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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗
NASA NTRS2019

Simulation and Flight Test Environments for the TASAR Traffic Aware Planner

The Traffic Aware Planner (TAP) software is a flight deck decision support tool that enhances the flight crew’s ability to make flight-optimizing route change requests while airborne. The software provides conflict-free, optimized trajectory suggestions during en route flight to produce time- and fuel-savings compared to the current trajectory. The TAP software requires evaluation in an operational environment with real pilot users to validate projected benefits. To this end, a set of developmental test environments have been developed to mature the software and mitigate technical risk prior to entering operational evaluation. The unique attributes of each test environment were leveraged to provide a range of purpose- and case-dependent TAP software tests. This paper describes the elements of a testing environment, discusses several environments of varying fidelity used to test the TAP software, and provides a review of two case studies highlighting the vital role testing played in the TAP software development process.

Barney, Terique L.↗
NASA NTRS2019

Gravity Effects in Two-Phase Microgap Flow

The high power density of emerging electronic devices is driving the transition from remote cooling, which relies on conduction and spreading, to embedded cooling, which extracts dissipated heat on-site. Two-phase microgap coolers employ the forced flow of dielectric fluids undergoing phase change in a heated channel within or between devices. Such coolers must work reliably in all orientations for a variety of applications (e.g., vehicle-based equipment), as well as in microgravity and high-g for aerospace applications, but the lack of acceptable models and correlations for orientation- and gravity-independent operation has limited their use. Reliable criteria for achieving orientation- and gravity-independent flow boiling would enable emerging systems to exploit this thermal management technique and streamline the technology development process. As a first step toward understanding the effect of gravity in two-phase microgap flow and transport, in an earlier effort, the authors studied the effects of evaporator orientation, mass flux, and heat flux on flow boiling of HFE7100 in a 1.01 mm tall by 13.0 mm wide by 12.7 mm long microgap channel. Orientation-independence, defined as achieving similar critical heat fluxes, heat transfer coefficients, and flow regimes across orientations, was achieved for mass fluxes of 400 kg/sq.m-s and greater (corresponding to a Froude number of about 0.8). In the present effort, the authors have studied the effects of gravity, mass flux, and subcooling on flow boiling of HFE7100 in a 0.17 mm tall by 13.0 mm wide by 12.7 mm long microgap channel. The Flow Boiling in Microgap Coolers payload experienced about three minutes of weightlessness and shorter periods of high-g (up to about 5 g) during two recent flights aboard the Blue Origin New Shepard reusable launch vehicle. The results from the flight experiments will be presented and compared with published criteria for achieving gravity-independence.

Robinson, Franklin L.↗
NASA NTRS2019

Standards and Best Practices - Two NASA Examples

Formal international standards as well as promotion of community or recommended practices have their place in ensuring "FAIRness" of data. Data management in NASA's Earth Observation System Data and Information System (EOSDIS) has benefited from both of these avenues to a significant extent. The purpose of this paper is to present one example of each of these, which promote (re)usability. The first is an ISO standard for specifying preservation content from Earth observation missions. The work on this started in 2011, informally within the Earth Science Information Partners (ESIP) in the US, while the European Space Agency (ESA) was leading an effort on Long-Term Data Preservation (LTDP). Resulting from the ESIP discussions was NASA's Preservation Content Specification, which was applied in 2012 as a requirement for NASA's new missions. ESA's Preserved Data Set Content (PDSC) document was codified into a document adopted by the Committee on Earth Observation Satellites (CEOS). It was recognized that it would be useful to combine PCS and PDSC into an ISO standard to ensure consistency in data preservation on a broader international scale. This standard, numbered ISO 19165-2 has been under development since mid-2017. The second is an example of developing recommendations for "best practices" within more limited (still fairly broad) communities. A Data Product Developers' Guide (DPDG) is currently being developed by one of NASA's Earth Science Data System Working Groups (ESDSWGs). It is for use by developers of products to be derived from Earth observation data to improve product (re)usability. One of the challenges in developing the guide is the fact that there are already many applicable standards and guides. The relevant information needs to be selected and expressed in a succinct manner, with appropriate pointers to references. The DPDG aims to compile the most applicable parts of earlier guides into a single document outlining the typical development process for Earth Science data products. Standards and best practices formally endorsed by the Earth Science Data and Information System (ESDIS) Standards Office (ESO), outputs from ESDSWGs (e.g., Dataset Interoperability Working Group, and Data Quality Working Group), and recommendations from Distributed Active Archive Centers and data producers are emphasized.

Ramapriyan, Hampapuram↗
NASA NTRS2019

Modeling Meteoroid Densities for Spacecraft Risk Assessment

This report describes the methodologies and algorithms that NASA’s Meteoroid Environment Office (MEO) currently utilizes to measure meteoroid densities. We discuss the needs for an accurate model for the meteoroid density distribution in its Meteoroid Engineering Model (MEM), and its potential implications for spacecraft design. The recently developed process is heavily derived from that of previous work, although subtle differences exist. A thorough comparison of the best-fit densities derived for sixty meteoroids in and with the process described here shows that discrepancies in final densities larger than a factor of two are measured for ∼ 20% of our test events. Such a level of discrepancy suggests that any density calculated using similar methods cannot be assumed to represent a unique fit to the data. Additional observational data for meteoroids beyond those utilized in this work will be essential for producing more reliable and repeatable density measurements.

Ehlert, Steven↗
NASA NTRSDate not supplied

Astrobee Free-Flyer Nozzle Mechanism

This paper describes the development and design of the Astrobee Free-Flyer propulsion nozzle assemblies. As will be illustrated in this paper, the Free-Flyer nozzles are thrust control devices used to propel the Astrobee Free-Flyer robot autonomously inside the International Space Station (ISS). The development process, design evolution, and prototyping methods, are described. Key design features are discussed in greater detail to highlight how a seemingly simple design can present surprisingly large challenges. Several lessons learned are given.

Earl Daley↗
NASA NTRSDate not supplied

cFS Test Framework (CTF)

NASA's Core Flight System (cFS) provides a generic flight software framework architecture for developing flight software. As the cFS framework has gained popularity over the years within the flight software community, supporting software tools have been developed to assist in the design, development, testing and verification of flight software. The cFS Test Framework (CTF) is a recently developed cFS tool with capabilities to develop and run automated test and verification scripts against flight software targets. The CTF tool parses and executes JSON-based test scripts containing test instructions, while logging and reporting the results. CTF utilizes a plugin-based architecture to allow developers to extend CTF with new test instructions, external interfaces, and custom functionality. To interface with flight software, CTF parses a set of CCSDS message definition files to create the necessary command and telemetry structures for use during the test run. Additionally, CTF also supports interfacing with multiple cFS instances, allowing a test script to verify requirements that involve multiple flight software targets. Lastly, CTF provides support for executing test scripts against FSW running on remote or embedded hardware. This allows CTF to execute the same test scripts across different target configurations throughout the development process. In this presentation, we will introduce the cFS Test Framework (CTF) architecture, discuss the history of cFS testing frameworks, and present the features and capabilities currently provided by CTF. Lastly, we will show a demo of the CTF tool being used to execute test scripts against flight software.

Aly I Shehata↗
NASA NTRS2021

MBSE Validation and Verification: Case Study for LADEE

The Lunar Atmosphere Dust Environment Explorer (LADEE) mission orbited the moon in order to measure the density, composition, and time variability of the lunar dust environment. The successful mission launched September 7, 2013 and was de-orbited and impacted the moon's surface on April 17, 2014. The ground-side and onboard flight software for the mission was developed using a “Model-Based Software Engineering” (MBSE) methodology combined with strong reuse of Government and Commercial Off-The Shelf (G/COTS) components. Models of the spacecraft and flight software were developed in a graphical dynamics modeling package. Flight Software requirements were prototyped and refined using the simulated models. After the model was shown to work as desired in the simulation framework, C-code software was automatically generated from the models. The auto-generated software was then tested in real-time Processor-in-the-Loop and Hardware-in-the-Loop test beds. “Traveling Road Show” test beds were used for early integration tests with payloads and other subsystems. Traditional techniques for verifying computational sciences models were used to characterize the spacecraft simulation. A lightweight set of formal methods analysis, static analysis, formal inspection, and code coverage analyses were utilized to further reduce defects in the onboard flight software artifacts. These techniques were applied early and often in the development process, iteratively increasing the capabilities of software and fidelity of vehicle models and test beds.

Model-Based Software Engineering, Validation and V↗
NASA NTRSDate not supplied

CFS Test Framework

NASA's Core Flight System (cFS) provides a generic flight software framework architecture for developing flight software. As the cFS framework has gained popularity over the years within the flight software community, supporting software tools have been developed to assist in the design, development, testing and verification of flight software. The cFS Test Framework (CTF) is a recently developed cFS tool with capabilities to develop and run automated test and verification scripts against flight software targets. The CTF tool parses and executes JSON-based test scripts containing test instructions, while logging and reporting the results. CTF utilizes a plugin-based architecture to allow developers to extend CTF with new test instructions, external interfaces, and custom functionality. To interface with flight software, CTF parses a set of CCSDS message definition files to create the necessary command and telemetry structures for use during the test run. Additionally, CTF also supports interfacing with multiple cFS instances, allowing a test script to verify requirements that involve multiple flight software targets. Lastly, CTF provides support for executing test scripts against FSW running on remote or embedded hardware. This allows CTF to execute the same test scripts across different target configurations throughout the development process. In this presentation, we will introduce the cFS Test Framework (CTF) architecture, discuss the history of cFS testing frameworks, and present the features and capabilities currently provided by CTF. Lastly, we will show a demo of the CTF tool being used to execute test scripts against flight software.

cfs↗
NASA NTRSDate not supplied

Verification and Validation of Elastodynamic Simulation Software for Aerospace Research

Physics-based simulation of nondestructive evaluation (NDE) inspection can help to advance the inspectability and reliability of mechanical systems. However, NDE simulations applicable to non-idealized mechanical components often require large compute domains and long run times. This has prompted development of custom NDE simulation software tailored to high performance computing (HPC) hardware. Verification and validation (V&V) is an integral part of developing this software to ensure implementations are robust and applicable to inspection problems, producing tools and simulations suitable for computational NDE research. This presentation addresses factors common to V&V of several elastodynamic simulation codes applicable to ultrasonic NDE. Examples are drawn from in-house simulation software at NASA Langley Research Center, ranging from ensuring reliability in a 1D heterogeneous media wave equation solver to the V&V needs of 3D cluster-parallel elastodynamic software. Factors specific to a research environment are addressed, where individual simulation results can be as relevant as the software product itself. Distinct facets of V&V are discussed including testing to establish software reliability, employing systematic approaches for consistency with fundamental conservation laws, establishing the numerical stability of algorithms, and demonstrating concurrence with empirical data. This talk also addresses V&V practices for small groups of researchers. This includes establishing resources (e.g. time and personnel) for V&V during project planning to mitigate and control the risk of setbacks. Similarly, we identify ways for individual researchers to use V&V during simulation software development itself to both speed up the development process and reduce incurred technical debt.

NDE↗
NASA NTRS2021

Potential impact of aerosols on convective clouds revealed by Himawari-8 observations over different terrain types in eastern China

Convective clouds are common and play a major role in Earth's water cycle and energy balance; they may even develop into storms and cause severe rainfall events. To understand the convective cloud development process, this study investigates the impact of aerosols on convective clouds by considering the influence of both topography and diurnal variation in radiation. By combining texture analysis, clustering, and thresholding methods, we identify all convective clouds in two warm seasons (May–September, 2016/17) in eastern China based on Himawari-8 Level 1 data. Having large diurnally resolved cloud data together with surface meteorological and environmental measurements, we investigate convective cloud properties and their variation, stratified by elevation and diurnal change. We then analyze the potential impact of aerosol on convective clouds under different meteorological conditions and topographies. In general, convective clouds tend to occur preferentially under polluted conditions in the morning, which reverses in the afternoon. Convective cloud fraction first increases then decreases with aerosol loading, which may contribute to this phenomenon. Topography and diurnal meteorological variations may affect the strength of aerosol microphysical and radiative effects. Updraft is always stronger along the windward slopes of mountains and plateaus, especially in northern China. The prevailing southerly wind near the foothills of mountains and plateaus is likely to contribute to this windward strengthening of updraft and to bring more pollutant into the mountains, thereby strengthening the microphysical effect, invigorating convective clouds. By comparison, over plain, aerosols decrease surface heating and suppress convection by blocking solar radiation reaching the surface.

clouds↗
NASA NTRSDate not supplied

Adaptive Stress Testing of Collision Avoidance Systems for Small UASs with Deep Reinforcement Learning

The next-generation Airborne Collision Avoidance System for smaller UASs (ACAS sXu) is currently being developed and tested by the Federal Aviation Administration (FAA) to provide detect-and-avoid capability for small unmanned aircraft operating beyond line-of-sight. Due to the complexity and safety-critical nature of the system, safety validation is important not only for the certification of the final system, but also for informing changes during the iterative development process. In this paper, we analyze a prototype of ACAS sXu in simulated aircraft encounters to discover scenarios of small near mid-air collisions (sNMACs), an important safety event in which two aircraft come closer than 50 feet horizontally and 15 feet vertically. Due to the size and complexity of the system as well as rarity of sNMAC events, traditional methods such as Monte Carlo testing often require informed setup and targeting to elicit failures. However, such a dependence on domain knowledge can be incompatible with the independent verification and validation (IV&V) process, the aim of which is to discover unforeseen issues. To address these challenges, we apply an accelerated validation method called adaptive stress testing (AST) to find the most likely sNMAC scenarios without reliance on system introspection. AST uses reinforcement learning to adapt the search towards the most promising areas of the search space as it progresses. We use a state-of-the-art deep reinforcement learning algorithm, proximate policy optimization, to more efficiently search the large and continuous state space. We find that this approach significantly improves the performance of AST compared to a prior approach based on Monte Carlo tree search. We perform experiments using AST to find sNMAC events under various encounter configurations, varying parameters pertaining to dynamics and coordination. Our experiments show AST to be very effective at finding sNMAC scenarios. We summarize our findings, presenting high-level categories of discovered sNMACs and specific examples of encounters in each category.

aircraft collision avoidance↗
NASA NTRSDate not supplied

Risk-Based Methodology for the Determination of Hall Thruster Performance Specifications

This work adapts manufacturing and metrology industry standards to create a risk-based approach for the determination of electric propulsion performance specifications. The developed process is applied to 208 total thrust measurements acquired using three different NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Unit (TDU) 12.5-kW Hall thrusters in three different test facilities in order to generate thrust specifications at the 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW operating conditions. These thrust specifications are used to perform a set of sample acceptance tests to illustrate the importance of adding additional conservatism using a parameter known of the Test Accuracy Ratio in order to control the risk to the thruster producer and consumer from false rejection and acceptance of thruster units.

HERMeS↗
NASA NTRSDate not supplied

Risk-based Methodology for the Determination of Hall Thruster Performance Specifications

This work adapts manufacturing and metrology industry standards to create a risk-based approach for the determination of electric propulsion performance specifications. The developed process is applied to 208 total thrust measurements acquired using three different NASA Hall Effect Rocket with Magnet Shielding (HERMeS) Technology Demonstration Unit (TDU) 12.5-kW Hall thrusters in three different test facilities in order to generate thrust specifications at the 300 V/6.25 kW, 400 V/8.33 kW, 500 V/10.42 kW, and 600 V/12.5 kW operating conditions. These thrust specifications are used to perform a set of sample acceptance tests to illustrate the importance of adding additional conservatism using a parameter known of the Test Accuracy Ratio in order to control the risk to the thruster producer and consumer from false rejection and acceptance of thruster units.

HERMeS↗
NASA NTRS2021

Potential impact of aerosols on convective clouds revealed by Himawari-8 observations over different terrain types in Eastern China

Convective clouds are common and play a major role in Earth’s water cycle and energy balance; they may even develop into storms and cause severe rainfall events. To understand the convective cloud development process, this study investigates the impact of aerosols on convective clouds by considering the influence of both topography and diurnal variation of radiation. By combining texture analysis, clustering and thresholding methods, we identify all convective clouds in two warm seasons (May-September, 2016-2017) in eastern China based on Himawari-8 Level 1 data. Having a large diurnally resolved cloud data together with surface meteorological and environmental measurements, we investigate convective cloud properties and their variation, stratified by elevation and diurnal change. We then analyze the potential impact of aerosol on convective clouds under different meteorological conditions and topographies. In general, convective clouds tend to occur preferentially under polluted conditions in the morning, which reverses in the afternoon. Convective cloud fraction first increases then decreases with aerosol loading, which may contribute to this phenomenon. Topography and diurnal meteorological variations may affect the strength of aerosol microphysical and radiative effects. Updraft is always stronger along the windward slopes of mountains and plateaus, especially in northern China. The prevailing southerly wind near the foothills of mountains and plateaus is likely to contribute to this windward strengthening of updraft and to bring more pollutant into the mountains, thereby strengthening the microphysical effect, invigorating convective clouds. By comparison, over plain, aerosols decrease surface heating and suppresses convection by blocking solar radiation reaching the surface.

Tianmeng Chen↗
NASA NTRSDate not supplied

Bion-M2

Bion-M2, scheduled to launch in April 2023, continues the 30+ year collaboration between the Institute of Biomedical Problems of the Russian Academy of Sciences (IBMP RAS) and the National Aeronautics and Space Administration (NASA). Bion-M2 is the second biosatellite in the Bion-M series and its goal is to investigate how the space environment affects living organisms, with emphasis on physiological changes in rodents, gravitational biology using a wide variety of specimens, and radiation biology. The Bion-M2 biosatellite will complete a 30-day low earth orbit (LEO) flight to study the combined effects of microgravity and ionizing radiation (IR) on multiple organisms, where the payload may be exposed to IR at 20-30 times thedose rate seen on the International Space Station. Following return, nine U.S. collaborators selected through the NASA Space Biology Research Announcement will conduct post-flight rodent experiments using male C57BL/6 mice. The post-flight experiments will investigate the effects of the space environment on bone and skeletal muscle health, cardiac function, reproductive system function, neurovascular systems, protein composition in plasma, and thermoregulation in the mice. Currently, the Bion-M2 mission is in the development phase of theproject lifecycle. The mission objectives, constraints, requirements, and timeline have been defined in the project plan and contracts. Technology for the mission is under development and science procedures will be finalized by FY22. The aim of this presentation is to highlight the importance of the Bion-M2 mission and provide insight into the mission development process, including an overview of the project plan and the tissue sharing plan that will be utilized during the post-flight dissection procedures.

Bion-M2↗
NASA NTRSDate not supplied

Origami-based Composite Space Structures

The main objective of my internship was working on developing a new type of deployable composite for space structures and new method of deployment via use of origami, composites, UV curing resins, and shape memory polymers. My role in the project was to collect an initial literature survey on the subject including origami, the history of deployable space structures, previous issues and problems faced in the field, previous and current research being done on the structural aspect as well as the materials aspect of the subject. I presented this information to our team, where we discussed and determined our research focus and project design specs. We have been making or will make decisions on the project’s purpose, material, origami type, manufacturing method, and testing methods. I am now in charge of the protype design as we enter the design stage of our research. I am using PTC Creo software to design the structural aspects of the first protype so that we can begin small scale testing. I will perform data analysis in order to review the results with our team, so we can make the next design decisions regarding changes or iterations of the design. We hope to renew this project in the next fiscal year in order to increase the TRL of the project so that it can eventually be used in multiple functions in space such as the construction of lunar habitats. In just my brief time with NASA, I have gained so much personally and professionally. I developed my ability to search through and narrow down information when doing research. In the weekly meetings I practiced presenting information to my peers and superiors, and, just as importantly, discussing and adapting to what we were learning. I acquired experience in using technology to my advantage including remote work, new software like PTC Creo, NASA archives, and connecting with others beyond my team to gain help. I enjoyed the immense resource of knowledge that my mentors had to offer, and that they gave me a large amount of responsibility in this research. I truly felt like I was contributing to something bigger than myself and understood how directly I was involved in NASA’s work. This internship has further cemented my love for space and desire to continue in the field. I have a better understanding of the research and development process and am now considering joining a research lab with my university next year.

Composite↗