National Aeronautics and Space Administration
Small Business Innovation Research 2002 Program Solicitations

TOPIC A4 Next Generation Access to Space

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A4.01 Space Transportation Architecture Definition
A4.02 Space Structures, Materials, and Manufacturing

NASA formed the 2nd Generation RLV Program to coordinate the development of the 2nd Generation RLV architecture. The Program, frequently referred to as the Space Launch Initiative (SLI), is focused on reducing the technical and business risks associated with developing a 2nd Generation Reusable Launch Vehicle system. The Program is built on four principles: (1) Commercial convergence - NASA seeks to fly its unique missions on privately owned and operated launch systems within an integrated architecture; (2) Competition - SLI seeks to enable at least two viable commercial competitors in the 2006 timeframe; (3) Assured access - Demonstrate the capability to autonomously deliver cargo to the International Space Station (ISS) as a backup to the Space Shuttle for meeting the United States' critical resupply manifest to ISS; (4) Evolvability - Develop systems that can affordably evolve to meet future mission requirements.

The Program focuses on four primary activities: (1) Systems Analysis/Engineering and Requirements Definition is critical to establishing the Program direction and determining NASA recommendations for the appropriate plans and budgets for architectures and systems that meet NASA requirements; (2) RLV Competition and Risk Reduction allows the government and US industry to mature technology and pursue significant technical and economic improvements that reduce risk through design maturation and hardware demonstration. It is this risk reduction that will enable a competition of architectures by the end of FY2006; (3) NASA Unique Systems will concentrate on developing the systems necessary to meet unique NASA mission requirements such as crew transport, cargo carriers, and rendezvous and docking; (4) Alternative Access will demonstrate the capability of providing an alternative and autonomous means of accessing ISS in the near term utilizing existing or emerging commercial launch vehicles.

A4.01 Space Transportation Architecture Definition
Lead Center: MSFC

Next generation RLV architectures will require high overall vehicle payload mass to lift-off mass ratios, propulsion systems which deliver higher thrust to engine weight ratios, increased trajectory averaged specific impulse, reliable overall vehicle systems performance, and extended reusability in order to achieve cost and crew safety goals. This subtopic emphasizes innovative launch vehicle architecture definition technology for subsystems, and vehicle system level design and analysis tools to support assessment of the credible physics and technical viability of proposed next generation launch vehicle architectures. Design and analysis tools proposed under this subtopic should address technical issues related to propellant tanks, thermal control subsystems, thermal protection systems, structures, guidance, navigation, and control (GN&C), loads and dynamics, fluid dynamics, integrated vehicle health management, turbomachinery, combustion devices, propulsion subsystems integration, vehicle layout, and overall vehicle level systems integration. Specific areas of interest for technology advancement and innovations include the following:

• Innovative analysis tools, and testing techniques applicable to assessment of credible physics associated with reusable launch vehicle thermal protection system designs, compartment thermal control requirements, cryo-tank thermal characteristics, and vehicle base heat shield requirements.
• Control and health management of vehicle structural systems by using sensors that have little influence on the structural parameters with the exception of the structural damping parameters
• Innovative vehicle preliminary design tools that support the design, analysis, and integration of vehicle systems and propulsions subsystems (such as the ability to assess operability of the overall launch vehicle concept and to model the impacts of design changes on vehicle cost, operations, crew safety, vehicle aerodynamics, and controllability). These tools would significantly enhance the overall systems engineering evaluation of potential reusable launch vehicle architectures.
• Integrated CAD, solid-model, structural, dynamic, thermal, and fluid-flow analysis methods for multi-disciplinary analysis and optimization of subsystems, components, and overall launch vehicle systems; and improved vehicle analysis tools in the areas of stress, thermal, structures, fluid dynamics, and acoustics.
• Manufacturing and testing techniques that will allow for significant reduction in the cost and schedule required to perform wind tunnel aerodynamic testing of candidate RLV configurations.
• Innovative analysis techniques to assess propellant management systems, feed lines, tank pressurization, fill, drain, and vent requirements.
• Methodologies and analysis tools for investigation and assessment of optimal fault detection and redundancy management strategies; execution software and advanced navigation hardware/software architectures; adaptive GN&C utilizing data from sensors such as GPS; guidance concepts that will reduce operational costs and increase reliability by autonomously reshaping trajectories and retargeting landing sites in the presence of abort/failure situations to satisfy vehicle and control constraints to achieve a safe abort.
• Methodologies and analysis tools for investigation and assessment of advanced control concepts that will reduce operational costs and increase reliability by adapting to changing missions/payloads/vehicle models/failures and abort scenarios without requiring ground effort to retune.
• Methodologies and analysis tools for investigation and assessment of automated mission planning techniques for planning flight operations of RLVs, including trajectory planning, launch window and timeline determination, generation of initialization loads, and verification that the GN&C will successfully fly the vehicle.
• Analysis and testing techniques for assessment of damage and stress including life cycle predictions, progressive internal damage and dynamic response in structures containing ceramic-matrix, metal-matrix composites, or other composite materials; and nondestructive evaluation of structural integrity of vehicle subsystem and component materials. Methods for efficient characterization of frequency response functions of large structures, and analysis and testing techniques for passive and active vibration isolation devices for launch vehicles and payloads.
• Advanced methods and tools for prediction and assessment of dynamic and unsteady environments applicable to reusable launch vehicle systems and components. Methods to predict and evaluate the internal fluctuating environments of propellant delivery systems, dynamic contribution of cavitating pumps, and vehicle/engine system dynamic stability. Methods to predict and evaluate steady and unsteady external environments of complex vehicle/engine combinations relating to geometrically complex external aerodynamics, engine start/launch overpressures, and noise related to flow dynamics.
• Advanced methodologies for thermal and structural assessment of large integrated composite cryogenic tanks, assessment of efficient and effective tank repair techniques, and technologies associated with modal, acoustic and static testing of large-scale aerospace structural systems. Innovative experimental-empirical methods for composite material thermal characterization and response prediction.

A4.02 Space Structures, Materials, and Manufacturing
Lead Center: MSFC

Innovative manufacturing technologies including materials, processes, and structures development are sought for increasing safety and reducing cost and weight of space transportation propulsion, launch vehicle, and spacecraft systems and components. Only processes which are environmentally friendly and worker health oriented will be considered. Areas of interest include, but are not limited to:

Polymer Matrix Composites (PMCs)
Large scale manufacturing; non-autoclave curing; damage tolerant and repairable structures; advanced thermal and fluid systems; advanced materials and manufacturing processes for both oxygen-rich and high-temperature applications; improved thermal protection systems (such as thermally integrated structures with integral cryogenic tanks); aerogel technologies; rapid, multidimensional preformed fabrication for continuous fiber-reinforced composites with simple or complex geometry and/or large dimensions; adhesive bonding materials with high-performance capabilities in extreme environments such as cryogenic temperatures and elevated temperatures above 520K; optical cements with a stable refractive index resistant to ionizing radiation and low outgasing; conformal cryogenic tanks; designs for cryogen leakage prevention; innovations in the manufacture of thin film structures.

Metals and Metal Matrix Composites (MMCs)
Advanced manufacturing processes such as pressure infiltration casting (for MMCs), laser engineered near net shaping (Metals and MMCs), electron beam physical vapor deposition (Metals and MMCs), and in situ MMC formation; processes and joining techniques such as friction stir and friction plug welding for manufacturing components which target increasing specific strength, reduced weight, specific stiffness, and high pressure gaseous or liquid oxygen or high pressure gaseous or liquid hydrogen environments; metallic matrix alloy compositions which optimize high ductility and good joinability (welding/brazing); improved bonding and joining technologies; fiber or hybrid composites, functionally graded materials, high or low temperature application; alloys and nanophase materials to achieve more than 120 ksi tensile strength at room temperature, and 60 ksi at elevated temperature above 500°F; new advanced superalloys that resist hydrogen embrittlement and are compatible with high pressure oxygen; and advanced low cost manufacturing processes for engine applications.

Spray and Coating Processes
Innovative thermal spray or cold spray coating processes, or novel uses of existing thermal spray process that substantially improve material properties, combine dissimilar materials in new and useful ways or drastically increase efficiency, equipment life, or allow new applications previously limited by the current state-of-the-art; innovative methods of coating protection which will reduce coating application time, increase coating life, eliminate steps in the coating application process and extend hardware life, reducing refurbishment costs. Applications of interest include: dense deposits of refractory metals and metal carbides, thicknesses greater than 0.125 inch; thermally sprayed coatings on non-metallic composite materials to enhance or extend utility or service limitations; coating or spraying processes that allow forming of dense, high quality structural parts of complex geometry; processes, hardware, or materials that allow application of high melting point materials to heat-sensitive substrate materials; use of thermal spray, wholly or in part, as a means of rapid prototyping in metallic materials.

Joining and Bonding
Innovative technologies for bonding and joining of materials to improve joint efficiency, allow joining of a wider range of materials, improve the quality and cost-effectiveness of the joint, and extend the understand-ing of factors influencing these characteristics; joining of aluminum alloys especially those applicable to high-performance aluminum-lithium alloys and aluminum metal-matrix composites; improvement in con-trol of welding, brazing and other joining processes as they are applied to joints for aerospace vehicles (these technologies should be compatible with the quality requirements for aerospace vehicles and should include process control technologies as well as non-destructive examination methods); sealant materials that remain ductile in cryogenic environments; sealants that will not crack, craze or peel when subjected to a high strain environment.

Electronic Systems and Computational Simulation and Analysis
Integrated design and analysis; advanced analysis, testing methods and tools; virtual product development and manufacturing simulation; process control and instrumentation for characterization and verification of material properties (including thermal, optical, electrical, mechanical, and moisture absorption);intelligent synthesis environment and collaborative engineering tools for manufacturing; health monitoring and maintenance technologies.

Rapid-prototyping
Rapid-prototyping technologies leading to improved structural integrity materials for use in end-item component processing; computer aided design driven additive manufacturing technologies producing near net shape hardware from metal or ceramic matrix composites, as well as improved monolithic and alloyed properties for direct hardware fabrication and custom part manufacturing (low run production); scalability effects for large component fabrication must be addressed as well.

Nanotechnology
Innovations that use nanotechnology, biomimetic, and self-healing processes to achieve low cost manufacturing of high quality materials for engineered structures; materials that have significantly improved physical and chemical properties; nano-sensors; reduction in the weight and volume of spacecraft; produc-tion of materials from the molecule upwards; continuous fibers based on nanotubes of carbon and other promising materials.

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