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Benefield Anechoic Facility tests first space satellite in decades


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      Image: ESA’s Metal 3D Printer has produced the first metal part ever created in space. 
      The technology demonstrator, built by Airbus and its partners, was launched to the International Space Station at the start of this year, where ESA astronaut Andreas Mogensen installed the payload in the European Drawer Rack of ESA’s Columbus module. In August, the printer successfully printed the first 3D metal shape in space.  
      This product, along with three others planned during the rest of the experiment, will return to Earth for quality analysis: two of the samples will go to ESA’s technical heart in the Netherlands (ESTEC), another will go to ESA’s astronaut training centre in Cologne (EAC) for use in the LUNA facility, and the fourth will go to the Technical University of Denmark (DTU). 
      As exploration of the Moon and Mars will increase mission duration and distance from Earth, resupplying spacecraft will be more challenging.  Additive manufacturing in space will give autonomy for the mission and its crew, providing a solution to manufacture needed parts, to repair equipment or construct dedicated tools, on demand during the mission, rather than relying on resupplies and redundancies. 
      ESA’s technology demonstrator is the first to successfully print a metal component in microgravity conditions. In the past, the International Space Station has hosted plastic 3D printers.
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    • By NASA
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      Two robotic arms wrapped in gold material sitting on top of a black and silver box.Naval Research Laboratory NASA and the Defense Advanced Research Projects Agency (DARPA) have signed an interagency agreement to collaborate on a satellite servicing demonstration in geosynchronous Earth orbit, where hundreds of satellites provide communications, meteorological, national security, and other vital functions. 
      Under this agreement, NASA will provide subject matter expertise to DARPA’s Robotic Servicing of Geosynchronous Satellites (RSGS) program to help complete the technology development, integration, testing, and demonstration. The RSGS servicing spacecraft will advance in-orbit satellite inspection, repair, and upgrade capabilities. 
      NASA is excited to support our long-term partner and advance important technologies poised to benefit commercial, civil, and national objectives. Together, we will make meaningful, long-lasting contributions to the nation’s in-space servicing, assembly, and manufacturing (ISAM) capabilities.
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      NASA will use expertise from the agency’s On-orbit Servicing, Assembly, and Manufacturing 1 project and other relevant efforts to provide hands-on support to RSGS in the areas of space robotics, systems engineering, spacecraft subsystems, integration and testing, operator training, and spaceflight operations. NASA’s involvement in RSGS will continue advancing the agency’s understanding of and experience with complex ISAM systems.
      DARPA will continue to lead the RSGS program, which has already achieved several important milestones, including the completion of two dexterous robotic arms designed for inspection and service that have been stress-tested for an on-orbit environment and the integration of those arms with their associated electronics, tools, and ancillary hardware to produce the fully integrated robotic payload. 
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    • By NASA
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      Preparations for Next Moonwalk Simulations Underway (and Underwater)
      A National Advisory Committee for Aeronautics researcher notes the conditions on the P-39L after its first test run in the Icing Research Tunnel on Sept. 13, 1944. The aircraft was too large to fit in the test section, so it was installed downstream in a larger area of the tunnel. The initial tests analyzed ice buildup on the nose, propeller blades, and antennae. In the summer of 1945, the P-39L was used to demonstrate the effectiveness of a thermal pneumatic boot ice-prevention system and heated propeller blades.Credit: NASA On Sept. 13, 1944, researchers subjected a Bell P-39L Airacobra to frigid temperatures and a freezing water spray in the National Advisory Committee for Aeronautics (NACA)’s new Icing Research Tunnel (IRT) to study inflight ice buildup. Since that first run at the Aircraft Engine Research Laboratory (now NASA’s Glenn Research Center) in Cleveland, the facility has operated on a regular basis for 80 years and remains the oldest and one of the largest icing tunnels in the world.
      Water droplets in clouds can freeze on aircraft surfaces in certain atmospheric conditions. Ice buildup on the forward edges of wings and tails causes significant decreases in lift and rapid increases in drag. Ice can also block engine intakes and add weight. NASA has a long tradition of working to understand the conditions that cause icing and developing systems that prevent and remove ice buildup.
      The NACA decided to build its new icing tunnel adjacent to the lab’s Altitude Wind Tunnel to take advantage of its powerful cooling equipment and unprecedented refrigeration system. The system, which can reduce air temperature to around –30 degrees Fahrenheit, produces realistic and repeatable icing conditions using a spray nozzle system that creates small, very cold droplets and a drive fan that generates airspeeds up to 374 miles per hour.
      View upstream of the Icing Research Tunnel’s 25-foot-diameter drive fan in 1944. The original 12-bladed wooden fan and its 4,100-horsepower motor could produce air speeds up to 300 miles per hour. The motor and fan were replaced in 1987 and 1993, respectively.Credit: NASA Two rudimentary icing tunnels had briefly operated at the NACA’s Langley Memorial Aeronautical Laboratory in Hampton, Virginia, but icing research primarily relied on flight testing. The sophisticated new tunnel in Cleveland offered a safer way to study icing physics, test de-icing systems, and develop icing instrumentation.
      During World War II, inlet icing was a key contributor to the heavy losses suffered by C-46s flying supply missions to allied troops in China. In February 1945, a large air scoop from the C-46 Commando was installed in the tunnel, where researchers determined the cause of the issue and redesigned the scoop to prevent freezing water droplets entering. The modifications were later incorporated into the C–46 and Convair C–40.
      A National Advisory Committee for Aeronautics engineer experiments with an Icing Research Tunnel water spray system design in September 1949. Researchers used data taken from research flights to determine the proper droplet sizes. The atomizing spray system was perfected in 1950.Credit: NASA Despite these early successes, NACA engineers struggled to improve the facility’s droplet spray system because of a lack of small nozzles able to produce sufficiently small droplets. After years of dogged trial and error, the breakthrough came in 1950 with an 80-nozzle system that produced the uniform microscopic droplets needed to properly simulate a natural icing cloud. 
      Usage of the IRT increased in the 1950s, and the controlled conditions produced by the facility helped researchers define specific atmospheric conditions that produce icing. The Civil Aeronautics Authority (the precursor to the Federal Aviation Administration) used this data to establish regulations for all-weather aircraft. The facility also contributed to new icing protections for antennae and jet engines and the development of cyclical heating de-icing systems.
      The success of the NACA’s icing program, along with the increased use of jet engines – which permitted cruising above the weather – reduced the need for additional icing research. In early 1957, just before the NACA transitioned to NASA, the center’s icing program was terminated. Nonetheless, the IRT remained active throughout the 1960s and 1970s supporting industry testing.
      The Icing Research Tunnel is highlighted in this 1973 aerial photograph. The larger Altitude Wind Tunnel (AWT) is located behind it, and the Refrigeration Building that supported both tunnels is immediately to the left of the AWT.Credit: NASA By the mid-1970s, new icing issues were arising due to the increased use of helicopters, regional airliners, and general aviation aircraft. The center held an icing workshop in July 1978 where over 100 icing experts from across the world converged and lobbied for a reinstatement of NASA’s icing research program.
      The agency agreed to provide funding to support a small team of researchers and increase operation of the icing facility. In 1982, a deadly icing-related airline crash spurred NASA to bring back a full-fledged icing research program.
      Nearly all the tunnel’s major components were subsequently upgraded. Use of the IRT skyrocketed, and there was at least a one-year wait for new tests during this period. In 1988, the facility operated more hours than any year since 1950.
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      The IRT was one of the busiest facilities at the center in the 2000s and continues to maintain a steady test schedule today, investigating icing on turbofan engines and propellers, refining testing of rotating models, validating 3D models, and much more. The IRT been used to develop nearly every modern ice protection system, provided key icing environment data to regulatory agencies, and validated leading ice prediction software. After 80 years, it remains a critical tool for sustaining NASA’s leadership in the icing field.
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      A prototype of the Mini Potable Water Dispenser, currently in development at NASA’s Marshall Space Flight Center, is displayed alongside various food pouches during a demonstration at NASA’s Johnson Space Center. NASA/David DeHoyos NASA engineers are working hard to ensure no astronaut goes hungry on the Artemis IV mission.
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      An engineer demonstrates the use of the Mini Potable Water Dispenser by rehydrating a food pouch during a testing session at Johnson Space Center on June 6, 2024. This compact, lightweight dispenser is designed to help astronauts prepare meals in deep space.NASA/David DeHoyos A close-up view of the Mini Potable Water Dispenser prototype during a testing demonstration at NASA’s Johnson Space Center on June 6, 2024.NASA/David DeHoyos NASA food scientists rehydrate a food pouch during a test of the Mini Potable Water Dispenser at Johnson Space Center on June 6, 2024. NASA/David DeHoyos A NASA food scientist captures video of the Mini Potable Water Dispenser during testing at Johnson Space Center.NASA/David DeHoyos Matt Rowell, an engineer from the Marshall Space Flight Center demonstrates the Mini Potable Water Dispenser to NASA food scientists during a testing session.NASA/David DeHoyos Project manager Shaun Glasgow (right) demonstrates the Mini Potable Water Dispenser. NASA/David DeHoyos Brett Montoya, a lead space architect in the Center for Design and Space Architecture at Johnson Space Center, rehydrates a package of food using the Mini Potable Water Dispenser.NASA/David DeHoyos Learn More about Gateway Facebook logo @NASAGateway @NASA_Gateway Instagram logo @nasaartemis Share
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