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NASA NTRS2018

Addressing Human Error in International Space Station Flight Control Teams: Advances in Ground Training for Science Operators

In flight control, as with any human in the loop system, operator error is an inevitable reality. On the International Space Station (ISS) where crew time and physical resources are precious and often irreplaceable, operator errors can result in significant, irreversible consequences. Flight controllers at the Payload Operations Integration Center (POIC) located at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama know this reality well. At the POIC, operator errors can be caused by a variety of factors, from poor hardware or software design to environmental factors such as time pressure or fatigue. The most difficult errors to address, however, are those which result from ineffective teamwork.Academic research in teamwork has resulted in the identification of many factors which make cross-functional teaming difficult, including leadership, trust building, and communication challenges. These factors, especially when combined with the challenging environmental factors flight control teams must contend with daily, make the goal of minimizing operator errors in payload operations challenging to achieve. To address such teamwork errors, trainers at the POIC have drawn best practices from high reliability industries such as commercial aviation, healthcare, and nuclear power plants, as well as from our sister ISS control center in Houston, Texas, to develop and institute a new training program focused specifically on teamwork skills.This training program, called the Team Skills Curriculum, is based on the concept of Crew Resource Management (CRM) which was developed by NASA in the 1970s for the commercial aviation industry in response to a series of aviation disasters resulting from ineffective teamwork. CRM was later tailored by the Johnson Space Center (JSC) for use in astronaut and flight control training. The result, called Space Flight Resource Management (SFRM) was formally introduced into manned spaceflight training in the late 90s. SFRM has evolved over the years, but the focus has remained on helping operators develop the skills needed to work as part of an effective team. Using these concepts as well as the latest research in cross-functional teaming and data on specific errors occurring at the POIC, trainers in the integrated flight control training branch created a custom training program for both new and certified payload operations specialists.

Harris, Samantha S.↗

NASA NTRSDate not supplied

NASA Kennedy Space Center Swamp Works 10th Anniversary: Innovative Research & Technology Development Summary

Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes rapid, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up fast, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This paper will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.

Robotic Mining↗

NASA NTRSDate not supplied

Swamp Works Technology Development 10th Anniversary: 2013-2023

Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes efficient, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up momentum, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This presentation will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.

Swamp Works↗

NASA NTRS2023

Swamp Works Technology Development 10th Anniversary: 2013-2023 - Innovative Research & Technology Development Summary

Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes rapid, innovative and cost-effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up efficiently, with lean development processes and a hands-on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. It consists of several teams with associated laboratories and test capabilities. The Granular Mechanics and Regolith Operations (GMRO) Laboratory and the Electrostatics and Surface Physics Laboratory (ESPL) are co-located in the Engineering Development Lab (EDL) facility high bay. The Applied Chemistry Lab (ACL) is in an adjacent facility and other KSC labs are being influenced by the innovation methods pioneered at the Swamp Works. The Swamp Works was founded in January 2013 by a group of scientists and engineers at KSC with the over-arching vision of expanding humanity and civilization into the solar system by the use of space resources via advanced technology. Ultimately, this will create a solar system economy that will improve the human condition due to the abundance of energy and resources. This presentation will summarize the projects and technology development that have been performed by the Swamp Works to celebrate its 10th Anniversary of innovation success.

Swamp Works↗

DOE OSTI2023

Development of dual phase soft magnetic laminate for advanced electric machines

The development of dual phase soft magnetic laminate for advanced electric machines at General Electric is summarized, including alloy development, properties, manufacturing trials, prototype experience, potential applications, and future material development. Dual phase soft magnetic laminates provide the flexibility to tune magnetic/non-magnetic state at the desired locations, using solution nitriding treatment with protective mask/coating. This enabling material technology benefits electric machine performance by reducing flux leakage in the laminates. It also decouples the electromagnetic and mechanical design, which opens up the design space for advanced electric machines. Magnetic and mechanical properties of dual phase laminates were compared to commercial FeSi and FeCo soft magnetic laminates. Driven by the market needs for high power density and high-speed electric machines, a synchronous reluctance (SynRel) machine without PMs using dual phase soft magnetic laminates was assessed in machine electromagnetic performance as well as rotor stress analysis by finite element simulation. Successful prototype build and testing further retired manufacturing risks and advanced the technology maturity level. Future material development with higher mechanical strength, higher saturation magnetization, higher permeability, and lower loss are highly desired for ground and air transportation electrification.

Rallabandi, Vandana↗

DOE OSTI2025

Analysis of Frost Formation and Novel Defrost Techniques for Commercial Refrigeration Applications

The purpose of this Cooperative Research and Development Agreement (CRADA) was to test a heat exchanger defrosting approach using radiant energy, including ultraviolet-C, -B, and -A. A preliminary test conducted at Oak Ridge National Laboratory demonstrated the concept of ultraviolet-based defrosting, which melts frost on the fin surface of a heat exchanger without increasing its overall temperature, thereby offering a new defrosting method that does not interrupt heat exchanger operation. Building on this key finding, this CRADA outlines a plan for upgrading the test equipment and for further testing to bridge the gap between the concept and its feasibility for industrial applications. This report also provides a brief review of existing defrosting technologies, the current state of the experimental system, and future parametric experiment plans.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Nitrogen-Doped PtNi Catalysts on Polybenzimidazole-Functionalized Carbon Support for the Oxygen Reduction Reaction in Polymer Electrolyte Membrane Fuel Cells

PtM (M = 3d transition metals) alloys are known as the promising oxygen reduction reaction catalysts and have been considered as the replacement of pure Pt catalysts for the commercialization of proton exchange membrane fuel cells. Although great progress has been made in the past three decades, the performance and durability of PtM catalysts still face stringent challenges from practical applications. Functionalization of a catalyst carbon support with nitrogen-contained groups can add charges onto its surface, which can be utilized to build a more complete ionomer/catalyst interface, to reduce the catalyst particle size, and to improve particle size distribution. Nitriding of PtNi catalysts can effectively improve the catalyst activity and stability by the modification of lattice strain. Hereby, we propose a synergistic approach of combining polybenzimidazole-grafted Vulcan XC72 carbon as the catalyst carbon support and the nitriding of PtNi to develop PtNiN/XC72-polybenzimidazole catalysts. Such PtNiN/XC72-PBI catalysts exhibit the excellent performance of fuel cell membrane electrode assembly (i.e., mass activity, 440 mA mgPt –1 ; electrochemical surface area, 51 m 2 gPt –1 ; and rated power density, 836 mW cm –2 ) as well as promising catalyst stability. The developed PtNiN/XC72-PBI meets the US DOE 2020 targets of mass activity for the fuel cell catalysts. This work provides a novel approach and a promising pathway on the development of the catalyst using such a synergistic approach-modification of the catalyst structure by nitrogen doping and functionalization of carbon support by polybenzimidazole for both high performance and high durability.

25 ENERGY STORAGE↗

NASA NTRS1980

Assessment of the risk due to release of carbon fiber in civil aircraft accidents, phase 2

The risk associated with the potential use of carbon fiber composite material in commercial jet aircraft is investigated. A simulation model developed to generate risk profiles for several airports is described. The risk profiles show the probability that the cost due to accidents in any year exceeds a given amount. The computer model simulates aircraft accidents with fire, release of fibers, their downwind transport and infiltration of buildings, equipment failures, and resulting ecomomic impact. The individual airport results were combined to yield the national risk profile.

Pocinki, L.↗

NASA NTRS2011

Methodology for Developing a Probabilistic Risk Assessment Model of Spacecraft Rendezvous and Dockings

In 2007 NASA was preparing to send two new visiting vehicles carrying logistics and propellant to the International Space Station (ISS). These new vehicles were the European Space Agency s (ESA) Automated Transfer Vehicle (ATV), the Jules Verne, and the Japanese Aerospace and Explorations Agency s (JAXA) H-II Transfer Vehicle (HTV). The ISS Program wanted to quantify the increased risk to the ISS from these visiting vehicles. At the time, only the Shuttle, the Soyuz, and the Progress vehicles rendezvoused and docked to the ISS. The increased risk to the ISS was from an increase in vehicle traffic, thereby, increasing the potential catastrophic collision during the rendezvous and the docking or berthing of the spacecraft to the ISS. A universal method of evaluating the risk of rendezvous and docking or berthing was created by the ISS s Risk Team to accommodate the increasing number of rendezvous and docking or berthing operations due to the increasing number of different spacecraft, as well as the future arrival of commercial spacecraft. Before the first docking attempt of ESA's ATV and JAXA's HTV to the ISS, a probabilistic risk model was developed to quantitatively calculate the risk of collision of each spacecraft with the ISS. The 5 rendezvous and docking risk models (Soyuz, Progress, Shuttle, ATV, and HTV) have been used to build and refine the modeling methodology for rendezvous and docking of spacecrafts. This risk modeling methodology will be NASA s basis for evaluating the addition of future ISS visiting spacecrafts hazards, including SpaceX s Dragon, Orbital Science s Cygnus, and NASA s own Orion spacecraft. This paper will describe the methodology used for developing a visiting vehicle risk model.

Farnham, Steven J., II↗

NASA NTRS2010

Ares I-X Ground Diagnostic Prototype

Automating prelaunch diagnostics for launch vehicles offers three potential benefits. First, it potentially improves safety by detecting faults that might otherwise have been missed so that they can be corrected before launch. Second, it potentially reduces launch delays by more quickly diagnosing the cause of anomalies that occur during prelaunch processing. Reducing launch delays will be critical to the success of NASA's planned future missions that require in-orbit rendezvous. Third, it potentially reduces costs by reducing both launch delays and the number of people needed to monitor the prelaunch process. NASA is currently developing the Ares I launch vehicle to bring the Orion capsule and its crew of four astronauts to low-earth orbit on their way to the moon. Ares I-X will be the first unmanned test flight of Ares I. It is scheduled to launch on October 27, 2009. The Ares I-X Ground Diagnostic Prototype is a prototype ground diagnostic system that will provide anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage thrust vector control (TVC) and for the associated ground hydraulics while it is in the Vehicle Assembly Building (VAB) at John F. Kennedy Space Center (KSC) and on the launch pad. It will serve as a prototype for a future operational ground diagnostic system for Ares I. The prototype combines three existing diagnostic tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool that is commercially produced by Qualtech Systems, Inc. It uses a qualitative model of failure propagation to perform fault isolation and diagnostics. We adapted an existing TEAMS model of the TVC to use for diagnostics and developed a TEAMS model of the ground hydraulics. The second tool, Spacecraft Health Inference Engine (SHINE), is a rule-based expert system developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification. The prototype uses the outputs of SHINE as inputs to TEAMS. The third tool, the Inductive Monitoring System (IMS), is an anomaly detection tool developed at NASA Ames Research Center and is currently used to monitor the International Space Station Control Moment Gyroscopes. IMS automatically "learns" a model of historical nominal data in the form of a set of clusters and signals an alarm when new data fails to match this model. IMS offers the potential to detect faults that have not been modeled. The three tools have been integrated and deployed to Hangar AE at KSC where they interface with live data from the Ares I-X vehicle and from the ground hydraulics. The outputs of the tools are displayed on a console in Hangar AE, one of the locations from which the Ares I-X launch will be monitored. The full paper will describe how the prototype performed before the launch. It will include an analysis of the prototype's accuracy, including false-positive rates, false-negative rates, and receiver operating characteristics (ROC) curves. It will also include a description of the prototype's computational requirements, including CPU usage, main memory usage, and disk usage. If the prototype detects any faults during the prelaunch period then the paper will include a description of those faults. Similarly, if the prototype has any false alarms then the paper will describe them and will attempt to explain their causes.

Schwabacher, Mark↗

NASA NTRSDate not supplied

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

NASA NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

Additive Manufacturing↗

NASA NTRS2026

A Dispersion-Strengthened Low-Density Niobium Alloy and Its Elevated Temperature Mechanical Performance

In response to the elevated-temperature and weight-reduction demands of modern aerospace applications, a novel oxide-dispersion-strengthened low-density niobium alloy (LDNb-ODS) was fabricated using laser powder bed fusion (L-PBF). To overcome powder procurement barriers, L-PBF feedstock was produced by blending commercial Nb521, Ti64, and Cr powder with Y2O3 nanoparticles via resonant acoustic mixing. Following L-PBF and a 1400°C vacuum heat treatment, the alloy achieved a density of 6.73 g/cc and a fine mean grain size of 4.62 µm stabilized by uniform ~30 nm yttria dispersoids. Microstructural analysis revealed a chemically inhomogeneous build with lack-of-fusion defects and a titanium (Ti) shift from a nominal 31.5 wt% in the starting powder blend to 24.8 wt% in the printed part due to preferential Ti loss during printing. Elevated-temperature tensile testing demonstrated that LDNb-ODS maintained a superior specific yield strength of 60-85 MPa/(g/cc) up to 800°C, outperforming nickel-based alloys Ni625, Ni230, and GRX-810. Between 870°C and 950°C, its specific strength surpassed both Ni718 and Ni625. In rapid stress-rupture testing at 1093°C and 20.7 MPa, uncoated LDNb-ODS survived 21.4 hours (a tenfold increase over legacy C-103) while an R512E silicide coating extended rupture life to 84.8 hours, confirming that oxidation accelerates low-stress failure. These findings demonstrate that additive manufacturing of LDNb-ODS provides a viable, lightweight alternative to nickel-based superalloys for high-temperature (>850°C) aerospace components.

Low Density Niobium Alloy↗

DOE OSTI2020

Real-Time Acoustic Analysis of Batteries

The project explored development and commercialization of an acoustical approach to battery diagnostics. The technology has significant potential impacts for battery manufacturing and quality assurance, battery management during operation, and could be an enabler for the second-life battery market. Research was focused on inspecting and analyzing the physical condition of batteries using ultrasound. This consisted of designing and building hardware for gathering high-quality acoustic data, as well as using battery charge-discharge cyclers and temperature chambers to operate and age the batteries. Over the course of the 2-year program, we were able to build our first prototypes that are robust enough to be used by industry partners to evaluate our technology. Using the same prototypes, we also showed preliminary evidence that our acoustic inspection method may have distinct advantages over standard electrical methods in terms of detecting differences in the physical quality of battery cells. The project also expanded the participant’s core capabilities beyond time-of-flight acoustic measurements.

25 ENERGY STORAGE↗

DOE OSTI2024

Multi-Scale Integrated Monitoring System for Enhancing Methane Emission Detection, Quantification & Prediction

This report details the progress and findings of a comprehensive study on reviewing existing solutions, identifying technology gaps, and formulating an “all-in-one” integrated strategy for developing the next-generation multiscale methane monitoring and modeling platform, conducted under grant number DE-FE0032292. Co-led by Dr. David Ebert, Dr. Binbin Weng, and Dr. Chenghao Wang at the University of Oklahoma, the project’s goal was to develop an integrated approach for building this engineering platform to detect, quantify, and mitigate methane emissions across various temporal scale, spatial scales, and sectors. The planning grant study began with an extensive review of various methane sensing and monitoring technologies and systems, surveying over 100 technology providers globally. This review revealed the prevalence of optical methods over chemical methods in commercially available sensors, with Non-Dispersive Infrared (NDIR), Tunable Diode Laser Absorption Spectroscopy (TDLAS), and Optical Gas Imaging (OGI) cameras being the most prevalent options. A trend towards more advanced optical techniques was observed, driven by increased regulatory focus and technological advancements. The technical evaluation of these sensing technologies provided crucial insights into their capabilities and limitations. The study examined emerging technologies such as Differential Absorption LiDAR (DIAL), which show promise for high-precision and long-range detection. The team then investigated the features and application bandwidth of various sensing platforms, including handheld, fixed/stationary, mobile, aerials, and spaceborne monitors. Pilot field studies were conducted to assess the capabilities of solutions for different emission scenarios. Field work with sensor deployments was conducted at three distinct site types: an oil & gas industry site, a cattle ranching operation, and a waste processing facility. The team also conducted a thorough review of methane flux inverse modeling approaches, focused on physically based methods. These approaches were categorized into simple, intermediate, and advanced methods. A realtime WRF-GHG (Weather Research and Forecasting-Greenhouse Gas) modeling system was developed and applied, incorporating multiple data sources to guide field experiments and inform methane plume detection. The project identified and analyzed numerous categories of methane data sources, including satellite measurements, ground-based sensors, and inventory databases. Key platforms examined include EDGAR, EPA GHGI, NASA TROPOMI, Carbon Mapper, and Climate TRACE, among others. The team proposed an architecture for a comprehensive methane monitoring platform. This system incorporates multi-source data acquisition, advanced data processing and assimilation, interactive visualization tools, and analytical capabilities for emissions forecasting and scenario analysis. The proposed platform aims to provide a user-friendly interface catering to various stakeholders, from researchers to policymakers. The architecture includes sophisticated data ingestion methods, a centralized data warehouse, and advanced analytical tools for data fusion and interpretation. To ensure the relevance and effectiveness of the proposed system, a comprehensive survey was conducted to gather stakeholder input on system requirements. Key findings include a strong need for integrating various data types and formats, a preference for real-time data updates and advanced visualization tools, and a demand for user-friendly interfaces catering to different expertise levels.

03 NATURAL GAS↗

DOE OSTI2021

CarbonSAFE North Dakota – Early Successes

Conference presentation for American Institute of Chemical Engineers (AIChE) Annual Meeting, Boston, MA and virtual, November 5–11 and 15–19, 2021. As part of the U.S. Department of Energy’s (DOE’s) CarbonSAFE program, the Energy & Environmental Research Center (EERC) is conducting commercial-scale site characterization and permitting of up to two geologic horizons for the geologic storage of anthropogenic CO2 emissions. These storage horizons would collectively and permanently store nearly 4 million metric tons (MMt) of CO2 per year captured as part of Minnkota Power Cooperative’s (Minnkota’s) Project Tundra. Minnkota’s ambitious initiative to build the world’s largest postcombustion carbon capture and storage facility in central North Dakota demonstrates the existence of a business case for carbon capture, and storage (CCS).

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS2007

Spinoff 2007

In accordance with congressional mandates cited in the National Aeronautics and Space Act of 1958 and the Technology Utilization Act of 1962, NASA was directed to encourage greater use of the Agency's knowledge by providing a link between the NASA research community and those who might use the research for commercial or industrial products. For more than 40 years, NASA has nurtured partnerships with the private sector to facilitate the transfer of NASA-developed technologies. The benefits of these partnerships have reached throughout the economy and around the globe, as the resulting commercial products contributed to the development of services and technologies in the fields of health and medicine, transportation, public safety, consumer goods, environmental resources, computer technology, and industry. Since 1976, NASA Spinoff has profiled more than 1,500 of the most compelling of these technologies, annually highlighting the best and brightest of partnerships and innovations. Building on this dynamic history, NASA partnerships with the private sector continue to seek avenues by which technological achievements and innovations gleaned among the stars can be brought down to benefit our lives on Earth. NASA Spinoff highlights the Agency's most significant research and development activities and the successful transfer of NASA technology, showcasing the cutting-edge research being done by the Nation's top technologies and the practical benefits that come back down to Earth in the form of tangible products that make our lives better.

Source record↗

NASA NTRSDate not supplied

SCaN: Space Communication and Navigation - 5G in Space

NASA’s Space Communications and Navigation (SCaN) program office builds, operates, and maintains NASA’s two primary communications networks – the Near Space Network and the Deep Space Network. These networks allow spacecraft near and far to send critical tracking, telemetry, command, and science data to Earth. SCaN also investigates new communications and navigation technologies so that these networks can support advanced missions. SCaN’s Commercialization, Innovation, and Synergies (CIS) office is dedicated to creating robust partnerships with industry, academia, and other government agencies to advance communications and navigation capabilities.

5G↗