilities, particularly to enable the development of the information technologies needed to support planning, evaluating, implementing, and operating dynamic, multi-element sets of observing assets. In this paper, we will introduce relevant NOS terminology and some key concepts before describing the objectives, driving factors and technology goals of this new thrust.

Advanced Information Systems↗

Environmental Control and Life Support System Evolution

The Space Station Freedom Environmental Control and Life Support System (ECLSS) will have to accommodate the changes to Freedom as it evolves over the design life of 30 years or more. Requirements will change as pressurized modules are added, crew numbers increase, and as the tasks to be performed change. This evolution will result in different demands on the ECLSS and the ECLSS wilt have to adapt. Technologies other than the baselined ones may be better able to perform the various tasks and technological advances will result in improved life support hardware having better performance, increased reliability, reduced power consumption, weight, and volume, greater autonomy, and fewer resupply requirements. A preliminary study was performed to look at alternative technologies for life support and evaluate them for their integration requirements, focusing on the fluid line interface requirements. (A follow-on study will expand greatly on the scope of this preliminary study.) The integration requirements of the alternative technologies may be different from those of the baselined technologies. If this is the case, then by designing the initial space station to have the necessary fluid lines, etc. required by the selected alternative technologies then the task of replacing the baselined ones will be greatly simplified, thereby reducing the cost in on-orbit time as well as dollars.

Wieland, Paul↗

A Guide to Engaging Underserved Communities in Commercial Energy Efficiency Field Validations

Underserved communities in the United States often experience the negative impacts of climate change and environmental degradation but enjoy few of the benefits of technological and environmental advances. The White House has addressed this inequity through the Justice40 initiative, which requires 40% of the benefits of select federal investments to be directed to underserved communities (The White House, 2022). Clean energy and energy efficiency are two highlighted investment categories, so the U.S. Department of Energy will guide implementation of the Justice40 initiative by, among other things, decreasing energy burdens, increasing parity in clean energy technology access and adoption, and increasing energy resiliency. A strategy for reaching these goals is to evaluate and validate new energy efficiency technologies in commercial buildings in underserved communities, where buildings may be older, smaller, and have deferred maintenance due to historical underinvestment. This paper develops guidance for researchers pursuing field validations with underserved communities. Historical redlining and past negative experiences with government and large institutions may make residents wary of participating in these field validations. Researchers, therefore, may need to spend more time building relationships and matching technologies to buildings. In this paper, we analyzed technical reports to identify common field validation building characteristics and conducted semi-structured expert conversations to identify key stages and major themes of engaging underserved communities. Results indicate there may be flexibility in site selection and there are steps researchers can take to support collaboration with communities. Results also suggest benefits to both the community and energy efficiency research.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Conducting Field Validations of Commercial Energy Efficiency Technologies with Underserved Communities: Preprint

Underserved communities in the United States often experience the negative impacts of climate change and environmental degradation but enjoy few of the benefits of technological and environmental advances. The White House has addressed this inequity through the Justice40 initiative, which requires 40% of the benefits of select federal investments to be directed to underserved communities (The White House, 2022). Clean energy and energy efficiency are two highlighted investment categories, so the U.S. Department of Energy will guide implementation of the Justice40 initiative by, among other things, decreasing energy burdens, increasing parity in clean energy technology access and adoption, and increasing energy resiliency. A strategy for reaching these goals is to evaluate and validate new energy efficiency technologies in commercial buildings in underserved communities, where buildings may be older, smaller, and have deferred maintenance due to historical underinvestment. This paper assesses the proficiency of the technologies under these conditions and increases awareness of the benefits to the communities. In addition, historical redlining and past negative experiences with government and large institutions may make residents wary of participating in these field validations. Researchers, therefore, may need to spend more time building relationships and matching technologies to buildings. In this paper, we analyzed technical reports to identify common required and desired field validation building characteristics, and conducted semi-structured expert conversations to identify key stages and major themes of engaging underserved communities. Our results indicate that the benefits to both the community and energy efficiency research justify the effort. The White House. (2022). Justice40. https://www.whitehouse.gov/environmentaljustice/justice40/

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗

Electrical Impedance Tomography Technology (EITT) Project

Development of a portable, lightweight device providing two-dimensional tomographic imaging of the human body using impedance mapping. This technology can be developed to evaluate health risks and provide appropriate medical care on the ISS, during space travel and on the ground.

Technology Portfolio System↗

Project 5S: A Safe Stepping Stone into the Solar System

The human exploration program, at least in NASA, has been directed to move beyond the Moon and travel on a flexible path into the solar system. Reaching a Near-Earth Asteroid (NEA) is a major human space flight goal but such missions have tight times and life-support requirements that require huge steps from current capabilities. An objective between the Moon and a NEA is needed. Example interim objectives are the Lagrangian points in either the Sun-Earth or Earth-Moon (EM) system. The nearest of these points beyond the Moon is E-M L2. The Lagrangian points are empty (as far as we know). As objectives for human flight,it has been argued that they suffer from a lack of public interest and of meaningful objectives for astronaut operations. To provide a physical target, a robotic spacecraft could retrieve a small NEA and bring it to a Lagrangian or other nearer-Earth point to be accessed and utilized for human-mission objectives. This paper reports on the results of a recently completed study of an asteroid retrieval mission sponsored by the Keck Institute for Space Studies (KISS) at the California Institute of Technology. The study included an evaluation of potential targets, mission objectives, mission and system design, and potential capture mechanisms. The study concluded that, while challenging, there are no fundamental show stoppers and that such a mission would be possible with technology expected to be available in this decade. The final destination selected (for safety and mission operations) was high lunar orbit. Two options for target selection are considered: (i) retrieving a small (7 meter) NEA with a mass of order 500,000 kg, and (ii) taking a similar size boulder of a large known carbonaceous NEA. Several areas of technology and program requirements were identified, but the most important conclusion was that this approach enables meeting a goal of humans going to a NEA by the mid-2020s. The advantages and benefits for human exploration are considerable as are the advances that would be made in space-resource utilization and science for further exploration and development of the solar system. The combination of the robotic mission to move the asteroid and the human mission to go to its new destination and conduct astronaut operations there would provide a boost and purpose to human space flight.

asteroid retrieval↗

Aviation safety and automation technology for subsonic transports

Discussed here are aviation safety human factors and air traffic control (ATC) automation research conducted at the NASA Ames Research Center. Research results are given in the areas of flight deck and ATC automations, displays and warning systems, crew coordination, and crew fatigue and jet lag. Accident investigation and an incident reporting system that is used to guide the human factors research is discussed. A design philosophy for human-centered automation is given, along with an evaluation of automation on advanced technology transports. Intelligent error tolerant systems such as electronic checklists are discussed along with design guidelines for reducing procedure errors. The data on evaluation of Crew Resource Management (CRM) training indicates highly significant positive changes in appropriate flight deck behavior and more effective use of available resources for crew members receiving the training.

Albers, James A.↗