This Is Where They 3D Print Cool Pieces That Are Needed For The ISS! They Use Cool Carbon Fiber Materials

See what goes on behind the gates of the NASA Langley Research Center (LaRC)!

The Space Shuttle Endeavour, atop a NASA 747, flies over Texas near the Johnson Space Center, December 11, 2008. (NASA)

NASA Langley researchers and engineers are:

Playing key roles in the development of both the Space Launch System and the Orion crew capsule, which will carry astronauts beyond the moon to an asteroid, and eventually to the dusty surface of the Red Planet.

Leading the aerodynamic design of the Space Launch System by doing analysis and extensive testing in facilities such as the Unitary Plan Wind Tunnel and Transonic Dynamics Tunnel.

Performing water impact testing and doing critical aerosciences and structural analyses for the Orion crew capsule. We also assist in analyzing and practicing recovery operations for Orion.

Developing Orion's Launch Abort System, or LAS, which is designed to protect astronauts in the unlikely event a problem arises during launch.

Spearheading work on advanced entry, descent, and landing (EDL) systems for planetary robotic missions and eventual human-scale missions to the surface of Mars. Understanding the aerodynamics and heating of atmospheric entry will enable more precise landing missions, while testing of new technologies will enable much larger missions to reach the Martian surface.

Developing safe and reliable autonomous systems to supplement human operations, including mechanisms that can work in deep space to maneuver, assemble and service structures. In the 2020s, NASA plans to use this kind of technology to retrieve an asteroid.

Leading the development of materials and structures for lightweight and affordable space transportation and habitation systems.

Solving the problems of deep space radiation protection, including leadership of the Human Research Program to develop a better understanding of space radiation on crew health and safety. Langley is also building prototype designs for habitats and storm shelters for use in space.

Working on sensor systems, known as Autonomous Landing Hazard Avoidance Technology (ALHAT), that will equip future planetary landers with the ability to assess landing hazards and land safely and precisely on many different planetary surfaces, including the moon, Mars and other planetary bodies.

Developing the Hypersonic Inflatable Aerodynamic Decelerator, or HIAD, a device that could some day help cargo, or even people, land on another planet. HIAD could give NASA more options for future planetary missions, because it could allow spacecraft to carry larger, heavier scientific instruments and other tools for exploration.

Robotic Arm Gets a Workout

A new robotic arm for assembling spacecraft and exploration platforms in space flexed its muscle in a successful ground demonstration Jan. 19.

The device, called the Tension Actuated in Space MANipulator (TALISMAN) was tested in the Structures and Materials Test Laboratory at NASA’s Langley Research Center in Hampton, Virginia.

TALISMAN is just one component of the Commercial Infrastructure for Robotic Assembly and Servicing (CIRAS). In this demonstration, the team manipulated the newer, longer arm back and forth from folded to extended positions to demonstrate that it is fully operational and ready for more comprehensive testing.  

“The demonstration we accomplished last week was the rough equivalent of what the Navy calls a “shakedown cruise,” said John Dorsey, NASA principal investigator for CIRAS.

The tests will get progressively more difficult over the coming months as more detailed tasks are demanded of the robots. Future tests include not only a series of demonstrations exercising TALISMAN’s ability to move and manipulate objects along a truss, but also a demonstration of the NASA Intelligent Jigging and Assembly Robot (NINJAR) and the Strut Assembly, Manufacturing, Utility & Robotic Aid (SAMURAI) building two truss bays from pieces.

CIRAS is a collaboration with industry partner Orbital ATK of Dulles, Virginia, aimed at developing a “toolbox” of capabilities for use in servicing, refueling, and ultimately the construction of assets on orbit.

Advanced in-space assembly technologies will provide a more cost-effective way to build spacecraft and future human exploration platforms in space, such as the tended spaceport between the Earth and the Moon the agency is looking to build that would serve as a gateway to deep space and the lunar surface.

One of the biggest benefits of in-space assembly is the ability to launch the necessary material and components in tightly packed envelopes, given rockets have limited capacity with strict requirements on the size and shape of pre-assembled items being launched into orbit.

“It’s the difference between taking your new bedroom suite home in a box from IKEA using your Honda Civic and hiring a large box truck to deliver the same thing that was fully assembled at a factory. Space is a premium on launches,” said Chuck Taylor, CIRAS project manager at Langley.

Being able to build and assemble components in space will allow more affordable and more frequent science and discovery missions in Earth orbit, across the solar system and beyond.

CIRAS is made up of several components. TALISMAN, the long-reach robotic arm technology, was developed and patented at Langley. TALISMAN moves SAMURAI, which is like the hand that brings truss segments to NINJAR, the robotic jig that holds the truss segments in place perfectly at 90 degrees while they are permanently fastened using electron beam welding to join together 3D printed titanium truss corner joints to titanium fittings at the strut ends. NINJAR was built almost entirely by interns in the lab. The students have done incredible things, Taylor said.

“We couldn't have done what we’ve done without them,” he added.

CIRAS is a part of the In-Space Robotic Manufacturing and Assembly project portfolio, managed by NASA’s Technology Demonstration Missions Program and sponsored by NASA’s Space Technology Mission Directorate.

The CIRAS team includes prime contractor Orbital ATK, supported by its wholly-owned subsidiary, Space Logistics, LLC; along with NASA Langley; NASA’s Glenn Research Center in Cleveland, Ohio; NASA’s Goddard Space Flight Center in Greenbelt, Maryland; and the U.S. Naval Research Laboratory in Washington, D.C. If Orbital and Langley are successful in this spring’s series of demonstrations, they may be awarded a second contract to demonstrate these same capabilities on orbit.

To learn more about NASA's Space Technology Mission Directorate, visit:

https://www.nasa.gov/spacetech

Kristyn Damadeo ​NASA Langley Research Center

@nasa

Life at the Lab: Dummies Crash Planes!

Get a behind-the-scenes look at how test dummies at NASA's Langley Research Center contribute to making the planes we fly on safer and developing space exploration vehicles. Work ranges from next-generation aircraft to water-impact tests that evaluate the splashdown of Orion astronaut crew capsules returning from space. 

Credit: NASA/Videographer: Gary Banziger; Writer and Co-Producer: Lily Daniels; Editor and Co-Producer: Kevin Anderson

Vibration test at 80% power of the European Structural Test Article conducted at NASA Glenn’s Space Power Facility at Plum Brook Station, Sandusky, Ohio.

Power of Pink Provides NASA with Pressure Pictures

They say you show your true colors when you’re under pressure.

Turns out the old saying works for models being tested in wind tunnels as well, specifically those coated with a unique Pressure-Sensitive Paint (PSP) that NASA engineers have used for more than 25 years.

Read more: https://www.nasa.gov/aero/power-of-pink-provides-nasa-with-pressure-pictures

Retired Major General Finds Balance as NASA Engineer

In many ways, the military and NASA couldn’t be different. Frank Batts has managed to navigate both worlds with precision, grace and just a bit of humor. After serving as a major general in the Army National Guard, he made the transition to working on computers as an engineer at NASA’s Langley Research Center in Hampton, Virginia.

“They’re opposites, but that keeps me balanced,” Batts said. “In the Army, you’re out there blowing things up in the field. Here, you’re trying to build electronic computer components.”

Batts is a senior data-systems engineer with the Advanced Measurement and Data Systems Branch at NASA’s Langley Research Center in Hampton, Virginia. He has been at Langley for 34 years and has seen the tools of the job change.

“Technology has changed tremendously,” said the 63-year-old Batts. “When we started out in the eighties, we were all using proprietary operating systems on real-time computers that were not widely used or understood. Now we’re pretty much using PCs for our work.”

In addition to his NASA career, Batts served his country with distinction in the armed forces – and made history along the way. He retired from the Army National Guard in 2012 as a major general and commander of the 29th Infantry Division in Fort Belvoir, Virginia - the first African-American to hold that post. He also served in the West Virginia and Tennessee national guards.

The adventure begins

Batts’ journey started in 1976, when he was accepted at North Carolina Agricultural and Technical State University in Greensboro and joined the Army Reserve Officer Training Corps (ROTC) there.

While at the university, Batts entered a cooperative program with the Union Carbide Corp., working in a gaseous diffusion plant in the nuclear division. After graduating from North Carolina A&T, Batts worked fulltime as an electrical engineer with Union Carbide, and as an engineering officer in the West Virginia National Guard.

“Initially when you get out of college, you’re competing with engineers from other schools,” Batts said. “I found out pretty soon that regardless of what school you came from, it got down to who can really deliver projects on time and on budget.”

Batts was pursuing a master’s degree in electronics engineering at North Carolina A&T around the time IBM introduced personal computers. He was told PCs were a fad and not worth investing in, but he glimpsed the future and got on board.

“It looked like to me it was the way to go,” he said.

But then in 1979, the Three Mile Island nuclear power plant in Pennsylvania experienced a partial core meltdown, releasing radioactive gas into the atmosphere.

The incident changed his professional trajectory, as the Union Carbide-run K-25 facility in Oak Ridge, Tennessee, where Batts was working, enriched uranium for nuclear power plants.

“Prior to Three Mile Island there were plans to construct nuclear plants all over the country, and K-25’s future was secure,” Batts said. “After Three Mile Island, all of those plans were dropped; we had more enriched uranium than was needed and K-25 was slated for closure.”

That meant he needed another job. While looking to move on, Batts found that NASA Langley was using a computing system similar to the one he used while he was with Union Carbide. He sets his sights on Langley, and has been on center as an electronic engineer since 1984 .

Two worlds in one

Batts’ military and NASA worlds were peacefully cohabitating until the Sept. 11, 2001, terrorist attacks. Batts was soon activated and from May 2004 through April 2005, served with the 54th Field Artillery Brigade Headquarters as the mobile liaison team chief in Kabul, Afghanistan as part of Operation Enduring Freedom.

“With the Army comes the leadership responsibilities. I managed a few thousand troops, and that’s no fun. I make an effort in my career at NASA to stay on the technical side rather than on the administrative side of things,” he said with a laugh.

What is fun for Batts, besides getting in more rounds at the golf course in his spare time, is serving as an example for engineering students though NASA’s outreach programs.

Batts, as the first engineer in his family, said he realizes the importance of recognizing those who blazed the trail for others.

“I have to pay homage to the people who came before me,” he said. “Before I was able to command a battalion, there was some else who commanded one, and did a credible enough job so that I had an opportunity.”

Batts also enjoys the reaction of people when they learn he works for NASA.

“There’s a lot of prestige that goes with working at NASA,” he said. “When people find out you work at NASA, they seem to look at you a bit differently.”

Eric Gillard NASA Langley Research Center

Landing and Impact Research Facility

From enabling astronauts to practice moon landings to aircraft crash testing to drop tests for Orion, NASA's gantry has come full circle.

The gantry, a 240-foot high, 400-foot-long, 265-foot-wide A-frame steel structure located at Langley Research Center in Hampton, Va., was built in 1963 and was used to model lunar gravity. Originally named the Lunar Landing Research Facility (LLRF), the gantry became operational in 1965 and allowed astronauts like Neil Armstrong and Edwin "Buzz" Aldrin to train for Apollo 11's final 150 feet before landing on the moon.

Because the moon's gravity is only 1/6 as strong as Earth's, the gantry had a suspension system that supported 5/6 of the total weight of the Lunar Excursion Module Simulator (LEMS), the device the astronauts used to perform the tests. This supportive suspension system imitated the moon's gravitational environment. Additionally, many of the tests were conducted at night to recreate lighting conditions on the moon.

Neil Armstrong with the LEMS at the Lunar Landing Research Facility. This picture (below) was taken in February 1969 - just five months before Armstrong would become the first person to set foot on the surface of the moon.

Aircraft Crash Test Research

After the Apollo program concluded, a new purpose emerged for the gantry – aircraft crash testing. In 1972, the gantry was converted into the Impact Dynamics Research Facility (IDRF) and was used to investigate the crashworthiness of General Aviation (GA) aircraft and rotorcraft. The facility performed full-scale crash tests of GA aircraft and helicopters, system qualification tests of Army helicopters, vertical drop tests of Boeing 707 and composite fuselage sections and drop tests of the F-111 crew escape capsule.

The gantry was even used to complete a number of component tests in support of the Mars Sample Return Earth Entry Vehicle.

With features including a bridge and a 72-foot vertical drop tower, the gantry was able to support planes that weighed up to 30,000 pounds. Engineers lifted aircraft as high as 200 feet in the air and released them to determine how well the craft endured the crash. Data from the crash tests were used to define a typical acceleration for survivable crashes as well as to establish impact criteria for aircraft seats. The impact criteria are still used today as the Federal Aviation Administration standard for certification.

In 1985, the structure was named a National Historic Landmark based on its considerable contributions to the Apollo program.

Revitalized Space Mission

The gantry provides engineers and astronauts a means to prepare for Orion's return to Earth from such missions. With its new mission, the gantry also received a new name – the Landing and Impact Research (LandIR) Facility.

Although originally capable of supporting only 30,000 pounds, the new bridge can bear up to 64,000 pounds after the summer 2007 renovations. Other renovations include a new elevator, floor repairs and a parallel winch capability that allows an accurate adjustment of the pitch of the test article. The new parallel winch system increases the ability to accurately control impact pitch and pitching rotational rate. The gantry can also perform pendulum swings from as high as 200 feet with resultant velocities of over 70 miles per hour.

The gantry makes researching for the optimal landing alternative for NASA's first attempted, manned dry landing on Earth possible. Orion's return on land rather than water will facilitate reuse of the capsule. A water landing would make reuse difficult due to the corrosiveness of salt water.

The testing process involves lifting the test article by steel cables to a height between 40 and 60 feet and swinging it back to Earth. Although the airbags appear most promising, the gantry has the capability to perform different kinds of tests, including a retro rocket landing system and a scale-model, water landing test using a four-foot-deep circular pool. So far, three types of tests have been conducted in support of the Orion program, each progressing from the previous to more realistic features.

The first test consisted of dropping a boilerplate test article that was half the diameter of what Orion will be. For the second round of testing, engineers added a welded structure to the top, with a shape more comparable to Orion to examine the article's tendency to flip or remain upright.

Hydro-Impact

The on-going tests for Orion continue with impacts on water. This is to ensure astronaut safety during a return to Earth mission. Similar to the Apollo program, Orion will re-enter Earth’s atmosphere at very high speeds and after slowing down, deploy parachutes to further slow the descent into the ocean. At NASA Langley Research Center, engineers use the hydro-impact research to determine the stresses on the vehicle and examine its behavior during a mock splashdown.