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At least 1,765 records · Page 98

Results of All Polyimide, Etched Foil Heater Qualification and Failure Limit Testing

Standard FEP (Fluorinated Ethylene Propylene resin) polyimide (SFP) or Kapton film heaters—which have a long history of space flight—are output-power limited by the melting point of Teflon which is used as an adhesive and insulator between the encasing layers of Kapton. The limit is expressed as a power density or through maximum operating temperature limits. All-polyimide (AP) heaters (also known as adhesive-less heaters) do not contain FEP Teflon between the layers of Kapton so the heaters are unconstrained by the melting point of Teflon. Thus, AP heaters have a higher maximum power density and operating temperature. AP heaters have not been qualified or flown on JPL missions but could be useful in applications that require a higher power density (Watt density) than the SFP heaters can support. The purpose of this paper is to document the qualification and property testing of the AP heaters for flight purposes. JPL (Jet Propulsion Lab.) tested several varieties of all-polyimide heaters to determine their functional equivalence to the standard heater which has substantial flight heritage and to determine their maximum limits. Tests included standard in-air burn-in tests, maximum power testing, lead pull strength, process qualification verification (PQV), long duration thermal cycling, and electro-magnetic compatibility shielding properties for copper-cladded shielded heaters. The results show that the all-polyimide heater appears to be functionally equivalent to the standard heater and has a higher Watt density and maximum operating temperature limit. The tests, test articles, failure analysis of the test articles, and results are described herein. These test results indicate that the all-polyimide heater is ready for flight applications.

Cucullu, Gordon C., III↗

Initial Criticality Assessments to Guide FMEAs on Rocket Engine Hot Fire Testing

Presented is an explanation of the use of the Initial Criticality Assessment (ICA) technique, a triage process for prioritizing required Failure Modes and Effects Analysis (FMEAs), for the European Service Module's main propulsion system's hot-fire test bed at White Sands New Mexico. Rather than instinctively performing many FMEAs of subsystems, or one large system level FMEA where every subcomponent is analyzed, the ICA guided an informed analysis of only the hardware that had a large impact to hazards. The low criticality hardware was documented via the ICA and no FMEA was performed; the work could then focus on the high criticality hardware. Thus a savings of Program resources was achieved. The experiences gained in creating these ICAs for this international collaborative project confirmed that the need for continuous communication across the technical teams is one of the greatest areas of emphasis. The European Space Agency (ESA) is developing the European Service Module (ESM), with its primary contractor, Airbus Defence and Space in Germany, for delivery to the National Aeronautics and Space Administration (NASA). The module will be equipped with a total of 21 engines to support NASA’s Orion spacecraft: one U.S. Space Shuttle Orbital Maneuvering System-Engine (OMS-E), eight auxiliary thrusters and 12 smaller RCS (Reaction Control System) thrusters. The main ESM propulsion system, used for large translational maneuvers, consists of one OMS-E... To qualify the design of the ESM propulsion subsystem (PSS) an all-steel Propulsion Qualification Module (PQM) structure is used to test the propulsion systems on Orion, including “hot firing” of the OMS engine, thrusters, and RCS. The PQM has been developed as a hot-fire test bed to be tested at the NASA White Sands Test Facility (WSTF). One of the objectives of the testing is to assure that the OMS-E can be safely operated with the PQM. Testing will also demonstrate that the PQM can set the proper upstream pressures and temperatures for the OMS-E to operate nominally given the PQM has never been tested in hot-fire operation with OMS-E before. In order to safely conduct the test campaign, hardware such as the engine subassembly, fluid feed lines, valves, electrical power lines, instrumentation, stiff links, installation Ground Support Equipment (GSE), and diffuser [whose objectives are to collect the exhaust of the OMS-E to actively cool down the exhaust gases, reduce thermal exchanges, and create a vacuum at OMS-E level before igniting], had to be analyzed for any hazards and failure modes.

Fault Tolerance↗

Low-cost, Risk-Reduction Testing of Class D Spacecraft Photovoltaic Systems

The end-to-end verification of a spacecraft photovoltaic power generation system requires light! A low-cost, portable, and end-to-end photovoltaic-system test appropriate for NASAs new generation of Class D missions is presented. High risk, low-cost, and quick-turn satellites rarely have the resources to execute the traditional approaches from higher-class (A-C) missions. The Class D approach, as demonstrated on the Lunar Atmospheric and Dust Environment Explorer (LADEE), utilizes a portable, metal-halide, theatre lamp for an end-to-end photovoltaic system test. While not as precise and comprehensive as the traditional Large Area Pulsed Solar Simulator (LAPSS) test, the LADEE method leverages minimal resources into an ongoing assessment program that can be applied through numerous stages of the mission. The project takes a true Class D approach in assessing the technical value of a costly, high-fidelity performance test versus a simpler approach with less programmatic risk. The resources required are a fraction of that for a LAPSS test, and is easy to repeat due to its portability. Further, the test equipment can be handed down to future projects without building an on-site facility.At the vanguard of Class D missions, the LADEE team frequently wrestled with and challenged the status quo. The philosophy of risk avoidance at all cost, typical to Class A-C missions, simply could not be executed. This innovative and simple testing solution is contextualized to NASA Class D programs and a specific risk encountered during development of the LADEE Electrical Power System (EPS). Selection of the appropriate lamp and safety concerns are discussed, with examples of test results. Combined with the vendors panel-level data and periodic inspection, the method ensures system integrity from Integration and Test (IT) through launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of available data.

photovoltaic↗

X-56A Structural Dynamics Ground Testing Overview and Lessons Learned

The X-56A Multi-Utility Technology Testbed (MUTT) is a subscale, fixed-wing aircraft designed for high-risk aeroelastic flight demonstration and research. Structural dynamics ground testing for model validation was especially important for this vehicle because the structural model was directly used in the development of a flight control system with active flutter suppression capabilities. Structural dynamics ground tests of the X-56A MUTT with coupled rigid-body and structural modes provided a unique set of challenges. An overview of the ground vibration test (GVT) and moment of inertia (MOI) test setup and execution is presented. The series of GVTs included the wing by itself attached to a strongback and complete vehicle at two mass conditions: empty and full fuel. Two boundary conditions for the complete-vehicle test were studied: on landing gear and suspended free-free. Pitch MOI tests were performed using a compound pendulum method and repeated with two different pendulum lengths for independent verification. The original soft-support test configuration for the GVT used multiple bungees, resulting in unforeseen coupling interactions between the soft-support bungees and the vehicle structural modes. To resolve this problem, the soft-support test setup underwent multiple iterations. The various GVT configurations and boundary-condition modifications are highlighted and explained. Lessons learned are captured for future consideration when performing structural dynamics testing with similar vehicles.

Chin, Alexander W.↗

Controlled Environmental Effects on Creep Test Data of Woven Fabric Webbings for Inflatable Space Modules

eveloping technologies for proposed lunar and Mars space exploration missions. Enhanced habitation sy g studied as potential habitats due to their inherent low mass and small launch volume. One goal of inflatable module research is quantification of the safe-life and end-of-life creep-strain spectrum. Full-scale pressurized inflatable modules are large, costly, and difficult to experimentally study. Therefore, material subcomponents are often studied as an alternative. An experimental thermally controlled long-term creep study of VectranTM webbings for application to inflatable modules is presented. Vectran fibers have high strength and low creep properties. High strength webbing materials are desirable for the load bearing restraint layer of inflatable modules because they are strong, flexible, and lightweight. Characterization of the creep behavior, safe-life, and end-of- life of webbing specimens will help quantify comparable life properties for inflatable modules. Several experimental multiple-year creep studies of webbing specimens in uncontrolled thermal environments have been conducted at NASA Langley Research Center. Experimental data obtained exhibits the classic creep-strain curve due to load, coupled with unique sinusoidal variation due to variation in temperature and humidity over daily and annual time periods. Results also have indicated that specimens fail within a year if the applied load is greater than 50 percent of the rated load. The primary goal of this study is to eliminate thermal effects from the creep data for a group of webbing specimens, and to allow uncontrolled thermal effects to influence the creep data of a second group of webbing specimens. Comparison of both sets of data will define how temperature influences creep data. A unique creep test facility was fabricated to facilitate the generation and comparison of the two sets of data. The facility consists of five creep test stands with an integrated heating and cooling system, and four creep test stands exposed to external environmental or ambient conditions. The facility contains displacement, temperature, humidity, and load sensors. Test specimens consist of one- inch wide, 48-inch long Vectran webbings rated at 12,500 pounds-per-inch. Experimental thermally controlled creep-strain data has been generated for two groups of webbing specimens. Applied load for all test stands was above 9000 lbs and greater than 50 percent of the rated load. Temperatures varied between 58˚F and 83˚F for the four test stands exposed to ambient conditions. Associated creep data exhibited the classic creep- strain profiles. The temperature was set to 72˚F for the five test stands in the controlled temperature environment. Creep data for tests with temperature control also exhibited the classic strain profiles. Data indicated that if the load is greater n thermal effects do not manifest. Therefore, creep tests with loads less than 50 percent of the rated load are planned for in the near future.

Kenner, Winfred S.↗

Reconstruction of the Advanced Supersonic Parachute Inflation Research Experiment Sounding Rocket Flight Tests with Strengthened Disk-Gap-Band Parachute

The Advanced Supersonic Parachute Inflation Research and Experiments project is a flight test program for development of supersonic parachutes for future use at Mars. The flight tests are a risk-reduction program for the Mars 2020 mission. The flight tests involve two Disk-Gap- Band parachute designs to be tested at relevant Mach number and dynamic pressure regimes for the Mars 2020 entry capsule. The first of these parachutes is a built-to-print design that was successfully employed by the Mars Science Laboratory lander at Mars in August 2012, and the second is a design that is strengthened in material properties and construction methods but has the same geometry as that used by Mars Science Laboratory. The first flight test of the built-to-print parachute took place on October 4, 2017 at NASA's Wallops Flight Facility. The parachute test was successful. The second and third flight tests took place on March 31st and September 7th 2018, respectively, and successfully tested the strengthened parachute design. This paper describes the instrumentation, data analysis techniques, and atmospheric and trajectory reconstruction results from the second and third flight tests.

Karlgaard, Christopher D.↗

Structural Analysis of Test Flight Vehicles with Multifunctional Energy Storage

Under the NASA Aeronautics Research Mission Directorate (ARMD) Convergent Aeronautical Solutions (CAS) project, NASA Glenn Research Center has been leading Multifunctional Structures for High Energy Lightweight Load-bearing Storage (M-SHELLS) research efforts. The technology of integrating load-carrying structures with electrical energy storage capacity has the potential to reduce the overall weight of future electric aircraft. The proposed project goals were to develop M-SHELLS in the form of honeycomb coupons and subcomponents, integrate them into the structure, and conduct low-risk flight tests onboard a remotely piloted small aircraft. Experimental M-SHELLS energy-storing coupons were fabricated and tested in the laboratory for their electrical and mechanical properties. In this paper, finite element model development and structural analyses of two small test aircraft candidates are presented. The finite element analysis of the initial two-spar wing is described for strain, deflection, and weight estimation. After a test aircraft Tempest was acquired, a load- deflection test of the wing was conducted. A finite element model of the Tempest was then developed based on the test aircraft dimensions and construction detail. The component weight analysis from the finite element model and test measurements were correlated. Structural analysis results with multifunctional energy storage panels in the fuselage of the test vehicle are presented. Although the flight test was cancelled because of programmatic reasons and time constraints, the structural analysis results indicate that the mid-fuselage floor composite panel could provide structural integrity with minimal weight penalty while supplying electrical energy. To explore potential future applications of the multifunctional structure, analyses of the NASA X-57 Maxwell electric aircraft and a NASA N+3 Technology Conventional Configuration (N3CC) fuselage are presented. Secondary aluminum structure in the fuselage sub-floor and cargo area were partially replaced with reinforced five-layer composite panels with M-SHELLS honeycomb core. The N3CC fuselage weight reduction associated with each design without risking structural integrity are described. The structural analysis and weight estimation with the application of composite M-SHELLS panels to the N3CC fuselage indicate a 3.2% reduction in the fuselage structural weight, prior to accounting for the additional weight of core material required to complete the energy storage functionality.

Mukhopadhyay, Vivek↗

TCL4 UTM (UAS Traffic Management) Nevada 2019 Flight Tests, Airspace Operations Laboratory (AOL) Report

The Unmanned Aircraft Systems (UAS) Traffic Management (UTM) research project has been developing and testing concept ideas for enabling small UAS (sUAS) operations in low altitude airspace (ground to 400 feet). To do this, NASA has organized a series of flight test demonstrations. Technology Capability Level-4 (TCL4) flight tests were conducted at a Nevada, USA test site, during June 2019. The testing resulted in over 300 data collection flights using eight live rotorcraft, 15 simulated vehicles, involving six flight crews and five Unmanned Aerial System (UAS) Service Suppliers (USS). The TCL4 approach was designed to demonstrate five scenarios that set up five diverse sets of UAS events and activities. The Nevada test site focused on three of these scenarios: an incoming weather front, a concert event with an incident requiring an emergency response, and a scenario where multiple vehicles experienced Communication, Navigation, and Surveillance (CNS) issues. The test site created their scenarios to each have three phases and were required to complete three executions of each scenario, for a total of nine missions per Nevada vehicle per scenario. This document presents data collected from participants during the TCL4-Nevada flight test that provides information about how much and how well operators were able to make use of UTM functions and information, with the goal of exploring what the minimum information requirements and/or best practices might be in TCL4 operations. The driving enquiry was: how do UTM tools and features support (human) operators leading to safe and effective conduct of large-scale beyond visual line of sight (BVLOS) sUAS operations in “urban canyon” environments? As with the data collected during previous similar tests (e.g., TCL3, Martin et al., 2019), the quality of the UTM information exchanged, and the meaningfulness and therefore usefulness of this information, were all focal points of the questions asked and the data collected. Data aligned with five human-system attributes to indicate that UTM provided information that contributed to users’ ability to operate safely and effectively within UTM, but that information was not always complete and was sometimes unclear.

UTM↗

SLS Integrated Modal Test Uncertainty Quantification using the Hybrid Parametric Variation Method

Uncertainty in structural loading during launch is a significant concern in the development of spacecraft and launch vehicles. Small variations in launch vehicle and payload mode shapes and their interaction can result in significant variation in system loads. In many cases involving large aerospace systems it is difficult, not economical, or impossible to perform a system modal test. However, it is still vital to obtain test results that can be compared with analytical predictions to validate models. Instead, the “Building Block Approach” is used in which system components are tested individually. Component models are correlated and updated to agree as best they can with test results. The Space Launch System consists of a number of components that are assembled into a launch vehicle. Finite element models of the components are developed, reduced to Hurty/Craig-Bampton models and assembled to represent different phases of flight. The only opportunity to obtain modal test data from an assembled Space Launch System will be during the Integrated Modal Test. There is always uncertainty in every model, which flows into uncertainty in predicted system results. Uncertainty Quantification is used to determine statistical bounds on prediction accuracy based on model uncertainty. For the Space Launch System, model uncertainty is at the Hurty/Craig-Bampton component level. Uncertainty in the Hurty/Craig-Bampton components is quantified using the hybrid parametric variation approach that combines parametric and nonparametric uncertainty. Uncertainty in model form is one of the biggest contributors to uncertainty in complex built-up structures. This type of uncertainty cannot be represented by variations infinite element model input parameters and thus cannot be included in a parametric approach. However, model-form uncertainty can be modeled using a nonparametric approach based on random matrix theory. The hybrid parametric variation method requires the selection of dispersion values for the Hurty/Craig-Bampton fixed-interface eigenvalues, and the Hurty/Craig-Bampton stiffness matrices. Component test/analysis frequency error is used to identify the fixed-interface eigenvalue dispersions, while test/analysis cross-orthogonality is used to identify stiffness dispersion values. The hybrid parametric variation uncertainty quantification approach is applied to the Space Launch System Integrated Modal Test configuration. Monte Carlo analysis is performed, and statistics are determined for modal correlation metrics, frequency response from Integrated Modal Test shakers to selected accelerometers, as well as other metrics for determining how well target modes are excited and identified. If the predicted uncertainty envelopes future Integrated Modal Test results, then there will be increased confidence in the utility of the component-based hybrid parametric variation uncertainty quantification approach.

Uncertainty Quantification↗

Performance test results of a skutterudite-based unicouple with a metallic coating

A performance test of a Skutterudite-based unicouple (MAY-04) with a metallic coating to suppress the sublimation of antimony from the legs near the hot junction is performed in vacuum (~ 9 x10-7 torr) for ~ 2,000 hours at hot and cold junction temperatures of 892.1 + 11.9 K and 316.1 + 5.5 K, respectively. The p-leg is made of CeFe3.5Co0.5Sb12 and the n-leg is made of CoSb3. Presented are the measured voltage-current characteristics, electrical power, open-circuit voltage, and Seebeck coefficients of the legs as functions of cumulative test time. Also presented is the estimate of the conversion efficiency, shortly (~ 96 hrs) after the start of test. To demonstrate the effectiveness of the metallic coating, the measurements for MAY-04 are compared with those of two uncoated unicouples of the same leg materials (MAR-03 and JUN-03), which had been tested earlier. The cross-sectional areas of the legs in MAY-04 are larger than those in MAR-03 and JUN-03, tested in argon cover gas at ~ 0.051-0.068 MPa for 450 and 1200 hours, respectively. The open circuit voltage, Voc (204 mV) of MAY-04 at Beginning-Of-Test (BOT) is almost the same as that of MAR-03, but higher than that of JUN-03 (~180 mV). Although the argon gas effectively decreased antimony loss from legs of MAR-03 and JUN-03, marked degradations in performance occurred with time in these tests. Conversely, the metallic coating in MAY-04 effectively reduced the performance degradation with cumulative test time. The estimated peak efficiency of MAY-04, shortly after BOT (10.65%) is only ~ 0.37 percentage point lower than the theoretical value, assuming zero side heat losses and zero contact resistance per leg. The peak power of MAY- 04 decreased by only ~12%, from its BOT value of ~1.6 We to ~ 1.4 We after ~ 2,000 of cumulative testing

Caillat, Thierry↗

Environmental Testing of the HERMeS TDU-2 Hall Thruster

The Hall Effect Rocket with Magnetic Shielding (HERMeS) is a 12.5 kW magnetically shielded Hall thruster presently under development for deep-space missions. A development model HERMeS thruster, TDU-2, with borosilicate channel walls, has successfully undergone proto-qualification testing including random vibration and thermal-vacuum, demonstrating the thruster can survive critical launch and operational environmental requirements. The three-axis random vibrational tests were performed with the thruster body mounted directly to the shaker table using a modified loading schedule to compensate for the vibration isolation dampers under design for the flight thruster. Initial random vibration testing revealed issues with fragmentation of magnetic coil potting material and thruster spool mount fabrication weaknesses that were addressed with an alternate potting material and fabrication revisions that were then successfully retested with an additional round of random vibration tests. Thermal-vacuum testing involved three cycles of full-power 600 V 12.5 kW thruster operation from -121°C to +373°C which included eight hours at peak temperature as well as a hot restart. A thermal model of the test configuration was developed and validated with the experiment results within an average difference of 5°C. Before and after the random vibrational and thermal-vacuum tests, the thruster performance, plasma plume, thrust vector angle, discharge characteristics, and magnetic field profile were measured. The thruster performance, magnetic field, and most other parameters remained invariant throughout the environmental testing campaign. During the thermal testing, an increase in the discharge oscillation amplitude of 11% was observed as well as subtle thrust vector changes of ±0.2° as the thruster warmed from -121°C to +373°C.

Sorenson, Ryan↗

T0TEM - T0 Test Evaluation Module Development and Verification

Transition temperature testing of ferritic steels evaluates the ductile to brittle transition temperature, where the behavior of the steel changes from controlled ductile tearing to uncontrollable brittle fracture. This testing is governed by ASTM (American Society of Testing and Materials) E1921 standard. The calculations and plots required by this standard are iterative in nature and require significant effort to produce by standard hand calculations. In addition to analysis of a complete data set, intermediate analysis during testing is beneficial to determine optimal test temperatures. Given the exhaustive nature of calculating the transition temperature, being able to quickly update target temperatures is a significant benefit to not only the quality of tests, but the number of required tests as well. T0 Test Evaluation Module (T0TEM) v1.5 is a software application created under the Layered Pressure Vessel (LPV) certification effort. To reduce the analysis time of transition temperature test data sets producedfor this effort, T0TEM was created to calculate the E1921 Master Curve along with all required data and validity checks. By creating this program, hundreds of hours of analysis time were saved. In addition, the creation of a standard program provided a significant improvement in the consistency with which results were reported. T0TEM also calculates the results and plots required for the E1921 inhomogeneity annex to determine whether a material behaves in a homogenous manner. This program was created by Levi Shelton and Cameron Bosley at NASA, with input and review from the E1921 committee. The results generated by T0TEM were compared to the validation data sets provided by ASTM with good concurrence. ASTM committee members have reviewed and applied T0TEM to other data sets with satisfactory results. T0TEM was originally released to the NASA Software Repository and publicly via SourceForge in May of 2020. Version 1.5 was released in April of 2021 with minor functionality updates and additional statistical analysis methods.

Levi Shelton↗

Proof Testing Aluminum and Titanium Thin-Walled Tubes for Aerospace Applications

Proof testing aerospace components aids in verifying the structural integrity of flight hardware. This process is often an important step in the certification process for critical parts. Though proof testing is a common practice at NASA and in industry, there is often a need to understand better the effectiveness of proof testing pressure systems discovering cracklike flaws or defects. Often proof tests are used in requirements and in practice as technical rationale for screening critical defects in a part in lieu of performing a non-destructive inspection. The intent of this work is to define proof test failure envelopes for thin-walled tubes composed of two materials: aluminum and titanium. Both materials are common in aerospace thin-walled tubing applications which is why these were the materials chosen for this study. The fracture mechanics software NASGRO was used to perform a parametric study on the effect of defects in thin-walled tubes subjected to proof testing. For both materials, the parameters varied in the NASGRO analyses were aspect ratio, proof test pressure, thickness, diameter, and flaw multiplier. With each case defined as a through crack or failure, the results were then pulled into MATLAB in order to parse through the data and produce failure envelope plots. Failure envelopes were created by meshing a surface in between the minimum proof pressure failing data points. As expected, based on material properties, the plots indicated the aluminum material would fail at much lower proof tests than the titanium. The parametric data and failure envelopes may be used as general qualitative insight on the effectiveness of proof testing thin-walled tubes of similar alloys.

Leah B Davis↗

Initial Testing the Exploration Extravehicular Mobility Unit (xEMU) in Lunar Environment Simulation at the Neutral Buoyancy Lab (NBL) in 2022

Understanding how to effectively train for Extravehicular Activities (EVAs) for Artemis missions is critical. Tasked by the new Extravehicular Activity and Human Surface Mobility Program(EHP), a team of stakeholders from engineering and flight operations worked together to test the Exploration Extravehicular Mobility (xEMU) in the Neutral Buoyancy Lab(NBL) simulating the lunar environment. The NBL is a pool in which astronauts are typically trained to complete simulated International Space Station (ISS) EVA tasks in a neutral weigh-out. The overall focus for this test series was evaluating how well the NBL could be used as an effective simulated environment for Artemis lunar EVAs. New NBL support hardware was manufactured to support this test series and update the interfaces to be more representative of xEMU hardware such as a new NBL Portable Life Support System(PLSS)mock-up and umbilical, lights and cameras, and display and control unit (DCU).To simulate the 1/6th-gravity (1/6-g) environment, extra weights were added around the suit to create an accurate center of gravity representation. The Partial Gravity Weigh-out Stand (PGWS) predicted where and how much weight would be required for the 1/6th-G simulation and predicted the center of gravity placement. After the weigh-out attempt was completed, the suited participant would complete a set of directed tasks such as kneeling, object pick-up, and walking to evaluate the weigh-out. To create the lunar environment, sand, boulders, and ramps were added to the pool floor. If time allowed after weigh-out was determined acceptable, the flight operations team would direct the suited participants to complete simulated Artemis EVA tasks using flight-like tools and tool cart. The team also evaluated turning out the overhead lights in the NBL for a portion of some of the test runs and using a solar simulator to create amore realistic lunar south pole lighting environment. The test series completed one unmanned test and nine manned tests. With four of the tests, dual xEMU suited operations were completed with subjects in both the small and large xEMU sizes. Overall, the NBL was able to create an acceptable lunar landscape and ability to have two subjects work side by side in pressurized xEMUs which currently cannot be achieved in other test environments. Achieving a stable 1/6th-G lunar weigh-out and clear, consistent dual suit communications was a challenge for this series. Future work is planned to continue to improve this simulation environment.

spacesuit↗

Verification Testing and Veg-05 Tomato Crop Production on the International Space Station

Production of fresh, nutritious, and tasty produce for astronauts during spaceflight may provide health-promoting, bioavailable nutrients and enhance the dietary experience as we move into longer-duration missions. Growing and caring for plants may also reduce the psychological stresses associated with spaceflight and enhance connections to Earth. Requirements to consistently grow a diversity of crops under spaceflight environmental conditions remain poorly defined. The VEG-05 experiment is part of a series of experiments with pick-and-eat salad crops to better define best practices for crop production and handling in space. VEG-05 and predecessor experiments VEG-04A and VEG-04B, use the Veggie vegetable production facilities on the International Space Station to grow salad crops under different spectral compositions. In VEG-04A and B, mizuna mustard was cultivated with two different red: blue light treatments, and in VEG-05 we are cultivating ‘Red Robin’ dwarf cherry tomatoes under the same light spectra. Light can impact the growth habit, yield, nutritional composition, microbial levels, and even flavor attributes within crops, and our team will assess these characteristics for this crop during VEG-05. Prior to launch and installation on ISS in late 2022, both a science verification test (SVT), and an experiment verification test (EVT) were conducted at Kennedy Space Center in ISS Environment Simulator Chambers. Science verification testing, and a previous fertilizer test, grew plants in both plant pillows and PONDS (Passive Orbital Nutrient Delivery System) units and tested two different fertilizer treatments in both sets of hardware, with each test under only one of the light conditions. Because of challenges validating the PONDS hardware on ISS, and with good crop production in plant pillows, the EVT moved forward using only plant pillows with the highest fertilizer composition tested during SVT, and two Veggie units were utilized. One Veggie had light settings consisting of equal levels of red: blue light (150 µmol/m2/s for each color) plus green light (30 µmol/m2/s) while the second Veggie had a 90:10 ratio of red: blue light (270 µmol/m2/s red and 30 µmol/m2/s blue) plus green, so each unit provided 330 µmol/m2/s of photosynthetically active radiation to the tomato crops on average. Our original plan, based on prior ground testing, was to grow the crop for 104 days and harvest at 80, 90 and 104 days after initiation. For SVT, under the equal red: blue light treatment, fruit ripening in plant pillows was delayed and fruit were not ripe by day 80, so actual harvest days were days 90, 97, and 104. For EVT we saw fruit ripening earlier, especially in the high red treatment, and so we harvested at days 83, 90, and 99 days after initiation. In SVT we had mostly daily watering, and this led to excess water in plant pillows, which leaked out. This excess water also caused fungus to grow on one leaf and a couple of plant stems. To reduce this excess moisture, we throttled back the watering for EVT, and used the root mat reservoir more frequently. This led to watering only every other day, reducing crew time needed for plant care, however, two wilting events occurred during this EVT, at days 51 and 75. Plants recovered from these wilting events, but these events may have influenced the rate of fruit ripening and flower formation. Regardless, more than 10 fruit were produced from each plant on average, with the high red treatment producing slightly heavier fruit. Microbial testing from fruit during SVT indicated that fruit were safe for consumption with microbial levels below detection limits. VEG-05 flight and ground operations are expected to run between December 2022 and March 2023. This research was co-funded by the Human Research Program and Space Biology (MTL#1075) in the ILSRA 2015 NRA call.

Gioia D. Massa↗

Flight Environment HEPA Filter Testing for Lunar Dust Removal Capability

Lunar dust is an abrasive regolith that can cause critical damage to hardware and crew. Its morphology and chemical makeup differs from typical earth dust due to space weathering effects. Current space missions require extensive air filtration of lunar dust to ensure mission success; as such filtration testing is paramount in verifying the dust-removal capabilities of the system. Previous testing at NASA GRC consisted of two stages: testing a flat high efficiency particulate air (HEPA) media sheet at various pressure ranges (Stage 1) and testing a pleated HEPA filter at different humidity and dust levels (Stage 2). This testing was done to buy-down risk when testing the flight-qualification HEPA filter for the proposed Stage 3 test. Stage 3 testing used a flight-ready HEPA filter to measure its performance characteristics to verify programmatic requirements. This included measuring lunar dust loading versus pressure drop performance and establishing a maximum capacity based on the allowable pressure drop, determining the HEPA filter efficiency utilizing two separate methodologies, and assessing if the lunar dust caused the HEPA filter to experience any damage. Additionally, dust removal from the HEPA filter was performed using a vacuum to ascertain if the filter life can be prolonged. These test results will aid the program in verifying programmatic requirements and ensuring risk buydown before this HEPA filter takes flight.

HEPA↗

Thermal Vacuum and Vibration Testing of the Differential Thermal Expansion Thermal Switch

The Extended Stroke, Reverse Operation, Differential Thermal Expansion (DTE) Thermal Switch (TS) for Extreme Variable Environments uses materials with both positive and negative coefficients of thermal expansion (CTE) arranged in concentric cylinders so that the TS operates passively, opening a gap between interfaces to create a low thermal contact when cold, and closing the gap between interfaces to create a high thermal contact when hot. This paper details the testing of the TS at Marshall Space Flight Center (MSFC) including the vibration (vibe) test, pre-vibe thermal vacuum (t-vac) cycle test, post-vibe t-vac cycle test, and long duration t-vac cycle test. The data collected from the pre- and post-vibe tests are compared to show the impact of the vibe test on performance. The data collected from the long duration test is used to calculate the total thermal contact conductance through the TS interfaces for both ‘on’ (TS closed, during hot plateau) and ‘off’ (TS open, during cold plateau) configurations, and the turndown ratio is also calculated. Challenges experienced throughout testing are also discussed.

Thermal control technology↗

Inflatable Softgoods Testing Capability Development for Habitation

The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. The office is responsible for formulation activities for Lunar Surface Habitat and Mars Transit Habitat. HP40 also manages commercial partnerships for exploration habitat development. The Lunar Surface Habitat is intended to initially support a minimum of two crew on the lunar surface for an approximately 30-day mission, with the ability to accommodate four crew for short durations. The Mars Transit Habitat will transport four crew to and from Mars orbit on a potentially 1,200 day mission. Both concepts are envisioned to leverage inflatable softgoods as the primary structural material for the habitation portion of the architecture. Inflatable softgoods are a complex, multi-material system consisting of multiple layers which perform specific functions. A bladder layer (polymer) contains the habitat’s atmosphere. The bladder is indexed to a woven restraint layer, usually Kevlar or Vectran, which serves as the structural layer. The remaining outer layers are for micro-meteoroid orbital debris (MMOD) shielding, protection from atomic Oxygen (if the material system is to be deployed in low earth orbit), and thermal insulation. The primary advantage of inflatable softgoods is that they can offer a larger volume per unit mass relative to a rigid metal structure. Inflatable softgoods have a strong development heritage within NASA, beginning with work in the 1960s in partnership with Goodyear Aerospace and continuing with Johnson Space Center’s TransHab project in the 1990s . Some development efforts subsequently transitioned into the private sector to mature the material technology for flight applications, including human habitation. In August 2022, NASA published its guidelines for certification of crewed inflatable softgoods structures (JSC-67721). This document outlines a series of tests which will be needed to certify inflatable softgoods material systems for use in crewed mission applications. It includes burst testing at the subscale and full-scale to determine the ultimate burst pressure of the softgoods architecture. Creep (long term deformation of the material under stress) is a key failure mode which must be characterized. Creep testing at the component and module levels is also recommended to generate time to failure curves and verify that the inflatable system has a predicted operational life which exceeds mission parameters. ET (Test Engineering) at MSFC and HP40 have worked together to establish softgoods testing capabilities for the center. This includes the ability to conduct module level burst tests and creep tests. The poster will highlight these capabilities and provide examples of testing which has been performed to date by ET. NASA MSFC anticipates that these test capabilities will continue to offer critical support for companies pursuing inflatable softgoods for exploration applications (lunar surface habitation, Mars transit) as well as commercial low earth orbit platforms.

habitation↗