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Dedicated technology has been developed to support long-term biological experiments on-board spacecraft. These developments include a microgravity compatible tubular photo bioreactor for the cultivation of micro algae at very high biomass concentrations and with very high gas exchange rates, a microgravity compatible gas / liquid phase separator which also works as a pneumatic low shear-stress pump, a microgravity compatible dehumidifier, and a maltose separating reverse osmosis unit. Integration of these technologies into a partially closed artificial ecosystem form the foundation of the SYMBIOSE concept (System for Microgravity Bioregenerative Support of Experiments).

The “Rigidization-on-Command”™ (ROC™) resin development has focused on the development of resin systems that use UV light cure for rigidization. Polymeric sensitizers have been incorporated into the resin formulations to promote cure using Pen-Ray lamps and UV light-emitting diodes (LED's). Formulations containing the polymeric sensitizers were examined by FTIR and DSC. Complete cure was observed after 15 min. exposure with the Pen-Ray lamps. Performance of the Pen-Ray lamps and UV LEDs was thoroughly characterized. Thermal models were developed to optimize the performance of the of the MLI insulation thermal oven used for orbital cure of the boom. Results show that -12°C is the lowest temperature required for cure of the ROC™ resin systems.

In recent years there has been increasing interest in quantifying the emissions from aircraft in order to generate inventories of emissions for climate models, technology and scenario studies, and inventories of emissions for airline fleets typically presented in environmental reports. The preferred method for calculating aircraft engine emissions of NOx, HC, and CO is the proprietary “P3T3” method. This method relies on proprietary airplane and engine performance models along with proprietary engine emissions characterizations. In response and in order to provide a transparent method for calculating aircraft engine emissions non proprietary fuel flow based methods 1,2,3 have been developed. This paper presents derivation, updates, and clarifications of the fuel flow method methodology known as “Fuel Flow Method 2”.

A wide body aircraft carries almost a half–ton of water and ice between the cabin and skin of the aircraft. The water can get on wires and connectors, which can cause electrical problems, cause corrosion and rust, and, eventually, “rain in the plane”. The speaker is the CEO of CTT Systems that has developed a system that solves the condensation by using dry air. The speaker will discuss how condensation can be prevented and how airlines can also save maintenance costs in the process. This topic is relevant for the attendees at the Aerospace Expo, as they are decision makers who need to be aware of this issue. It is also important for the MRO shows as the attendees are on the front lines of dealing with this problem.

The airline industry seems to be providing more leisure features on planes like inflight entertainment, Internet access and Digital TV, but it seems the airline industry has ignored the issue of excess condensation on aircraft, which had plagued carriers since the birth of the airline industry. How safe are passengers when a wide body aircraft carries in excess almost a half ton of water and ice between the cabin and skin of the aircraft? Besides the added weight straining the aircraft, excess condensation soaks wires and connectors which can cause electrical shorts. There have been instances of emergency doors frozen shut, locked by ice stemming from excess water dripping inside the plane. Extra water also causes “rain-in-the-plane”, an issue that has gained national attention and causes passenger discomfort. It's time for the industry to address what has become a serious issue.

During several ISS missions, there were false alarms at both US and Russian smoke detectors. High local airborne particulate concentrations and interior deposits are considered the causes for such anomalies. Alternatives are proposed to replace or complement these faulty smoke detectors. The entrained zeolite particles may play a role in causing problems with check valves and air save pumps in CDRA and Vozdukh. Another incidence has been the dispersion of particulates out of Metox regeneration oven. Particulate matters with aerodynamic diameter of 15 microns and above, which normally settle down on earth, stay airborne under micro-gravity and thereby cause the above-mentioned nuisances. The motion of such a particle along a gas stream with an initial velocity can be expressed by theoretical equations. Stokes' Law leads to the descriptions of inertial precipitation of aerosols that are important in solving the issues.

This Life Support Laboratory consists of a simulator of the spacecraft called Nautilus, which houses Air Revitalization Subsystem, Atmospheric Control and Supply, and Fire Detection and Suppression in the Equipment Area. There are supporting facilities including a Human Metabolic Simulator, simulated Low and Moderate Temperature Coolant Loop, chemical analysis bench, purified water supply, vacuum and gas supplies. These facilities are scheduled to be completed and start to operate for demonstration purposes by March 2005. There are an ARES Ground Model (AGM) and a Trace Contaminant Control Assembly in the ARS. The latter will be integrated with the AGM and a Condensing Heat Exchanger. The unit of AGM is being engineered, built, and will be delivered in early 2005 by EADS Space Division. These assemblies will be operated for sensitivity analysis, integration and optimization studies. The main goal is the achievement for optimal recovery of oxygen.

The paper summarizes the experience gained on the ISS water management system during the missions of ISS-1 through ISS-16 (since November 2 2000, through December 31, 2007). The water supply sources and structure, consumption and supply balance at various phases of space station operation are reviewed. The performance data of the system for water recovery from humidity condensate SRV-K and urine feed and pretreatment system SPK-U in the Russian orbital segment are presented. The key role of water recovery on a board the ISS and the need to supplement the station's water supply hardware with a system for water reclamation from urine, water from a carbon dioxide reduction system and hygiene water is shown.

NEW WELDING processes are dropping costs while providing improvements in weld quality. This paper describes some of the more promising new developments in pressure and fusion welding and brazing. Included in the discussion are ultrasonic, high frequency resistance, foil seam, magnetic force, percussion, friction, and thermopressure welding and diffusion bonding. The description of adhesive bonding includes the development of glass or ceramic materials as structural adhesives.*

easyJet has set new targets for 2020 that will contribute to a reduction of 7% over the next five years compared to ‎it‎s emissions today.

The likelihood of transmission of potential disease agents between animals and man during spaceflight is a real concern. Development of disease exclusion lists for animals and refinement of animal containment units have been the principal means of providing protection to the crew members. Awareness of potential latent infections and a judicious use of the higher risk category of animals such as wild-caught nonhuman primates provides another level of protection. Use of high efficiency filters, gasketing, and differential air pressures have all enabled increasing levels of safety through containment of potential aerosol escape from animal habitats.

A “next generation” condensing heat exchanger for space systems has to satisfy demanding operational requirements under variable thermal and moisture loads and reduced gravity conditions. Mathematical models described here are used to investigate transient behavior of wetting and de-wetting dynamics in the binary porous system of porous tubes and porous cold plate. The model is based on the Richard's equation simplified for the zero-gravity conditions. The half-saturation distance or the zone of influence of the porous annular suction tubes on the cold-plate porous material will be in the range of 1 to 10 cm for the time scales ranging from 100 to 10,000 seconds and moisture diffusivity in the range of D = 10-4 to 10-6 m2/s.

A zirconia electroysis cell is an all-solid state (mainly ceramic) device consisting of two electrodes separated by a dense zirconia electrolyte. The cell electrochemically reduces carbon dioxide to oxygen and carbon monoxide at elevated temperatures (800 to 1000°C). The zirconia electrolysis cell provides a simple, lightweight, low-volume system for Mars In-Situ Resource Utilization (ISRU) applications. This paper describes the fabrication process and discusses the electrochemical performance and other properties of zirconia electrolysis cells made by the tape calendering method. Electrolytes produced by this method are very thin (micrometer-thick); the thin electrolyte reduces ohmic losses in the cell, permitting efficient operation at temperatures of 800°C or below.

In spite of environmental issues related to cadmium and its electroplating process, electroplated cadmium is still extensively used in the aerospace and defense sectors. This trend is likely to continue especially for high strength steels because cadmium provides the best known corrosion and embrittlement protection for this application. Consequently, the environmental concerns related to the cadmium electroplating have been addressed using an alternative Zero-waste Physical Vapor Deposition (Z-PVD). This method does not use liquids, it recycles cadmium in situ, and is free of hydrogen embrittlement. The Z-PVD process is now in commercial production for the aerospace fasteners. The quality of the coatings has been at least equal to that of the electroplated cadmium.

Future space exploration missions will require a lightweight spacesuit that expends no consumables. This paper describes the design and performance of a prototype heat rejection system that weighs less than current systems and vents zero water. The system uses regenerable LiCl/water absorption cooling. Absorption cooling boosts the heat absorbed from the crew member to a high temperature for rejection to space from a compact, non-venting radiator. The system is regenerated by heating to 100°C for two hours. The system provides refrigeration at 17°C and rejects heat at temperatures greater than 50°C. The overall cooling capacity is over 100 W-hr/kg.

This paper describes the testing of a waste management system designed and fabricated for use in a space vehicle. The system provides for the collection and inactivation of urine, feces, emergency diarrheal disorders, vomitus, and debris; the volumetric determination of each micturition; and onboard storage of the inactivated wastes within the waste management system compartment. The zero-gravity test program conducted in a KC-135 aircraft provided the primary verification of the performance of the waste collection and urine volume determination functions prior to actual space flight. The test hardware simulated the actual system to a high degree of fidelity with respect to operational characteristics of the airflow required in collection, mechanical functions and system pressure differentials, in order to minimize simulation errors.

This paper presents a trade-off study to select a water separator system for a 3-man, 140-day, zero-g mission. Included is a summary of feasible concepts, a compilation of data on existing hardware, and a comparison of the performance characteristics of each with respect to the overall system. Six approaches to zero-g water separation were considered and are discussed: hydrophobic/hydrophilic screens; integrated condenser-water separators; centrifugal separators; cellular sponges; vortex separators; and elbow separators. Some of these techniques have high-performance characteristics with regard to water removal efficiency. However, when reduced to hardware, these same techniques may not integrate well with the overall system. The system selected was the integrated condenser-water-separator. This system requires no power, has no moving parts, and has a very small envelope.

For human beings who have been reared on the earth with its 1 G gravitational field, the condition of weightlessness is a world with which we are unfamiliar. Even if the layout and equipment configuration of a spacecraft designed to compensate for operation under Zero-G conditions, there are some things which are not effective under actual weightless conditions. In the design of a manned spacecraft, it is necessary to accumulate design data on human performance in a weightless condition, then to undertake design evaluations and verification under weightless conditions. In this paper, testing for the purpose of evaluating the effectiveness of Zero-G simulation using neutral buoyancy, conducted first of all in Japan, and recommendations on the equipment and Facilities required to conduct such simulations, are described.

Manned spacecraft life suport systems must operate in a zero gravity environment. Lack of the “pull” of gravity affects heat and mass transfer, fluid transport, phase change, and chemical and electrochemical processes. This paper covers new concepts necessary for humidity control, evaporative coolers, distillation units, and similar equipment required for spacecraft life support. Specific applications used on the Space Shuttle and in development for advanced regenerative systems are discussed, including how they work, how they are tested on earth, and how much, if at all, the weightless environment penalizes the designs.