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Participating Center(s): ARC, GRC, GSFC, JPL, JSC, KSC, LaRC, MSFC



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Participating Center(s): ARC, GRC, GSFC, JPL, JSC, KSC, LaRC, MSFC

Related Subtopic Pointers: A1.01, Z11.02
Technologies sought under this SBIR program can be defined as advanced sensors, sensor systems, sensor techniques or software that enhance or expand NASA’s current senor capability. It desirable but not necessary to target structural components of space flight hardware. Examples of space flight hardware will include light weight structural materials including composites and thin metals. Technologies sought include modular, smart, advanced Nondestructive Evaluation (NDE) sensor systems and associated capture and analysis software. It is advantageous for techniques to include the development on quantum, meta- and nano sensor technologies for deployment. Technologies enabling the ability to perform inspections on large complex structures will be encouraged. Technologies should provide reliable assessments of the location and extent of damage. Methods are desired to perform inspections in areas with difficult access in pressurized habitable compartments and external environments for flight hardware. Many applications require the ability to see through assembled conductive and/or thermal insulating materials without contacting the surface. Techniques that can dynamically and accurately determine position and orientation of the NDE sensor are needed to automatically register NDE results to precise locations on the structure. Advanced processing and displays are needed to reduce the complexity of operations for astronaut crews who need to make important assessments quickly. NDE inspection sensors are needed for potential use on free-flying inspection platforms. Integration of wireless systems with NDE may be of significant utility. It is strongly encouraged to provide explanation of how proposed techniques and sensors will be applied to a complex structure. Examples of structural components include but are not limited to multi-wall pressure vessels, batteries, tile, thermal blankets, micrometeoroid shielding, International Space Station (ISS) Radiators or aerospace structural components.
Phase I Deliverables - Lab prototype, feasibility study or software package including applicable data or observation of a measurable phenomenon on which the prototype will be built. Inclusion of a proposed approach to develop a given methodology to Technology Readiness Level (TRL) of 2-4. All Phase I’s will include minimum of short description for Phase II prototype. It will be highly favorable to include description of how the Phase II prototype or methodology will be applied to structures.
Phase II Deliverables - Working prototype or software of proposed product, along with full report of development and test results. Prototype or software of proposed product should be of Technology Readiness Level (TRL 5-6). Proposal should include plan of how to apply prototype or software on applicable structure or material system. Opportunities and plans should also be identified and summarized for potential commercialization.
For proposers interested in the simulation and analysis of NDE data, please see Subtopic Z11.02 - NDE Simulation and Analysis.
For proposers with an interest in airframes, please see Subtopic A1.01 - Structural Efficiency - Tailored Airframes and Structures.

 

Z11.02 NDE Simulation and Analysis



Lead Center: LaRC

Participating Center(s): ARC, JSC

Related Subtopic Pointers: Z11.01
Technologies sought under this subtopic include near real-time large scale nondestructive evaluation (NDE) and structural health monitoring (SHM) simulations and automated data reduction/analysis methods for large data sets. Simulations techniques will seek to expand NASA’s use of physics based models to predict inspection coverage for complex aerospace components and structures.  Analysis techniques should include optimized automated reduction of NDE/SHM data for enhanced interpretation appropriate for detection/characterization of critical flaws in space flight structures and components. Space flight structures will include light weight structural materials such as composites and thin metals. Future purposes will include application to long duration space vehicles, as well as validation of SHM systems. It is also considered highly desirable to develop tools for automating detection of material Foreign Object Debris (FOD) and/or defects and evaluation of bondline and in-depth integrity for light-weight rigid and/or flexible ablative materials are sought. Typical internal void volume detection requirements for ablative materials are on the order of less than 6mm and bondline defect detection requirements are less than 25mm.
Techniques sought include advanced material-energy interaction (i.e., NDE) simulations for high-strength lightweight material systems and include energy interaction with realistic damage types in complex 3D component geometries (such as bonded/built-up structures).  Primary material systems can include metals but it is highly desirable to target composite structures and/or thermal protection systems.  NDE/SHM techniques for simulation can include ultrasonic, laser, Micro-wave, Terahertz, Infra-red, X-ray, X-ray Computed Tomography, Fiber Optic, backscatter X-Ray and eddy current. It is assumed that any data analysis methods will be focused on NDE techniques with high resolution high volume data.  Modeling efforts should be physics based and it is desired they can account for material aging characteristics and induced damage, such as micrometeoroid impact.  Examples of damage states of interest include delamination, microcracking, porosity, fiber breakage.  Techniques sought for data reduction/interpretation will yield automated and accurate results to improve quantitative data interpretation to reduce large amounts of NDE/SHM data into a meaningful characterization of the structure.  Realistic computational methods for validating SHM systems are also desirable.  It is advantageous to use co-processor configurations for simulation and data reduction. Co-Processor configurations can include graphics processing units (GPU), system on a chip (SOC), field-programmable gate array (FPGA) and Intel’s Many Integrated Core (MIC) Architecture.  Combined simulation and data reduction/interpretation techniques should demonstrate ability to guide the development of optimized NDE/SHM techniques, lead to improved inspection coverage predictions, and yield quantitative data interpretation for damage characterization.
Phase I Deliverables - Feasibility study, including demonstration simulations and data interpretation algorithms, proving the proposed approach to develop a given product (TRL 2-4).  Plan for Phase II including proposed verification methods.
Phase II Deliverables - Software of proposed product, along with full report of development and test results, including verification methods (TRL 5-6). Opportunities and plans should also be identified and summarized for potential commercialization.
Potential NASA Customers include:


  • Space exploration missions such as missions to Asteroids, Mars or various Earth-Moon Liberation Waypoints.

  • International Space Station.


For proposers with an interest in the sensors used in NDE, please see Subtopic Z11.01 - NDE Sensors.

 
Focus Area 16: Ground and Launch Processing



Participating MD(s): HEOMD
Ground processing technology development prepares the agency to test, process and launch the next generation of rockets and spacecraft in support of NASA’s exploration objectives by developing the necessary ground systems, infrastructure and operational approaches.
This focus area seeks innovative concepts and solutions for both addressing long-term ground processing and test complex operational challenges and driving down the cost of government and commercial access to space. Technology infusion and optimization of existing and future operational programs, while concurrently maintaining continued operations, are paramount for cost effectiveness, safety assurance, and supportability.
A key aspect of NASA’s approach to long term sustainability and affordability is to make test, processing and launch infrastructure available to commercial and other government entities, thereby distributing the fixed cost burden among multiple users and reducing the cost of access to space for the United States. Unlike previous work focusing on a single kind of launch vehicle such as the Saturn V rocket or the Space Shuttle, NASA is preparing common infrastructure to support several different kinds of spacecraft and rockets that are in development. Products and systems devised at a NASA center could be used at other launch sites on earth and eventually on other planets or moons.
H10.01 Advanced Propulsion Systems Ground Test Technology

Lead Center: SSC

Participating Center(s): KSC
Rocket propulsion development is enabled by rigorous ground testing to mitigate the propulsion system risks that are inherent in spaceflight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth.  It involves a combination of component-level and engine-level testing to demonstrate the propulsion devices were designed to meet the specified requirements for a specified operational envelope and over robust margins and shown to be sufficiently reliable, prior to its first flight.
This topic area seeks to develop advanced ground test technology components and system level ground test systems that enhance Chemical and Advanced Propulsion technology development and certification. The goal is to advanced propulsion ground test technologies to enhance environment simulation, minimize test program time, cost and risk and meet existing environmental and safety regulations.  It is focused on near-term products that augment and enhance proven, state-of-the-art propulsion test facilities. This project is especially interested in ground test and launch environment technologies with potential to substantially reduce the costs and improve safety/reliability of NASA's test and launch operations.  
In particular, technology needs include producing large quantities of hot hydrogen, and developing robust materials, advanced instruments and monitoring systems capable of operating in extreme temperature and harsh environments. 
This subtopic seeks innovative technologies in the following areas:


  • Efficient generation of high temperature (>2500°R), high flowrate (<60 lb/sec) hydrogen

  • Devices for measurement of pressure, temperature, strain and radiation in a high temperature and/or harsh environment.

  • Development of innovative rocket test facility components (e.g., valves, flowmeters, actuators, tanks, etc.) for ultra-high pressure (>8000 psi), high flow rate (>100 lbm/sec) and cryogenic environments.

  • Robust and reliable component designs which are oxygen compatible and can operate efficiency in high vibro-acoustic, environments.

  • Advanced materials to resist high-temperature (<4400°F), hydrogen embrittlement and harsh environments. 

  • Tools using computational methods to accurately model and predict system performance are required that integrate simple interfaces with detailed design and/or analysis software. SSC is interested in improving capabilities and methods to accurately predict and model the transient fluid structure interaction between cryogenic fluids and immersed components to predict the dynamic loads, frequency response of facilities. 

  • Improved capabilities to predict and model the behavior of components (valves, check valves, chokes, etc.) during the facility design process are needed. This capability is required for modeling components in high pressure (to 12,000 psi), with flow rates up to several thousand lb/sec, in cryogenic environments and must address two-phase flows. Challenges include: accurate, efficient, thermodynamic state models; cavitation models for propellant tanks, valve flows, and run lines; reduction in solution time; improved stability; acoustic interactions; fluid-structure interactions in internal flows.

For all above technologies, research should be conducted to demonstrate technical feasibility during Phase I and show a path towards Phase II hardware/software demonstration with delivery of a demonstration unit or software package for NASA testing at the completion of the Phase II contract.


H10.02 Improved Operations via Interface Design

Lead Center: KSC

Participating Center(s): AFRC, SSC
This subtopic seeks to simplify prelaunch and surface operations through improved interface design concepts.  Development and adoption of improved, standardized interfaces holds the potential of reducing the cost and complexity of future space systems and their related design and implementation, which can increase the funding available for additional flight hardware.
NASA is interested in areas of interface technology that lower launch vehicle operations costs and provide evolution paths for in-space exploration.  This includes interfaces between systems normally present within a launch system.  For the purpose of this subtopic a launch system includes a vehicle ready for flight with payload, and includes all related support systems and infrastructure.
A substantial portion of pre-launch processing involves the integration of spacecraft assemblies to each other or to the ground/surface systems that supply the commodities, power or data. Each assembly requires a reliable interface that connects it to the adjacent hardware which includes flight critical seals or connectors and other components.
The benefits of standardized, simplified interfaces are particularly strong for small launch vehicles.  Due to a lack of common specifications and standards, each launch vehicle system may impose different interface requirements thereby resulting in unique components/subsystems tailored for each vehicle.  This complicates recent efforts to establish a multi-user capability within the existing launch infrastructure.  For the launch provider, unique interface requirements result in higher recurring cost per launch vehicle and reduced ability to incorporate newer subsystems as the vehicle matures.
Future activities at exploration destinations in space and on other surfaces will rely on a combination of structures and systems working together with a high degree of reliability.  The impact of these interface-dependent tasks are of particular concern for surface systems where the additional work must be accomplished by crew performing Extra-Vehicular Activities (EVAs) or by purpose-built robotic systems. Areas of interface technology development relevant for surface operations may include (but are not limited to) cryogenics, modular systems, dust tolerance, standardized disconnects, and embedded intelligence.
For all above technologies, research should be conducted to demonstrate technical feasibility during Phase I and show a path toward Phase II demonstration, and delivering a demonstration package for NASA testing in operational or analog test environments at the completion of the Phase II contract.
Phase I Deliverables - Research to identify and evaluate candidate technology applications, demonstrate the technical feasibility, and show a path towards a demonstration. Concept methodology should include the path for adaptation of the technology, infusion strategies (including risk trades), and business model.  Identify improvements over the current state of the art for both operations and systems development and the feasibility of the approach in a multi-customer environment. Bench or lab-level demonstrations are desirable.
Phase II Deliverables - Emphasis should be placed on developing and demonstrating the technology under simulated operational conditions with analog earth-based systems including dynamic events such as commodity loading, disconnect or engine testing. The proposal shall outline a path showing how the technology could be developed into or applied to mission-worthy systems. The contract should deliver demonstration hardware for functional and environmental testing at the completion of the Phase II contract. The technology concept at the end of Phase II should be at a TRL of 5 or higher.
H10.03 Cryogenic Purge Gas Recovery and Reclamation

Lead Center: SSC

Participating Center(s): GRC, KSC
Helium is becoming a major issue for NASA and the country. Helium is used as a purge gas to reduce the concentration of hydrogen below the flammable threshold at test and launch complexes. Most of the Nation's helium comes from the National Helium Reserve operated by the Bureau of Land Management (BLM). The statutory authority for BLM to operate is expiring and responsibility is being transferred to the commercial sector. Helium is a non-renewable gas that is in limited supply. There are already helium supply constrictions and prices are going up. Conservation and/or reuse of this non-renewable resource would substantially reduce the cost of operating NASA's test and launch facilities.
Specific areas of interest include the following technologies:


  • Development of non-proton exchange helium/hydrogen gas separation technologies.

  • Technologies for the rapid capture and safe storage of high volumes of mixed helium/hydrogen gas mixtures.

  • Development of zero trapped gas system technologies to improve purge effectiveness.

  • Development of sensor technologies that can validate that recycled gases meet stringent cleanliness levels of Table 2 of MSFC-STD-3535. 

Focus Area 17: Thermal Management Systems



Participating MD(s): SMD, STMD
All spacecraft, regardless of size or power consumption, must be able to manage the flow of heat and energy. Temperatures must be maintained within design limits, whether those be cryogenic systems for science instruments, or comfortable shirt sleeve operations temperatures for crew missions. NASA seeks components for both active and passive thermal systems that collect heat, transport heat, and reject heat, or insulate components to prevent the flow of heat. These components may be designed to operate in challenging temperature ranges, and must survive mission environments such as launch, space vacuum, or planetary surfaces. They also must be highly efficient and lightweight to minimize use of launch mass and power allocations.
S3.06 Thermal Control Systems

Lead Center: GSFC

Participating Center(s): ARC, JPL, JSC, LaRC, MSFC
Future Spacecraft and instruments for NASA's Science Mission Directorate will require increasingly sophisticated thermal control technology.  Innovative proposals for the cross-cutting thermal control discipline are sought in the following areas:


  • Advanced thermal devices capable of maintaining components within their specified temperature ranges are needed for future advanced spacecraft. Some examples are:

    • Phase change systems with high thermal capacity and minimal structural mass.

    • High performance, low cost insulation systems for diverse environments.

    • High flux heat acquisition and transport devices.

    • Thermal coatings with low absorptance, high emittance, and good electrical conductivity.

    • Radiator heat rejection turndown devices (e.g., mini heat switches, mini louvers).

    • Miniature pumped fluid loop systems with passive valve for radiator heat rejection turndown, and consumes minimal power.

  • Current capillary heat transfer devices require tedious processes to insert the porous wick into the evaporator and to seal the wick ends for liquid and vapor separation. Advanced technology such as additive manufacturing is needed to simplify the processes and ensure good sealing at both ends of the wick. Additive manufacturing technology can also be used to produce integrated heat exchangers for pumped fluid loops in order to increase heat transfer performance while significantly reducing mass, labor and cost.

  • Science missions are more dependent on optically sensitive instruments and systems, and effects of thermal distortion on the performance of the system are critical. Current Structural-Thermal-Optical (STOP) analysis has several codes that do some form of integrated analysis, but none that have the capability to analyze any optical system and do a full end-to-end analysis. An improvement of existing code is needed in order to yield software that can integrate with all commonly used programs at NASA for mechanical, structural, thermal and optical analysis. The software should be user-friendly, and allow full STOP analysis for performance predictions based on mechanical design, and structural/thermal material properties.

  • Thermoelectric converts (TEC) have advantages of small size, long life, solid state design, and no moving parts or fluid operation, and have been used on many science instruments requiring dedicated/localized cooling to meet their stringent requirements. However, they have historically exhibited poor efficiency and have not been able to provide the cold temperatures needed by certain types of space science instruments.  Research and development in areas of advanced materials, processes, and designs are needed in order to improve its efficiency, and extend its low temperature (<90K) capability for space science application.

  • Water has been used in two-phase thermal control devices such as heat pipes due to its high heat transport capability. However, water has two main drawbacks that limit its use in many aerospace applications. Its expansion upon freezing creates a concern about rupture of the heat pipe and the concern for reliable startup from an initially frozen state. Water-containing azeotropes, which behave as a single-component working fluid, can offer substantial benefits as alternatives to use of pure water for applications where freeze/thaw and frozen startup concerns exist. High-performance water azeotropes which can lower the freezing point of water below -40°C while providing improved reliability for aerospace thermal control systems are needed.  

  • Three-dimensional (3D) integrated circuits (ICs) offer unprecedented functionality and efficiency in small form factors, but their operation is constrained by the current remote cooling paradigm that relies on conduction and heat spreading across multiple interfaces. An embedded approach, which facilitates in-situ cooling of the chip stack is needed. Such a cooling device must also accommodate high heat fluxes and minimize the thermal resistance between the heat source and sink.

Research should be conducted to demonstrate technical feasibility during Phase I and show a path toward a Phase II hardware demonstration.  Phase II should deliver a demonstration unit for NASA testing at the completion of the Phase II contract.


Note to Proposers - Cubesat thermal technologies have been moved to a new STMD subtopic:  Z8.03 Small Spacecraft Power and Thermal Control
Z2.01 Thermal Management

Lead Center: JSC

Participating Center(s): GRC, GSFC, JPL, MSFC
Exploration Vehicle Thermal Systems

Variable Heat Rejection Technologies

Exploration vehicles require variable heat rejection due to the potential to operate in environments ranging from full sun on one side to a cold deep space environment, while rejecting a range of waste heat loads.  NASA Technology Roadmap Area 14 identifies a turn down goal of 6 to 1 for a thermal control system. Room temperature thermal control systems are sought that are sized for nominal operation in full sun exposure, yet are able to maintain set point control and stable operation at one-sixth of their design heat load when in a deep space (0°K) environment. Solutions for variable heat rejection may include novel architectures, novel thermal control fluids, advanced radiator technologies, and/or variable working fluid/radiator conductance. Radiator-based technologies should have an areal mass no greater than 5.8 kg/m2.


Advanced-Closed Loop Extravehicular Activity Thermal Control

NASA continues to evolve space suit technology for exploration missions; however, the portable life support system (PLSS) includes a water evaporator to reject waste energy produced by the suit. Closed-loop, non-venting thermal heat rejection systems that are capable of rejecting heat in the Martian atmosphere are needed to create a PLSS that minimizes consumable use and does not impact the Mars environment. NASA seeks novel approaches to close the thermal control system of the space suit, targeting 80% or greater reductions in evaporated water mass for the same heat rejection. However, the mass and volume of the system must be limited as it must be carried on the crewmember's back.  Approaches may include novel radiative approaches and/or desiccant systems to reclaim evaporants, as well as other novel solutions. Examples of such technologies and goals are outlined in NASA's Technology Roadmap Area 06, but more innovative concepts are also sought.


Advanced Heat Exchangers and Coldplates
Air/liquid heat exchangers (HXs), liquid/liquid HXs, and coldplates are at the core of any active thermal control system for a space vehicle. While these individual components are small, they are found throughout spacecraft vehicles and their cumulative mass and volume is significant.  Advances in materials or manufacturing may yield a considerable mass savings over the current state of the art heat exchangers.  NASA's Technology Roadmap Area 14 details various points of interest for these heat exchangers, and key goals are listed below:


  • Corrosion resistant coldplates with less than the state of the art 8.8 kg/m2 mass per area.

  • Heat exchangers with minimal structural mass and good thermal performance to reduce mass below 2 kg/kW of heat transfer, assuming delta-T on the order of 5°C.

  • Condensing heat exchangers (air/liquid heat exchangers) for closed loop life support, achieving highly reliable 3-year minimum lifetime, not contaminated by microbial growth, and whose coatings do not impact the life support system's water recovery system.


High Lift Heat Pumping Devices

Heat pumps are needed to reject spacecraft waste heat to a higher temperature sink.  At lunar equatorial locations, lunar surface temperatures can climb to 400°K, making it difficult to reject waste heat at nominal temperatures. A more severe application involves rejecting waste heat for a Venus lander where environmental sink temperatures can exceed 700°K. Ground-based designs that do not rely on gravity for elements of heat pump operation, such as lubricant management, contaminant control, or phase separation, are a reasonable starting point for a high lift heat pump device for extreme environment applications.  However, these designs must be adapted or proven to work in space applications. Intermittent operation in microgravity, low gravity, and/or in severe environments, such as hard vacuum, radiation, and extreme temperatures, are significant challenges to viable space-based heat pumps. NASA seeks targeted improvements for space-based heat pump technology, which may include exceptionally long life, low mass, and operation with high temperature lifts (50°C or more) and a coefficient of performance at least at 30% of Carnot efficiency.


Thermal Insulation for Pressurized Environments

To enable longer duration missions to the surface of Venus, advanced insulation systems are required.  External insulation on a Venus lander pressure vessel allows the system to take advantage of the thermal mass of the pressure vessel and reduce the heat transfer rate into the pressure vessel. The goal is to extend mission lifetime to collect and transmit more science data by allowing multiple communication passes with an orbiter. In addition to Venus in-situ explorers, this insulation can be used for future deep atmospheric probes for gas giant planets, or even in high temperature and pressure chemical processes in other systems. The current state-of-the-art in insulation systems considered for the Venus atmosphere are heavy, fragile and difficult to implement on the exterior of a pressure vessel.  NASA seeks a lightweight, flexible insulation system that can be accommodated on the exterior of a pressure vessel. The insulation thermal conductivity should be less than 0.1 W/m-K at 470°C and 90 bar pressure in a carbon dioxide environment.



Focus Area 18: Air Vehicle Technology



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