George C. Marshall Space Flight Center Research and Technology Report 2014 NASA/TM—2015–218204 A.S. Keys, M.L. Tinker, and A.D. Sivak, Compilers Marshall Space Flight Center, Huntsville, Alabama National Aeronautics and Space Administration George C. Marshall Space Flight Center, Huntsville, AL 35812 www.nasa.gov/marshall www.nasa.gov The point of contact and coordinator at Marshall Space Flight Center (MSFC) for this Technical Memorandum (TM) is Amy Sivak (256–544–4720). She was assisted by the MSFC Scientific and Technical Information Group, in particular Susan Burrer, Vicki Hocutt, and Mary Vaughn. The Center Chief Technologist, Andrew Keys, and the Deputy Chief Technologist, Mike Tinker, gave support, knowledge, insight, and assisted with compiling and making decisions on this TM. Available from: NASA STI Information Desk Mail Stop 148 NASA Langley Research Center Hampton, VA 23681–2199, USA 757–864–9658 This report is also available in electronic form at <http://www.sti.nasa.gov> The American public widely recognizes NASA for its ability to deliver amazing missions capable of providing new knowledge about the universe around us, new understanding about the Earth on which we live, and new capabilities that serve to improve our daily lives. Many of these NASA missions would not be possible if it were not for the investments made in research advancements and technology development efforts. The technologies developed at Marshall Space Flight Center contribute to NASA's strategic array of missions through technology development and accomplishments. They also provide all Marshall Space Flight Center employees the opportunity to gain and maintain critical skills necessary to be more innovative in solving the complex problems associated with spaceflight. The scientists, researchers, and technologists of Marshall Space Flight Center who are working these enabling technology efforts are facilitating NASA's ability to fulfill the ambitious goals of innovation, exploration, and discovery. As you read through this report detailing Marshall Space Flight Center's technological accomplishments of 2014, I trust you will take a moment to appreciate the incredible legacy of research and technology advancements that NASA Marshall Space Flight Center provides to the nation. Patrick E. Scheuermann Director Marshall Space Flight Center It is my exceeding pleasure to present to you the Marshall Space Flight Center Research and Technology Report for 2014. This document showcases the wide diversity of research and technology efforts being pursued by our talented and innovative workforce. From the early stage innovations being developed as a part of the Center Innovation Fund program to the advanced technologies being investigated to enable future Space Launch System capabilities, the efforts detailed in this report strive to advance the current state of technology such that future NASA missions are enabled. The range and diversity of the activities described herein is certainly impressive. Innovators used selective laser melting as an advanced manufacturing technology for the fabrication of turbopump impellers that could enable upper stage engine development. Engineers employed models of combustion stability within engine injector designs to improve future SLS propulsion system developments. Materials experts tested the ability of a composite cryotank to successfully store cryogenic fuels and to withstand structural loads representative of launch conditions. Technologists facilitated the launch of the first additive manufacturing printer to the International Space Station. Scientists demonstrated new methods of fabricating lightweight, high-resolution, grazing incidence optics for use in future x-ray observatories. These innovations, plus the many more described within this report, may serve to not only enhance and enable NASA's current slate of programs and projects, but could also provide the solutions required to facilitate human and robotic exploration of other solar system bodies and destinations beyond. I trust you will enjoy reviewing the Marshall research and technology accomplishments of 2014. I am greatly looking forward to what 2015 will bring! Andrew Keys Center Chief Technologist Marshall Space Flight Center TECHNOLOGY PROGRAMS: 1 HUMAN EXPLORATION AND OPERATIONS MISSION DIRECTORATE (HEOMD): 3 Advanced Exploration Systems (AES): 5 - Lander Technologies: 6 - Three-Dimensional Printing In Zero Gravity: 8 - Nuclear Thermal Propulsion: 10 - Deep Space Habitat Concept Demonstrator: 12 - Near-Earth Asteroid Scout: 14 - Lunar Flashlight: 16 - Source Contaminant Control for the Heat Melt Compactor: 18 - Atmosphere Resource Recovery and Environmental Monitoring: 20 Space Launch System Advanced Development (SLS AD): 23 - Advanced Booster Composite Case/Polybenzimidazole Nitrile Butadiene Rubber Insulation Development: 24 - Q4 Titanium 6-4 Material Properties Development: 26 - Testing of Selective Laser Melting Turbomachinery Applicable to Exploration Upper Stage: 28 - Additive Manufacturing Infrared Inspection: 29 - Booster Interface Loads: 30 - Cryoinsulation Material Development to Mitigate Obsolescence Risk for Global Warming Potential Foams: 32 - Hexavalent Chromium IV-Free Primer Development: 34 - Low-Profile Diffuser: 36 - Composite Dry Structure Cost Improvement Approach: 38 - Advanced Booster Liquid Engine Combustion Stability: 40 - Lattice Boltzmann Method for Spacecraft Propellant Slosh Simulation: 42 - Hot-Fire Test of Liquid Oxygen/Hydrogen Space Launch Mission Injector Applicable to Exploration Upper Stage: 44 - Nanoelectric Materials Laboratory Development: 46 - Insulation Reformulation Development: 48 - Aluminum 2195 T8 Gore Development for Space Launch System Core and Upper Stage: 50 - Thermal Protection System Application to Composite Cryotank Technology Demonstrator: 52 - Performance Improvement of Friction Stir Welds by Better Surface Finish: 54 SCIENCE MISSION DIRECTORATE (SMD): 57 - Advanced UVOIR Mirror Technology Development for Very Large Space Telescopes: 58 - Mars Ascent Vehicle—First Stage Motor: 60 - Mars Ascent Vehicle—Propellant Aging: 62 SPACE TECHNOLOGY MISSION DIRECTORATE (STMD): 65 Technology Demonstration Missions (TDM): 67 - Technology Demonstration Missions: 68 - Cryogenic Propellant Storage and Transfer Engineering Development Unit Hydrogen Tank: 70 Centennial Challenges Program (CCP): 73 - Centennial Challenges Program: 74 Game Changing Development (GCD): 77 - Bosch Reactor Development for High Percentage Oxygen Recovery From Carbon Dioxide: 78 - Soldier-Warfighter Operationally Responsive Deployer for Space: 80 - Fast Light Optical Gyroscopes: 82 - Adjustable Grazing-Incidence X-ray Optics: 84 - Altitude Compensating Nozzle: 86 - Multi-spacecraft Autonomous Positioning System: 88 - Magnetogram Forecast: An All-Clear Space Weather Forecasting System: 90 - Composite Cryotank Technologies and Demonstration: 92 - Advanced Near Net Shape Technology: 94 - Materials Genome Initiative: 96 - Low Cost, Upper Stage-Class Propulsion: 98 - Space Synthetic Biology Project: 100 - Programmable Ultra-Lightweight System Adaptable Radio: 102 - Microelectrospray Thrusters: 104 Small Business Innovation Research (SBIR): 107 - Small Business Innovation Research and Small Business Technology Transfer Programs: 108 Center Innovation Fund (CIF): 111 - Flexible Hybrid Battery/Pseudocapacitor: 112 - Ultrasonic Stir Welding Development for Ground-Based and In Situ Fabrication and Repair for In-Space Propulsion Systems/Commercial Space Sector: 114 - Lightweight Damage Tolerant, High-Temperature Radiators for Nuclear Power and Propulsion: 116 - Solid State Ultracapacitor: 118 - Spherically Actuated Motor: 120 - Targeted Structural Optimization With Additive Manufacturing of Metals: 122 - Flexible Electrostatic Technologies for Capture and Handling, Phase 1: 124 - Direct Drive Solar-Powered Arcjet Thruster: 126 - Active Collision Avoidance for Planetary Landers: 128 - A Magnetron Sputter Deposition System for the Development of X-ray Multilayer Optics: 130 - Electronegative Gas Thruster: 132 - Green Application for Space Power: 134 MARSHALL SPACE FLIGHT CENTER (MSFC)/CENTER MANAGEMENT AND OPERATIONS (CMO): 137 Technology Investment Program (TIP): 139 - Low-Energy Microfocus X-Ray Source for Enhanced Testing Capability in the Stray Light Facility: 140 - Charge Analyzer Responsive Local Oscillations: 142 - High Thermal Conductivity NARloy-Z-Diamond Composite Liner for Advanced Rocket Engines: 144 - Portable Virtual Training Units: 146 - Radio Frequency Identification for Space Habitat Inventory and Stowage Allocation Management: 148 - Formation Flying for Satellites and Unmanned Aerial Vehicles: 150 - Programmable Ultra-Lightweight System Adaptable Radio Satellite Base Station: 152 - Laser Imaging Detection and Ranging Performance in a High-Fidelity Lunar Terrain Field: 154 Center Strategic Development Steering Group (CSDSG): 157 - Grazing Incidence Optics Technology: 158 - Peregrine Sustainer Motor Development: 160 - Iodine Satellite: 162 - NanoLaunch: 164 - Low Noise Camera for Suborbital Science Applications: 166 Dual-Use Technology Cooperative Agreement Notice (CAN): 169 - Improving Interlaminar Shear Strength: 170 - Printing Outside the Box: Additive Manufacturing Processes for Fabrication of Large Aerospace Structures: 172 - Interplanetary Radiation and Fault Tolerant Mini-Star Tracker System: 174 AES: Advanced Exploration Systems CAN: (Dual-Use Technology) Cooperative Agreement Notice CCP: Centennial Challenges Program CIF: Center Innovation Fund CSDSG: Center Strategic Development Steering Group GCD: Game Changing Development HEOMD: Human Exploration and Operations Mission Directorate MSFC/CMO: Marshall Space Flight Center/Center Management and Operations SBIR: Small Business Innovation Research SLS AD: Space Launch System Advanced Development SMD: Science Mission Directorate STMD: Space Technology Mission Directorate TDM: Technology Demonstration Missions TIP: Technology Investment Program Project Manager(s)/Lead(s): Greg Chavers, Ph.D./FP30 (256) 544–0494 Sponsoring Program(s): Human Exploration and Operations Mission Directorate, Advanced Exploration Systems, Science Mission Directorate Project Description: Since 2006 NASA has been formulating robotic missions to the lunar surface through programs such as Robotic Lunar Exploration Program, Lunar Precursor Robotic Program, and International Lunar Network. From 2010 to 2013, the Robotic Lunar Lander Development Activity was funded by SMD. In 2013, a low-cost robotic lunar lander concept was developed for the Resource Prospector Mission. In 2014, AES funded the team (MSFC leading, JSC, APL, JPL). The lander concept to place a 300-kg rover on the lunar surface has been described in New Technology Report Case Number MFS-33238-1. Partnering with commercial companies under the Lunar CATALYST initiative (Astrobotic, Masten Space Systems, Moon Express). The inspace engine (ISE100) is a 100-lbf thruster operating on MMH/MON25 at temperatures as low as –40 °F. Anticipated Benefits: Low-cost lunar surface access for multiple missions feeding forward to Mars landers. Notable Accomplishments: Design of low-cost robotic lunar lander prototype/engineering unit at system level with flight software and hardware-in-the-loop simulation. Project Manager(s)/Lead(s): Niki Werkheiser/ZP30 (256) 544–8406 Sponsoring Program(s): HEOMD, AES, STMD, Game Changing Development Project Description: The 3D printing in zero-g (3D Print) technology demonstration assesses melt deposition modeling additive manufacturing on the ISS. Developed with Made In Space, Inc. through SBIR Phase III to advance TRL for operational flight production of plastics on ISS. Anticipated Benefits: First step toward a machine shop in space for long-duration human missions. Notable Accomplishments: Launched on SpaceX-4 on September 21, 2014; installed in Microgravity Science Glovebox (MSG) on November 17, 2014; successfully extruded calibration coupons. Project Manager(s)/Lead(s): Sonny Mitchell/ZP30, Michael G. Houts/ZP30, Tony Kim/ZP30 Sponsoring Program(s): HEOMD, STMD, AES Project Description: Focuses on demonstrating the affordability and viability of a fully integrated NTP system with specific impulse >900 s, emphasizing fuel fabrication and testing. Anticipated Benefits: Doubled Isp compared to chemical engines, shortest trip times to Mars, saving approximately four SLS launches per human Mars mission. Notable Accomplishments: Dedicated fuel materials and processing laboratories operational at ORNL and MSFC; CFEET and NTREES test facilities designed and brought to operational status. Project Manager(s)/Lead(s): Paul S. Bookout/FP30, David Smitherman/ED04 Sponsoring Program(s): HEOMD, AES, Exploration Augmentation Module Project, Technology Excellence Project Description: In FY 2014 focused on a large volume SLS-class habitat (Skylab Gen 2) based on SLS hydrogen tank components for lunar orbit (LDRO) and Mars transit. Anticipated Benefits: Utilizes SLS components as long-duration outposts and testbeds for advancing TRLs. Notable Accomplishments: Trade study determined horizontal interior layout was optimal over vertical layout; flooring system designed, procured, and installed; staircase and interior wall materials procured. Project Manager(s)/Lead(s): Amy Walden/FP30, Dennon Clardy/FP01, Les Johnson/ED04 Sponsoring Program(s): HEOMD, AES Project Description: A 6U CubeSat secondary payload on SLS EM-1 utilizing an 85 m² solar sail (based on NanoSail-D heritage) to perform reconnaissance and imaging of a near-Earth asteroid (<100 m size). Anticipated Benefits: Milestone for low-cost asteroid science, informing planetary defense and Asteroid Redirect Mission. Notable Accomplishments: Completed MCR and SRR in August 2014; solar sail packaging characterized, reflectivity testing conducted, boom deployer system designed. Project Manager(s)/Lead(s): John Baker/JPL, Barbara Cohen/ZP13, Amy Walden/FP30 Sponsoring Program(s): HEOMD, AES Project Description: A 6U CubeSat with an 85 m² solar sail designed to reflect sunlight into lunar permanently shadowed regions (PSRs) to detect and map surface water ice using a four-filter point spectrometer. Anticipated Benefits: Directly maps lunar volatile resources addressing NASA Strategic Knowledge Gaps. Notable Accomplishments: Successfully completed MCR and SRR in August 2014; science goals underwent nonadvocate peer review in June 2014. Project Manager(s)/Lead(s): Monsi Roman/FP10, David Howard/FP10 Sponsoring Program(s): HEOMD, AES Project Description: Developing a two-stage contamination control system to treat exhaust purge gasses from the Heat Melt Compactor (HMC) before releasing back into cabin atmosphere. Anticipated Benefits: Preserves cabin atmosphere and enables safe volume reduction and radiation shield production from waste. Notable Accomplishments: Designed, fabricated, and tested two-stage source contaminant control system (sorbent bed and catalytic oxidizer), delivered to NASA Ames for Gen 2 HMC integration. Project Manager(s)/Lead(s): Monsi Roman/FP10, David Howard/FP10 Sponsoring Program(s): HEOMD, AES Project Description: Maturing closed-loop life support technologies to increase oxygen recovery from CO2 from 43% to >90% (using plasma pyrolysis and advanced catalytic oxidation). Anticipated Benefits: Essential for long-duration Mars missions by eliminating Earth resupply dependency. Notable Accomplishments: Completed multiple integrated system test phases; demonstrated 40% reduction in cabin CO2 levels with CDRA alternate mode; validated trace contaminant control and JPL environmental monitors. Project Manager(s)/Lead(s): Steve Gentz/C105, Robert Taylor/ER51, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Evaluated co- and multiple-cure processing and NDE methods for polybenzimidazole nitrile butadiene rubber (PBI-NBR) insulation and composite motor cases. Notable Accomplishments: Mixed and tested HTPB and HTPE propellant formulations; fabricated and inspected 45 test bottles; burst testing showed comparable burst strength between pristine co-cured and multiple-cured bottles; evaluated IRT, radiography, and computed tomography. Project Manager(s)/Lead(s): Kenneth Cooper/EM42, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Development and characterization of selective laser melting (SLM) process parameters for Ti-6Al-4V to generate a design allowables database for rotating turbomachinery. Notable Accomplishments: Tested initial build samples; resolved plate peeling issues by transitioning to Ti-6Al-4V build plates to match thermal expansion coefficients. Project Manager(s)/Lead(s): Marty Calvert/ER31, Jason Turpin/ER21, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Designed, fabricated, and spin tested an SLM Ti-6Al-4V hydrogen turbopump impeller sized for upper stage engine requirements. Notable Accomplishments: Completed spin burst testing up to 147,600 rpm where the impeller remained intact without failure. Project Manager(s)/Lead(s): Darrell Gaddy/ER43, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Developing real-time dimensional inspection techniques and digital quality records for additive manufacturing using IR camera imaging. Notable Accomplishments: Proved feasibility of IR monitoring during AM process and developed custom software to create 3D geometry files directly from process data. Project Manager(s)/Lead(s): Steve Gentz/C105, Bill Wood/LaRC, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD, NESC Project Description: Numerical simulations and wind tunnel tests investigating forward booster nosecone shapes to reduce shock-wake buffeting loads at the attach hardware. Notable Accomplishments: Completed CFD and tested six booster nose configurations in NASA Ames 11-ft Transonic Wind Tunnel, identifying shapes that significantly reduce RMS pressure buffet environments. Project Manager(s)/Lead(s): Alison Protz/EM41, Roland Bruyns/EM41, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Proactive evaluation and reformulation of cryoinsulation spray foams using low-GWP blowing agents (CO2, methyl formate/Ecomate, HFOs) to replace HFC-245fa ahead of environmental regulations. Notable Accomplishments: Evaluated thermal conductivity (Lambda) values across multiple blowing agent formulations; coordinated with foam suppliers (Icynene, FSI) to tailor formulations for aerospace cryogenic requirements. Project Manager(s)/Lead(s): Michael J. Alldredge/EM41, Amy L. Buck/EM41 Sponsoring Program(s): HEOMD, SLS AD, SLS SPIE Office Project Description: Evaluation of non-carcinogenic, chromate-free primers for cryogenic corrosion protection and thermal protection system adhesion on metallic launch structures. Notable Accomplishments: Screened 12 primers in phase 1; phase 2 testing showed strong thermal/mechanical performance with PRC-Desoto CF/CA 7502 (with PPG EAP-9) and Sherwin Williams CM0483787 leading corrosion resistance. Project Manager(s)/Lead(s): Michael A. Martin/ER22, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Design and CFD optimization of a compact pressurization gas diffuser using wire-cloth screens to minimize vertical height while maintaining uniform flow in liquid propellant tanks. Notable Accomplishments: Ran ~20 CFD iterations; characterized flow across two wire-cloth weaves; built and tested a full-scale prototype validating the CFD models. Project Manager(s)/Lead(s): Alan Nettles/EM20, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Developing a streamlined design and test methodology focusing on relevant damage-tolerant properties for dry composite launch structures (interstages/shrouds) rather than extensive unnotched coupon testing. Notable Accomplishments: Established rationale and remedies addressing the major cost barriers and test-method inefficiencies in composite qualification. Project Manager(s)/Lead(s): Kevin Tucker/ER28, Steve Gentz/C105, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Improving CFD and analytical predictive tools for combustion stability in liquid oxygen/hydrocarbon booster engine injectors to mitigate chug/screech instabilities. Notable Accomplishments: Tested baseline element 1b and redesign 1b4 at AFRL and Purdue; developed redesign 1b5; completed 3D reacting CFD simulations of a seven-element injector assembly. Project Manager(s)/Lead(s): Joseph Powers/EV41, Jeb Orr/EV41 Sponsoring Program(s): HEOMD, SLS AD Project Description: Application of the Lattice Boltzmann Method (LBM) with real gas equations of state to model low Bond number (Bo < 10) microgravity multiphase fluid slosh and contact line dynamics. Notable Accomplishments: Developed scalable MATLAB-based multiphase LBM solver incorporating nonideal gas EOS and multiple-relaxation-time collision operator; verified against theoretical droplet oscillation dynamics. Project Manager(s)/Lead(s): Greg Barnett/ER32, Jason Turpin/ER21, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Hot-fire testing of 3D additively manufactured (SLM) liquid oxygen/hydrogen injectors for expander cycle exploration upper stage engines. Notable Accomplishments: Selected two vendor SLM injectors, completed NDE, welded Rigimesh face plates, performed water flow and blow-down testing, and conducted successful hot-fire testing. Project Manager(s)/Lead(s): Lee Allen/EM41, Curtis Hill/ES43 Sponsoring Program(s): HEOMD, SLS AD, CIF Project Description: Development of printed solid-state ceramic ultracapacitors using 3D aerosol jet printing and customized dielectric/conductor inks to exceed Li-ion energy densities. Notable Accomplishments: Established vibratory milling and ALD coating processes; demonstrated trivalent doping of perovskite ceramic nanoparticles achieving capacitances in microFarad range on 30-µm layers. Project Manager(s)/Lead(s): Cynthia Chapman/EM41, Mark Bray/EM41 Sponsoring Program(s): HEOMD, SLS AD Project Description: Reformulating internal solid rocket motor insulation (PBI-NBR / silica-filled NBR) to overcome air entrapment and improve mechanical and thermal erosion properties. Notable Accomplishments: Tested multiple formulations with plasma-treated sulfonated fibers; selected two promising formulations for 100-lb batch scale-up testing. Project Manager(s)/Lead(s): Martin Volz/EM31 Sponsoring Program(s): HEOMD, SLS AD Project Description: Developing optimized heat treatment and stretch-forming processes for heavy Al-Li 2195 plates (up to 0.75 in) to replace Al 2219 on cryogenic tank dome gores, potentially saving ~3,800 lbm. Notable Accomplishments: Developed proprietary annealing process (MFS-32954-1); successfully stretch formed 0.525-in and 0.75-in Al 2195 plates using Ares I tooling; heat treated to T8 temper yielding tensile properties exceeding specifications. Project Manager(s)/Lead(s): Alison Protz/EM41, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Developed and executed manual spray application of Stepanfoam S-180 polyurethane cryoinsulation onto the 5.5-m Composite Cryotank Technology Demonstrator (CCTD). Notable Accomplishments: Successfully applied foam over large-scale barrel and dome sections across horizontal and vertical orientations; validated foam adhesion during subsequent cryogenic testing. Project Manager(s)/Lead(s): Sam Russell/EM20, Mindy Nettles/XP50 Sponsoring Program(s): HEOMD, SLS AD Project Description: Investigating post-weld surface milling/shaving of friction stir welds to eliminate stress concentrations and reduce false-positive ultrasonic (PAUT) indications. Notable Accomplishments: Fabricated and evaluated self-reacting FSW baseline and raised weld land panels; conducted tensile testing across room temperature, LN2, and LH2; established PAUT defect detection calibration using EDM notches. Project Manager(s)/Lead(s): Mike Effinger/ZP21, H. Philip Stahl/ZP10 Sponsoring Program(s): SMD, Cosmic Origins Program Project Description: Maturing critical technologies for ≥4-m space telescope primary mirror assemblies for ultraviolet, optical, and infrared astronomy. Notable Accomplishments: Characterized fine-stage actuators with 6.6 nm resolution; conducted low temperature fusion bond strength tests on 50 samples showing strength 50% above design allowables; advanced finite element integrated modeling tools. Project Manager(s)/Lead(s): John Dankanich/ZP30, Scott Doudrick/JPL, Jacob Williams/ATK Sponsoring Program(s): SMD, Mars Exploration Program Project Description: Development and preliminary design trades of a two-stage solid rocket motor MAV first stage for robotic Mars Sample Return. Notable Accomplishments: Completed multiple preliminary design and analysis cycles including motor ballistics, ignition gas dynamics, plume analysis, and thermal-structural modeling. Project Manager(s)/Lead(s): John Dankanich/ZP30, Jeremy Rousseau/ER52, Jacob Williams/ATK Sponsoring Program(s): SMD, ISPT Program, Mars Exploration Program Project Description: Formulating and environmentally testing low-temperature HTPB propellant (TP-H-3544) capable of surviving deep space vacuum and Mars surface thermal cycling (–40 °C, CO2 atmosphere). Notable Accomplishments: Completed Phase 1 vacuum aging test with <0.1% mass loss; demonstrated superior Isp and density compared to heritage CTPB propellants. Project Manager(s)/Lead(s): John McDougal/FP50, Beth Adams-Fogle/FP50, Raymond French/FP50, Karen Stephens/FP50 Sponsoring Program(s): STMD, TDM Project Description: Managing 11 portfolio demonstration projects bridging TRL gaps to flight qualification: eCryo, CEUS, DSAC, GPIM, HET, LCRD, LDSD, MEDLI, SEP, SSD, and THOR. Notable Accomplishments: Successful KDP milestones across projects; delivered R2 climbing legs and Smart SPHERES phone to ISS; LDSD supersonic flight test; MegaFlex/ROSA solar array testing; Hall thruster and PPU integration for SEP. Project Manager(s)/Lead(s): Arthur Werkheiser/ZP30 Sponsoring Program(s): STMD, TDM Project Description: Proof-of-manufacturability and cryogenic thermal performance validation of a 1,000-gallon flight-like LH2 tank equipped with SOFI, MLI, thermodynamic vent system, and liquid acquisition devices (LADs). Notable Accomplishments: Conducted 20-day thermal vacuum boil-off and pressurization tests in MSFC Test Stand 300; demonstrated liquid column support in LADs for 61 minutes; validated RF mass gauge within 1.5% accuracy. Project Manager(s)/Lead(s): Sam Ortega/ZP30, Eric Eberly/ZP30 Sponsoring Program(s): STMD, CCP Project Description: Administers open public prize competitions to incentivize non-traditional innovation for challenging NASA technology needs. Notable Accomplishments: Executed 2014 Sample Return Robot Challenge ($5,000 Level 1 award to West Virginia University); announced MAV Challenge for Mars autonomous sample return; launched $5M Cube Quest Challenge for lunar and deep-space CubeSats. Project Manager(s)/Lead(s): David Howard/FP10, Morgan Abney/ES62 Sponsoring Program(s): STMD, GCD Project Description: Development of two-stage Bosch reaction systems recovering up to 100% oxygen from metabolic CO2, while utilizing byproduct carbon to form nanotubes and sintered bricks with lunar/Martian regolith catalysts. Notable Accomplishments: Demonstrated extended metal catalyst lifetime via two-stage reaction and tumbling bed designs; validated martian and lunar regolith as effective in situ catalysts. Project Manager(s)/Lead(s): Benny Davis/ZP30, Larry Huebner/LaRC, Richard Kuhns/KSC Sponsoring Program(s): STMD, GCD, HEOMD, AES Project Description: Joint NASA/US Army SMDC effort to develop a low-cost, pressure-fed three-stage LOX/methane launch vehicle capable of placing 25 kg into a 750-km orbit. Notable Accomplishments: Conducted successful hot-fire testing of a 60,000-lbf class LOX/methane engine (most powerful in the world at the time); completed multi-lobed aerodynamic and asymmetric nozzle analyses. Project Manager(s)/Lead(s): David D. Smith/ES31 Sponsoring Program(s): STMD, GCD Project Description: Enhancing gyroscope scale factor sensitivity by ~100x using anomalous dispersion / fast light materials inside the laser cavity to enable fully autonomous spacecraft inertial navigation. Notable Accomplishments: Built temperature-stabilized atomic vapor ovens for PFLOG sensitivity tuning; demonstrated scale factor enhancement in atomic ring cavities and by polarization mode coupling; built custom vacuum enclosure eliminating beat-note noise in AFLOG. Project Manager(s)/Lead(s): Stephen L. O’Dell/ZP12, Paul B. Reid/SAO Sponsoring Program(s): STMD, GCD Project Description: Developing active lightweight grazing-incidence x-ray optics using slumped-glass mirrors backed with thin-film piezoelectric actuator arrays to achieve subarcsecond resolution. Notable Accomplishments: Fabricated 7x7 pixelated piezoelectric arrays with >90% yield; demonstrated on-device TFTs and anisotropic conductive films; developed MSFC in-situ thin film coating stress monitor. Project Manager(s)/Lead(s): Joseph H. Ruf/ER42, Daniel Jones/AFRC Sponsoring Program(s): STMD, GCD Project Description: Developing dual-bell altitude compensating rocket nozzles that automatically transition flow modes with altitude to increase average Isp by up to 5%. Notable Accomplishments: Sized a subscale cold-flow test article for cross-testing at MSFC Nozzle Test Facility and in-flight testing on AFRC's F-15D flight test bed. Project Manager(s)/Lead(s): Dr. Evan Anzalone/EV42 Sponsoring Program(s): STMD, GCD Project Description: Software-based autonomous interplanetary navigation system utilizing inter-spacecraft communication cross-links and ranging to perform onboard orbit determination. Notable Accomplishments: Developed agent-based simulation tool; constructed hardware-in-the-loop testing framework with flight radios and atomic clocks; designed LEO CubeSat demo mission concept. Project Manager(s)/Lead(s): Nasser Barghouty/ZP12, David Falconer/ZP12 Sponsoring Program(s): STMD, GCD Project Description: Automated space weather forecasting tool using SDO/HMI magnetograms and magnetic free-energy proxies to predict solar flares, CMEs, and solar energetic particle events. Notable Accomplishments: Incorporated historical flaring into forecast curves yielding significant improvements in Heidke Skill Score; began deprojecting HMI vector magnetograms to improve accuracy. Project Manager(s)/Lead(s): John Vickers/EM01 Sponsoring Program(s): STMD, GCD Project Description: Agency effort with Boeing to manufacture and test out-of-autoclave composite cryogenic tanks (2.4-m and 5.5-m diameters) for heavy-lift launch vehicles. Notable Accomplishments: Successfully tested 2.4-m tank in 2013; tested 5.5-m tank filled with ~30,000 gal LH2 at –423 °F with structural mechanical loads and 20–53 psi pressure cycling in MSFC test stand, representing the largest composite LH2 tank ever built and tested. Project Manager(s)/Lead(s): John Vickers/EM01 Sponsoring Program(s): STMD, GCD Project Description: Spin/flow-forming single-piece integrally stiffened cylinders (ISC) from aerospace Al-Li alloys to eliminate longitudinal welds and reduce tank manufacturing cost by 40% and scrap by up to 30%. Notable Accomplishments: Successfully adapted automotive steel spin forming to Al-Li 2195; demonstrated selective reinforcement of stiffeners using metal matrix composites (30% stiffness increase with 1% mass increase). Project Manager(s)/Lead(s): John Vickers/EM01 Sponsoring Program(s): STMD, GCD Project Description: Integrating multiscale physics modeling and computational simulations to optimize additive manufacturing parameters and predict woven thermal protection system behavior. Notable Accomplishments: Developed and calibrated near-IR melt pool imaging with closed-loop control algorithms for SLM metal printers; performed micromechanical simulations of 2D/3D woven TPS architectures. Project Manager(s)/Lead(s): John Vickers/EM01 Sponsoring Program(s): STMD, GCD Project Description: Developing additive manufacturing processes combining SLM copper alloy (GRCop) liners with electron beam freeform fabrication (EBF3) nickel alloy jackets and manifolds. Notable Accomplishments: MSFC printed demo chambers in C18150 copper and nickel-silicon-bronze; NASA LaRC completed trial depositions of Inconel 625 onto copper substrate. Project Manager(s)/Lead(s): David Howard/FP10, Monsi Roman/FP10, James Mansell/ES62 Sponsoring Program(s): STMD, GCD Project Description: Developing bioelectrochemical systems utilizing electrotrophic microorganisms for CO2 reduction, biomanufacturing, and life support integration. Notable Accomplishments: Evaluated five bioelectrochemical ECLS concepts; built ECLS laboratory testbed to quantify and optimize microgravity gas-liquid contactor membranes for dissolved CO2 injection. Project Manager(s)/Lead(s): Arthur Werkheiser/ZP30 Sponsoring Program(s): STMD, GCD Project Description: Developing a modular, low-mass (2.2 kg), software-defined S-band/X-band transceiver (PULSAR) based on FPGAs for CubeSats and deep space communications. Notable Accomplishments: Delivered two PULSAR 2.2A radios for testing at JSC and SSC; prepared PULSAR 2.3 for flight test on a Peregrine sounding rocket. Project Manager(s)/Lead(s): John Dankanich/ZP30, Nate Demmons/Busek, Colleen Marrese-Reading/JPL, Paulo Lozano/MIT Sponsoring Program(s): STMD, GCD Project Description: Maturing high-Isp (>1,500 s), low-power microelectrospray propulsion systems for CubeSats and small spacecraft. Notable Accomplishments: Advanced three competing concepts toward TRL-5: Busek HARPS porous metal thruster, MIT S-iEPS ionic liquid MEMS thruster pair, and JPL microfabricated indium liquid metal thruster. Project Manager(s)/Lead(s): Lynn Garrison/ZP30, Gwen Jasper/ZP30 Sponsoring Program(s): STMD, SBIR/STTR Program Office Project Description: Manages competitive seed funding to engage small businesses and research institutions in developing high-value aerospace technologies. Notable Accomplishments: MSFC led multiple subtopics across HEOMD, SMD, and STMD; received 32 Phase I and 8 Phase II awards; awarded 6 Phase III follow-on contracts supporting SLS and AES. Project Manager(s)/Lead(s): Dennis S. Tucker/EM32, Steven Paley/AZ Technology Sponsoring Program(s): STMD, CIF Project Description: Developing flexible, conformable energy storage combining battery energy density (target 100 Wh/kg) and supercapacitor power density (target 1,000 W/kg) using ionic liquids and carbon nanotube electrodes. Notable Accomplishments: Built electrochemical test cells; evaluated electrochemical windows of three ionic liquids; tested bare and silicon-coated CNT sheet electrodes. Project Manager(s)/Lead(s): Jeff Ding/EM32 Sponsoring Program(s): STMD, CIF Project Description: Developing ultrasonic stir welding (USW) systems combining pulsed ultrasonic energy with stir welding to reduce forces and improve weld mechanical properties on Al 2219. Notable Accomplishments: Demonstrated 33% reduction in plunge forces at 90% ultrasonic amplitude and significant traverse force reductions during weld trials. Project Manager(s)/Lead(s): Paul D. Craven/EM50, Michael P. SanSoucie/EM50 Sponsoring Program(s): STMD, CIF Project Description: Developing woven bare pitch-based carbon fiber radiator fins without matrix material to dissipate waste heat in nuclear electric propulsion systems at 2–4 kg/m² areal densities. Notable Accomplishments: Successfully wove K13D2U high thermal conductivity carbon fibers into mats commercially; bonded fins to stainless steel heat pipes using TiCuSil active braze alloys in vacuum. Project Manager(s)/Lead(s): Dr. Terry D. Rolin/ES43 Sponsoring Program(s): STMD, CIF Project Description: Developing internal barrier layer ceramic ultracapacitors (IBLC) using 3D aerosol jet printed dielectric inks to replace flight batteries with high-reliability solid-state devices. Notable Accomplishments: Produced ultracapacitors exceeding 1 J/cc energy density, breakdown voltages up to 900 V across 30 µm, and sub-millisecond charge times; filed three patent applications; discovered low-temperature conductor ink and ultrasensitive ceramic humidity sensor spinoffs. Project Manager(s)/Lead(s): Steven Peeples/ES33 Sponsoring Program(s): STMD, CIF Project Description: Developing a three-degree-of-freedom (DOF) spherical actuator replacing three single-DOF actuators to simplify robotic manipulators and multi-mode rolling/walking planetary rovers. Notable Accomplishments: Completed 3D CAD modeling and additive manufacturing of a working prototype SAM unit. Project Manager(s)/Lead(s): Adam Burt/ES22, Patrick Hull/ES21 Sponsoring Program(s): STMD, CIF Project Description: Integrating topology optimization, shape optimization, and finite element modeling with metal additive manufacturing to hollow and lightweight structural interiors while preserving exterior envelope and stiffness. Notable Accomplishments: Developed automated algorithms to convert solid tetrahedral finite elements into optimized 2D shell structures and generate AM-ready CAD geometries. Project Manager(s)/Lead(s): Thomas Bryan/ES32 Sponsoring Program(s): STMD, CIF Project Description: Developing compliant electrostatic/electroadhesion grippers capable of grasping non-magnetic, irregular space objects and spacecraft surfaces without grapple fixtures. Notable Accomplishments: Demonstrated dynamic capture, translation, and release of a 150-lb FASTSAT satellite mockup on air bearings using an electrostatic gripper on a simulated space tug. Project Manager(s)/Lead(s): Kurt Polzin/ER24, Adam Martin/ER24 Sponsoring Program(s): STMD, CIF Project Description: Evaluating the feasibility of directly coupling photovoltaic solar arrays to a low-power (400–1,000 W) tungsten arcjet thruster without an intervening power processing unit (PPU). Notable Accomplishments: Operated 1-kW class arcjet prototype on argon at 20 mg/s, sustaining an arc at 20 V and 25 A (500 W) in vacuum conditions. Project Manager(s)/Lead(s): Doug Rickman/ZP11, Mike Hannan/EV41, Karthik Srinivasan/USRA Sponsoring Program(s): STMD, CIF Project Description: Evaluating commercial automotive radar systems as lightweight, dust-penetrating hazard detection sensors for planetary landers in place of optical/LIDAR systems. Notable Accomplishments: Built Raspberry Pi-based data acquisition system and conducted terrain mapping tests at the MSFC Lunar Terrain Testbed. Project Manager(s)/Lead(s): David Broadway/ZP12 Sponsoring Program(s): STMD, CIF Project Description: Establishing a magnetron sputter deposition capability to coat full-shell replicated x-ray optics with multilayer coatings for high-energy astrophysics (>200 keV), EUV, and neutron applications. Notable Accomplishments: Completed design, procurement, and acceptance of custom vacuum deposition chamber. Project Manager(s)/Lead(s): John Dankanich/ZP30, Kurt Polzin/ER24, Mitchell Walker/Georgia Tech Sponsoring Program(s): STMD, CIF Project Description: Maturing an electric propulsion concept (PEGASES) accelerating both positive and negative ions from electronegative gases (SF6, xenon, argon) via RF bias grids, eliminating the neutralizer cathode. Notable Accomplishments: Built and tested thruster prototypes on MSFC thrust stand across 100–600 W RF power; submitted two new technology reports. Project Manager(s)/Lead(s): Joel Robinson/CS10 Sponsoring Program(s): STMD, CIF, SLS AD Project Description: Evaluating non-toxic green monopropellants (AF-M315E variant) in legacy F-16 emergency power units (EPUs) and Shuttle APU hardware to replace hydrazine. Notable Accomplishments: Successfully completed 64 test pulses in an F-16 gas generator using AF-M315E over Shell 405 catalyst, generating 300 psi chamber pressure. Project Manager(s)/Lead(s): Dr. Jessica Gaskin/ZP12, Dr. Stephen O’Dell/ZP12, Dr. Jeff Kolodziejczak/ZP12 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Procured and installed a windowless low-energy microfocus (~0.1 mm spot, Al target) x-ray source in the 100-m Stray Light Facility beamline for subarcsecond optics testing. Notable Accomplishments: Source successfully integrated into SLF and demonstrated stable operation over multi-day test runs. Project Manager(s)/Lead(s): Linda Habash Krause/ZP13, Gary Thornton/ES63 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Development of a frequency-domain ion spectrum analyzer (1 Hz to 10 kHz) for CubeSat platforms to measure ionospheric turbulence and plasma bubbles. Notable Accomplishments: Sensor heads completed plasma chamber testing; CARLO selected as primary science payload for InterAmerican University 3U CubeSat mission. Project Manager(s)/Lead(s): Biliyar Bhat/EM31, Sandra Greene/ER32 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Embedding 40 vol% diamond particles in NARloy-Z alloy via Field Assisted Sintering Technology (FAST) to increase combustion liner thermal conductivity by 69% and decrease mass by 24%. Notable Accomplishments: Sintered subscale cylindrical liner segments using FAST; demonstrated successful diffusion bonding and joint strength for subscale hot-fire test articles. Project Manager(s)/Lead(s): Reagan Malone/EO20, Alan Johnston/EO20 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Developing mobile and tablet-based Virtual Training Units (VTUs) interfacing with Huntsville Operations Support Center (HOSC) simulators for remote astronaut and flight controller training. Notable Accomplishments: Established secure mobile networking and demonstrated standalone mobile VTU integration with Lab Training Complex simulations. Project Manager(s)/Lead(s): Carole Y. Wagner Sponsoring Program(s): MSFC/CMO, TIP Project Description: Implementing EPCglobal Gen 2 RFID automated tracking tags and sensors in cargo transfer bags (CTBs) and ISS racks to eliminate manual barcode scanning and inventory audits. Notable Accomplishments: Integrated and demonstrated RFID hardware, readers, and middleware for automated sample/cargo tracking in laboratory simulation facilities. Project Manager(s)/Lead(s): Garrick Merrill/ES33 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Developing autonomous distributed mesh networking software using commercial credit-card size computers for precision multi-vehicle formation flight. Notable Accomplishments: Successfully demonstrated multi-node mesh networking and coordinated autonomous flight with eight quadcopter UAVs; released software via NASA Software Catalog. Project Manager(s)/Lead(s): Kosta Varnavas/ES33, Dr. Herb Sims/ES63 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Adapting the PULSAR software-defined radio into a low-cost, portable ground base station paired with inflatable/mobile antennas for small sat and CubeSat communication. Notable Accomplishments: Procured and integrated base station hardware components to support upcoming small sat flight missions. Project Manager(s)/Lead(s): Jason Chuang/EV42 Sponsoring Program(s): MSFC/CMO, TIP Project Description: Evaluating and benchmarking commercial and prototype LIDAR systems for hazard avoidance (boulders, slopes, craters) during autonomous lunar landing simulations. Notable Accomplishments: Conducted tethered balloon and crane LIDAR scans over MSFC lunar terrain field; created 3D ground-truth hazard maps using Faro and Leica LIDARs. Project Manager(s)/Lead(s): Brian Ramsey/ZP12, W. Scott Smith/ES31, Mikhail Gubarev/ZP12, Jeff McCracken/ZP20 Sponsoring Program(s): MSFC/CMO, CSDSG Project Description: Direct computer-controlled deterministic robotic polishing (Zeeko 7-axis machine) of thin glass and metal full-shell grazing incidence x-ray mirror mandrels/shells. Notable Accomplishments: Fabricated custom metrology support fixturing; created stitched metrology software directly generating polishing machine tool paths. Project Manager(s)/Lead(s): Chuck Brodell/WFF, Philip Franklin/ER52 Sponsoring Program(s): MSFC/CMO, CSDSG Project Description: Developing a NASA-designed sounding rocket solid sustainer motor offering ~15% higher performance and lower lifecycle cost than heritage systems. Notable Accomplishments: Selected domestic manufacturing vendors; prepared motor cases and exit cones for static hot-fire testing at MSFC East Test Facility. Project Manager(s)/Lead(s): John Dankanich/ZP30, Hani Kamhawi/GRC, James Szabo/Busek Sponsoring Program(s): MSFC/CMO, CSDSG Project Description: Developing a 12U CubeSat demonstration flight of a 200-W iodine propellant Hall thruster achieving >1,300 s Isp and >500 m/s delta-V from unpressurized solid iodine. Notable Accomplishments: Tested Busek BHT-200-I thruster, solid iodine feed system/valves, and electride cathode on MSFC pendulum thrust stand; project approved by SSTP for flight demo. Project Manager(s)/Lead(s): Jonathan Jones/ER50, Lawanna Harris/ZP30 Sponsoring Program(s): MSFC/CMO, CSDSG, TIP, CIF, Tech Excellence Project Description: Developing a suborbital/orbital nanosatellite launch capability (1–10 kg payloads) utilizing 3D printed solid rocket motors and Android smartphone avionics. Notable Accomplishments: Tested NL1D subscale vehicle; developed NL2A two-stage 9-in diameter vehicle featuring 3D printed 9M upper stage motor, cold-gas RCS, and secondary avionics payloads from ARC, KSC, and ATK. Project Manager(s)/Lead(s): David Hyde/ES33, Bryan Robertson/ES33, Todd Holloway/ZP21 Sponsoring Program(s): MSFC/CMO, CSDSG, CIF Project Description: Ruggedized low-noise science camera platform (~7 e- noise) matching custom flight electronics performance at an order-of-magnitude lower cost. Notable Accomplishments: Integrated e2v CCD57 camera into CLASP sounding rocket payload; completed adaptations for CCD230 detector for ESIS, MaGIXS, and Hi-C missions. Project Manager(s)/Lead(s): Justin Jackson/EM42 Sponsoring Program(s): MSFC/CMO, Dual-Use Technology CAN Project Description: Partnership with Mississippi State University to locally enhance interlaminar shear strength in out-of-autoclave composite scarf joints using CNT-doped interply resin. Notable Accomplishments: Three-point bend coupon testing demonstrated notable increases in interlaminar shear strength and energy absorption across room and cryogenic temperatures. Project Manager(s)/Lead(s): Majid Babai/EM42, Warren Peters/ER32 Sponsoring Program(s): MSFC/CMO, Dual-Use Technology CAN Project Description: Evaluating pulsed arc solid-wire free-form additive manufacturing to print large rocket engine nozzle extensions and casings in Inconel 718. Notable Accomplishments: Fabricated preliminary Inconel 718 test builds; performed transient thermal modeling in ANSYS to regulate build temperatures; tensile strength and yield matched standard specifications. Project Manager(s)/Lead(s): John Rakoczy/EV40, Pete Paceley/Draper Laboratory Sponsoring Program(s): MSFC/CMO, Dual-Use Technology CAN, CSDSG Project Description: Developing a low-SWaP, radiation-hardened mini-star tracker delivering ~10 arcsecond pointing accuracy for deep space CubeSats and nanosatellites. Notable Accomplishments: Completed project kickoff; designed prototype optics/electronics; fabricated mount for night-sky characterization on MSFC's ALAMO telescope. Report Date: 01-03-2015 Report Type: Technical Memorandum Dates Covered: October 2013–September 2014 Title: George C. Marshall Space Flight Center Research and Technology Report 2014 Authors: A.S. Keys, M.L. Tinker, and A.D. Sivak, Compilers Performing Organization: George C. Marshall Space Flight Center, Huntsville, AL 35812 Performing Organization Report Number: M-1393 Sponsoring Agency: National Aeronautics and Space Administration, Washington, DC 20546-0001 Report Number: NASA/TM—2015–218204 Distribution: Unclassified-Unlimited, Subject Category 12 Pages: 192 Abstract: Many of NASA’s missions would not be possible if it were not for the investments made in research advancements and technology development efforts. The technologies developed at Marshall Space Flight Center contribute to NASA’s strategic array of missions through technology development and accomplishments. The scientists, researchers, and technologists of Marshall Space Flight Center who are working these enabling technology efforts are facilitating NASA’s ability to fulfill the ambitious goals of innovation, exploration, and discovery.