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Advanced aircraft tracking will come live from space
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By European Space Agency
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 European Space Agency
Image: The Copernicus Sentinel-2B satellite captured this image over Europe’s Spaceport in French Guiana on 2 September, just ahead of the Sentinel-2C launch. View the full article
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By NASA
5 min read
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.
This model was installed in the Icing Research Tunnel in 2023 as part of the Advanced Air Mobility Rotor Icing Evaluation Study, which sought to refine testing of rotating models in the tunnel, validate 3D computational models, and study propeller icing issues.Credit: NASA The facility was used in a complementary way with the Twin Otter aircraft and computer simulation to improve de-icing systems, predictive tools, and instrumentation. IRT testing also accelerated the all-weather certification of the OH-60 Black Hawk helicopter. In the 1990s, the icing program turned its attention to combatting super-cooled large droplets, which can cause ice buildup in areas not protected by leading edge de-icing systems, and tailplane icing, which can cause commuter aircraft to pitch forward.
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.
More Resources:
“We Freeze to Please”: A History of NASA’s Icing Research Tunnel and the Quest for Flight Safety Icing Research Tunnel Website International Historic Mechanical Engineering Landmark NASA Glenn’s Aeronautics Research NASA’s Aeronautics Research Mission Directorate Explore More
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Article 1 day ago 8 min read 40 Years Ago: STS-41D – First Flight of Space Shuttle Discovery
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Article 7 days ago View the full article
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By NASA
On Aug. 30, 1984, space shuttle Discovery lifted off on the STS-41D mission, joining NASA’s fleet as the third space qualified orbiter. The newest shuttle incorporated newer technologies making it significantly lighter than its two predecessors. Discovery lofted the heaviest payload up to that time in shuttle history. The six-person crew included five NASA astronauts and the first commercial payload specialist. During the six-day mission, the crew deployed a then-record three commercial satellites, tested an experimental solar array, and ran a commercial biotechnology experiment. The astronauts recorded many of the activities using a large format film camera, the scenes later incorporated into a motion picture for public engagement. The mission marked the first of Discovery’s 39 trips to space, the most of any orbiter.
Left: Space shuttle Discovery rolls out of Rockwell’s Palmdale, California, facility. Middle: Discovery atop the Shuttle Carrier Aircraft during the cross-country ferry flight. Right: Discovery arrives at NASA’s Kennedy Space Center in Florida.
Space shuttle Discovery, the third space-qualified orbiter in NASA’s fleet and named after several historical ships of exploration, incorporated manufacturing lessons learned from the first orbiters. In addition, through the use of more advanced materials, the new vehicle weighed nearly 8,000 pounds less than its sister ship Columbia and 700 pounds less than Challenger. Discovery rolled out of Rockwell International’s plant in Palmdale, California, on Oct. 16, 1983. Five of the six crew members assigned to its first flight attended the ceremony. Workers trucked Discovery overland from Palmdale to NASA’s Dryden, now Armstrong, Flight Research Center at Edwards Air Force Base (AFB), where they mounted it atop a Shuttle Carrier Aircraft (SCA), a modified Boeing 747, for the transcontinental ferry flight to NASA’s Kennedy Space Center (KSC) in Florida. Discovery arrived at KSC on Nov. 9 following a two-day stopover at Vandenberg Air Force, now Space Force Base, in California.
Left: STS-41D crew patch. Middle: Official photograph of the STS-41D crew of R. Michael “Mike” Mullane, front row left, Steven A. Hawley, Henry “Hank” W. Hartsfield, and Michael L. Coats; Charles D. Walker, back row left, and Judith A. Resnik. Right: Payloads installed in Discovery’s payload bay for the STS-41D mission include OAST-1, top, SBS-4, Telstar 3C, and Leasat-2.
To fly Discovery’s first flight, originally designated STS-12 and later renamed STS-41D, in February 1983 NASA assigned Commander Henry W. Hartsfield, a veteran of STS-4, and first-time flyers Pilot Michael L. Coats, and Mission Specialists R. Michael Mullane, Steven A. Hawley, and Judith A. Resnik, all from the 1978 class of astronauts and making their first spaceflights. In May 1983, NASA announced the addition of Charles D. Walker, an employee of the McDonnell Douglas Corporation, to the crew, flying as the first commercial payload specialist. He would operate the company’s Continuous Flow Electrophoresis System (CFES) experiment. The mission’s primary payloads included the Leasat-1 (formerly known as Syncom IV-1) commercial communications satellite and OAST-1, three experiments from NASA’s Office of Aeronautics and Space Technology, including the Solar Array Experiment, a 105-foot long lightweight deployable and retractable solar array. Following the June 1984 launch abort, NASA canceled the STS-41F mission, combining its payloads with STS-41D’s, resulting in three communications satellites – SBS-4 for Small Business Systems, Telstar 3C for AT&T, and Leasat 2 (Syncom IV-2) for the U.S. Navy – launching on the flight. The combined cargo weighed 41,184 pounds, the heaviest of the shuttle program up to that time. A large format IMAX® camera, making its second trip into space aboard the shuttle, flew in the middeck to film scenes inside the orbiter and out the windows.
Left: First rollout of Discovery from the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. Right: The June 26 launch abort.
The day after its arrival at KSC, workers towed Discovery to the Orbiter Processing Facility (OPF) to begin preparing it for its first space flight. They towed it to the Vehicle Assembly Building (VAB) on May 12, 1984, for mating with its External Tank (ET) and Solid Rocket Boosters (SRBs). The completed stack rolled out to Launch Pad 39A a week later. On June 2, engineers successfully completed an 18-second Flight Readiness Firing of Discovery’s main engines. Post test inspections revealed a debonding of a thermal shield in main engine number 1’s combustion chamber, requiring its replacement at the pad. The work pushed the planned launch date back three days to June 25. The failure of the shuttle’s backup General Purpose Computer (GPC) delayed the launch by one day. The June 26 launch attempt ended just four seconds before liftoff, after two of the main engines had already ignited. The GPC detected that the third engine had not started and shut all three down. It marked the first time a human spaceflight launch experienced an abort after the start of its engines since Gemini VI in October 1965. The abort necessitated a rollback to the VAB on July 14 where workers demated Discovery from the ET and SRBs. Engineers replaced the faulty engine, and Discovery rolled back out to the launch pad on Aug. 9 for another launch attempt. The six-person crew participated in the Terminal Countdown Demonstration Test, essentially a dress rehearsal for the actual countdown to launch, on Aug. 15. A software issue delayed the first launch attempt on Aug. 29 by one day.
Left: The STS-41D crew pose at Launch Pad 39A at NASA’s Kennedy Space Center in Florida following the Terminal Countdown Demonstration Test. Right: Liftoff of Discovery on the STS-41D mission.
Finally, on Aug. 30, 1984, Discovery roared off its launch pad on a pillar of flame and within 8 and a half minutes entered orbit around the Earth. The crew got down to work and on the first day Mullane and Hawley deployed the SBS-4 satellite. On the second day in space, they deployed Leasat, the first satellite designed specifically to be launched from the shuttle. On the third day, they deployed the Telstar satellite, completing the satellite delivery objectives of the mission. Resnik deployed the OAST-1 solar array to 70% of its length to conduct dynamic tests on the structure. On the fourth day, she deployed the solar array to its full length and successfully retracted it, completing all objectives for that experiment.
The deployment of the SBS-4, left, Leasat-2, and Telstar 3C satellites during STS-41D.
Walker remained busy with the CFES, operating the unit for about 100 hours, and although the experiment experienced two unexpected shutdowns, he processed about 85% of the planned samples. Hartsfield and Coats exposed two magazines and six rolls of IMAX® film, recording OAST-1 and satellite deployments as well as in-cabin crew activities. Clips from the mission appear in the 1985 IMAX® film “The Dream is Alive.” On the mission’s fifth day, concern arose over the formation of ice on the orbiter’s waste dump nozzle. The next day, Hartsfield used the shuttle’s robotic arm to dislodge the large chunk of ice.
Left: Payload Specialist Charles D. Walker in front of the Continuous Flow Experiment System. Middle: Henry “Hank” W. Hartsfield loading film into the IMAX® camera. Right: The OAST-1 Solar Array Experiment extended from Discovery’s payload bay.
On Sep. 5, the astronauts closed Discovery’s payload bay doors in preparation for reentry. They fired the shuttle’s Orbital Maneuvering System engines to slow their velocity and begin their descent back to Earth. Hartsfield guided Discovery to a smooth landing at Edwards AFB in California, completing a flight of 6 days and 56 minutes. The crew had traveled 2.5 million miles and orbited the Earth 97 times.
Left: The STS-41D crew pose in Discovery’s middeck. Right: Space shuttle Discovery makes a perfect landing at Edwards Air Force Base in California to end the STS-41D mission.
By Sept. 10, workers had returned Discovery to KSC to prepare it for its next mission, STS-51A, in November 1984. During its lifetime, Discovery flew a fleet leading 39 missions, making its final trip to space in February 2011. It flew both return to flight missions, STS-26 in 1988 and STS-114 in 2005. It launched the Hubble Space Telescope in 1990 and flew two of the missions to service the facility. Discovery flew two mission to Mir, docking once. It completed the first docking to the International Space Station in 1999 and flew a total of 13 assembly and resupply missions to the orbiting lab. By its last mission, Discovery had traveled 149 million miles, completed 5,830 orbits of the Earth, and spent a cumulative 365 days in space in the span of 27 years. The public can view Discovery on display at the National Air and Space Museum’s Stephen F. Udvar-Hazy Center in Chantilly, Virginia.
Read recollections of the STS-41D mission by Hartsfield, Coats, Mullane, Hawley, and Walker in their oral histories with the JSC History Office. Enjoy the crew’s narration of a video about the STS-41D mission.
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