Space Structures, Materials, and Manufacturing of Materials Weight Reduction on Launch Vehicle Gross...

GAME CHANGING TECHNOLOGY DEVELOPMENT

National Aeronautics and Space Administration

www.nasa.gov



www.nasa.gov

Project Title

AIAA Adaptive Structures Conference 2013

NASA Space Technology Mission Directorate and

Game Changing Development Program

Presented by

Stephen Gaddis

GAME CHANGING TECHNOLOGY DEVELOPMENT GAME CHANGING TECHNOLOGY DEVELOPMENT

Agenda

• Space Technology Overview

• Game Changing Development (GCD) Overview (video)

• Adaptive Structures Investment Areas

• GCD Current Adaptive Structure Activities and Needs

• Deployable Structures (animation)

• Lightweight Materials & Structures (CCTD video)

• Inflatable Structures & Habitats (video)

• Nanotechnology

• Human Robotic Systems

• Tether Dynamics

• MGI

• Advanced Manufacturing (Video)

• Challenge

• Summary

• Back up


NASA Space Technology

• Space Technology Mission Directorate (STMD)

– Established officially Feb. 21, 2013

– Portfolio management and program implementation

– Nine programs covering the full TRL range

– Executes more than 1,000 projects

30 NASA Innovative Advanced

Concepts (NIAC)

80 Space Technology Research Grants

(STRG) & Fellowships

~750 SBIR/STTR

~100 Center Innovation Fund (CIF)

2 Centennial Challenges

4 Small Spacecraft

23 Flight Opportunities (FO)

~53 Game Changing Development

(GCD)

9 Technology Demonstration Missions

(TDM)


STMD Roadmap 14 Technical Areas

TA01

TA02

TA03

TA04

TA05

TA06

TA07

TA08

TA09

TA10

TA13

TA14

TA11

TA12


Space Technology:

Investing in Our Future

• Enabling Our Future in Space: By investing in cross-cutting

technologies that industry cannot tackle today, Space Technology matures the technology required for NASA’s future missions in science

and exploration.

• Invests in a Comprehensive Portfolio: Covers the full TRL range.

• Infuses Rapidly or Fails Fast: Rapid cadence of technology

maturation and infusion.

• NASA at the Cutting Edge: Pushing the boundaries of aerospace

technology and seizing opportunities.


STMD 9 Technology Programs (Red # indicates number of Structures & Material activities)

Early Stage Innovation Center Innovation Fund

Program NASA Innovative Advanced Concepts (NIAC) Program

Space Technology Research Grant Program

Low TRL Technology Research & Development

Small Business Innovation Research and Small Business Technology Transfer (SBIR/STTR) Program

Mid TRL Technology Development

Game Changing Development Program

Centennial Challenges Prize Program

High TRL Technology Capability Demonstrations

Flight Opportunities Technology Demonstration Missions

Small Spacecraft Technologies Program

15 21 25

20 5

1 2


Space Technology Big 9 Projects (GCD has 4 of the 9)

7

4 of the


Key Program in the STMD “Pipeline”

Bridge

between

ideas and

flight demos


Brief Video Introduction to GCD


What is Game Changing

Development?

• Disruptive or Transformative Technologies

• Orders of Magnitude advancement enabling new missions and capabilities

• Principal Investigator led investment strategy

• Push for rapid technology infusion to future NASA missions

• Partnerships for cost sharing and infusion

• Informed risk management posture for developing High Payoff Technologies

• Changing the way a thing is done or made

www.gameon.nasa.gov

WE DON’T CARE WHERE THE GAME CHANGING IDEAS COME FROM


11

To be the premier organization within the

Agency/Country to rapidly advance mid

TRL disruptive space technologies from

concept to demonstration

Premier means first in rank, first in importance, to

be the leader

Vision Statement GCD Mission


GCD Addressing National Needs

Electron beam manufacturing

SWORDS

Carbon nanotube CNT sheet

• Partnering with US Industry, Academia and Other Government

Agencies (OGAs) to develop technologies

• Partnering with Industry through National Initiatives:

– National Robotic Initiative

– Synthetic Biology

– Advanced Manufacturing Initiative

– Nanotechnology

– Materials Genome Initiative (New for FY 2013)

• DARPA

– “Next Generation Humanoid for Disaster Response”

– Advanced Manufacturing

• Army/Strategic Missile Defense Command collaboration on

low cost access to space

• SWORDS (Soldier-Warfighter Operationally

• Responsive Deployer for Space)

– Multi-agency effort to develop a low-cost

access to space for small payloads


Joint STMD/GCD & OGA Technology

Initiatives

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• AFRL—Orbital Debris, Processors

• High speed, multi-core processing capability

• NRL—Electro Dynamic Debris Eliminator (EDDE)—capture small orbital

debris

• NRO—Nanotechnology

• Veterans Administration—Human Robotic Exoskeleton (in work)

• ARPA-e—Battery and fuel cell technologies (in work)


GCD 8 Investment Areas for

Adaptive Structures

Disruptive and radical technologies for:

1. Large, deployable structures for spacecraft and science

mission applications

2. Lightweight materials and structures including non-

destructive evaluation and improved damage tolerance

3. Inflatable structures, habitats

4. Nano-materials and nano-structures

5. Unique structural design or framework for robotics

6. Tether dynamics

7. Materials genome

8. Advanced Manufacturing


Deployable Structures


Large Area Structures for Solar

Array Deployment

• Conducted preliminary

independent verification &

validation of proposed 30 kW solar

array designs by ATK, DSS,

Boeing, and LM during both

deployment and operation.

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DSS Mega-ROSA design

FEM model

developed for booms

ATK MegaFlex design

FEM model

developed for

11.2 m

diameter

circular solar

array

FEM model developed (based on

Boeing’s FAST/IBIS design)


Extensibility Assessment for Larger

Solar Array Structures

Aggressive Array Parameters

Power: 300 kW

Specific Power ~200 W/kg

Blanket Surface Area ~1500 m2

Mass of Array Blankets ~1500 kg

Mass of Array Structure ~420 kg

Government Reference Array (GRA)

Intended to be an achievable lower limit for solar array structural mass fraction

(Goal: Mechanical mass/electrical mass <0.2 vs SOA 0.5-0.6)

Stowed

(1.2 m x 6 m per

wing)

Deployed (24 m x 32 m per wing)


GRA Animation


GCD Formulation Activity: Exoplanet Light

Imaging And Spectroscopy (ELIAS)

19

From NASA Space Technology Roadmaps and Priorities, page K-9: Coronographs

Occulters

Interferometers


Formulation Project: • Formulation effort is underway (previously named

Starshade) whose products will be used to define

the pace and overall cost profile of the follow-on

solicitation.

• Solicitation will focus on technologies that can

deliver the next level of exoplanet imaging and

spectroscopy, in the 2020-2022 timeframe, and can

do it with a budget profile that OCT and SMD can

afford.

Project Deliverables: • Additional scale hardware

• Report assessing the capabilities of current test

hardware and outlining features of next iteration of

scale hardware and test program

• Report detailing available high altitude platforms,

projected costs, and schedules

• Design Reference Missions for orbital demonstration

missions, including TDM demonstration mission,

Probe-class mission and Flagship-class mission

O2 H2O

CH4 NH3

Earth-like

Jupiter-like

ELIAS Occulter Deployment


Lightweight Materials & Structures


Composite Cryotank Technologies

& Demonstration (CCTD)

Tool for 2.4 meter risk

reduction, 5.5 meter tank in

design

Fluted Panel

CCTD Goal: 20-25% cost reduction due to out-

of-autoclave manufacturing, and a 25-30%

weight reduction compared to comparable

aluminum-lithium propellant tanks.


Composite Cryotank Technologies

and Demonstration (CCTD)

2.4 meter

pathfinder test

article


2.4 Meter Fabrication


CCTD Technology Firsts

Technology First Outcome/Impact Why Important or How is it a technology first.

1st successful large, fiber placed test article using Out of Autoclave 5320-1/IM7 material

Matures manufacturing processes that do not require autoclaves. Pioneering ability to process

aerospace grade materials

without the autoclave.

5320-1/IM7 has never been fiber placed. Dramatically reduces manufacturing cost and schedule.


CCTD Technology Firsts

Technology First Outcome/Impact Why Important or How is it a technology first.

1st successful thin ply fiber placed layup and cryotank cure (hybrid laminate)

Enables all-composite tanks to store liquid hydrogen for long duration missions.

Prior cryotanks using thin plies were made by hand. AFP enables thin ply usage for large structures resulting in the best combination of

cost, schedule and technical performance.


CCTD 5.5 m Tank Build Underway


Inflatable Structures & Habitats



www.nasa.gov



www.nasa.gov STMD GCD:

Lightweight Materials and Structures Project

Inflatable Structures for Exploration Missions

Inflatable Airlock

Hybrid Habitation for Cis-lunar/Mars

Asteroid Capture Envelope


Inflatable Habitat Video


• Full-scaled inflatable test article pressurized at NASA White Sands Test Facility (WSTF)

— 7.3-ft diameter x 10-ft length, 1-inch wide Kevlar, ‘basket-weave’ design

• Testing habitat structures for Micrometeoroid and Orbital Debris damage at JSC & WSTF

• Linear shape charges designed to cut specific configuration of straps

• Painted speckle pattern used to measure strain with vision image correlation

• Analysis models are being developed to correlate full-scale test behavior

Inflatable Habitat Structures—

Damage Tolerance


• Bi-Axial panel test fixture designed to apply load to integrated woven straps

and measure resulting strains

• One-of-kind prototype test-technology-development

• Analysis models are being developed to correlate load response in the

structure and predict full scale behavior

• 15” x 9” panel section

Test

Assembly ~

30 x 10-feet

representative panel

section

analytical

model

analysis

Inflatable Habitat Structures—

Material Characterization


Master Creep Curves for a 12k

UTS Vectran Strap

• Long-term material behavior predicted with short-

term tests—Creep Testing

• Strain measured as a function of time, and

temperature, along with data reduction resulted

in master curves for creep life prediction

• First of its kind material database will help

designers at JSC and Bigelow

Habitat Structures—Material

Characterization


Inflatable Re-Entry Vehicle

Experiment 3 (IRVE-3)

IRVE Concept (left), Inflated aeroshell

under test (lower left), packed

aeroshell (lower right). Successful

Launch July 23, 2012.


Nanotechnology


Nanotechnology

CNT material held in place

with Kapton tape

Distributed

resistive &

capacitive

sensor

technologies

Modeling of CNT

composites

under strain

Radiation effects testing of

CNT sheets


Nanotechnology Goals

• Develop CNT based reinforcements with 2X increase in

specific tensile strength and 3X increase in tensile

modulus

• Demonstrate the use of CNT reinforcements in polymeric

composites that are 20% lighter than state-of-the-art

• Improve processing and post-processing methods to

increase tensile strength

• Demonstrate manufacturability and improved mechanical

properties

• Validate benefits through the design, fabrication and

testing

• Partner with DoD organizations to leverage technology

investments and accelerate technology transfer.


Nanotechnology—Progress to

Date

General Nano Forests Nanocomp CNT Yarn/Tape Nanocomp CNT Sheets

Conventional

CFRP

State-of-the-Art CNT

Materials

Project Goal:

CNT Composite

Project will develop CNT composites with 2X specific tensile strength and modulus over

conventional composites


Nano-materials for Sounding

Rocket Fairing

30% Reduction in

Gross Weight

Effect of Materials Weight Reduction on Launch Vehicle Gross Weight

• Use of 7-10 GPa CNT fiber would reduce composite areal density by 20%

30% reduction in launch vehicle gross weight

• Future Goal – 20 GPa CNT fiber

50% reduction in composite areal density

65% reduction in launch vehicle gross weight

Enable shift from 2-stage-to-orbit to single stage-to-orbit vehicle design

Future Goal


Human Robotic Systems


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PROBLEM / NEED BEING ADDRESSED

PROJECT DESCRIPTION:

Human Robotic Systems (HRS)

Current State-of-the-Art

Robots on Earth kept apart from people (factories)

New robots market emerging

- Household (elderly) assistance

- Surgical robots

- Sentry, patrol, defense robots

Robots in space used in limited roles with people

- Distant planetary exploration

- Multiple crew operating RMS

Specific power and density of batteries is enabling mobility

Software and computing allow for multiple layers of redundancy and safety for robots to be trusted

New sensors and algorithms are providing robust and safe operation in complex worlds

Improved mechatronic design enables integration of mobility and manipulation

Precursor robots that arrive ahead of crew enable new missions

Increase EVA mobility options from 2 to 3

Increase Centaur-2 base payloads by > 2

Increase mean time between user intervention when driving to > 1 km

Vastly extend exploration range with flyers and ballistic probe launcher

Increase number of arms on MMSEV to > 2

Increase range of “asteroid” surface

properties that may be anchored to by

50%

Decrease operators required for excavation

with Centaur 2 by 1.

Reduce hands needed to fly EVA jetpack to

zero

Provide ground data systems for 1 or more

NASA analogs

Remotely drive Centaur 2 base greater than

1 km with minimal comm

Critical Technologies @ TRL 5-6

Integrated Prototypes Evaluated

Position Human-Robotic technology by developing & testing prototypes ahead of key decision points for orbital, asteroid, & planetary missions

Provide capabilities to NASA that don’t currently exist

Humans need to explore with

robots and human-robot teams

Mature technology through component testing and integration with prototypes

Mobility: Jetpacks, free flyers, rovers, climbing, ballistics

Manipulation: arms, sampling, tools, anchors

Human-System Interaction: software to allow all HRS robots to be commanded by humans on Earth, from the safety of IVA, or adjacent to robots in EVA


Human Robotic Systems (HRS)

Exploration Ground Data

Systems (xGDS) successfully

tracked Centaur 2 location

throughout plan execution

Wrist and shoulder

assemblies for

MMSEV grappling arm

Modular “snake” tensegrity

robot being built by Univ of

Idaho students.

Hinge joint configuration

design

Prototype jetpack

drawings complete


Tether Dynamics


Tether Dynamics

Mature propellantless vehicle concepts via analysis and ground-based

technology development to provide game-changing capabilities in LEO

Preliminary Design Review for a <50 kg, <3 km long ElectroDynamic

Tether vehicle: Successfully completed Feb 2014.

Test deployment, orbit change, operations, active avoidance, and tracking

of a maneuvering tether vehicle.


Tether Dynamics


Material Genome Initiative (MGI)


Materials Genome (New this Fiscal Year)

Problem

Insertion of new materials into aerospace vehicle designs

typically requires more than 20 years and over $400M to

accumulate enough data documenting the structure-

property relationships for designers to have confidence in

their insertion.

Challenge

Demonstrate the value of multi-scale modeling to accelerate

emerging materials maturation and insertion by linking

materials design and fabrication with validated physical

properties and performance.


Materials Genome

Technical Goals

Reduce time between discovery to technology insertion by at

least half relative to current practice.

Lower costs providing greater affordability due to the shorter

maturation and insertion period

Potential to greatly reduce required material testing for

new systems and optimize material design, while reducing

cycle time for the integration of emerging materials and

manufacturing processes for flight hardware.


Advanced Manufacturing


“Today, I’m calling for all of us to come together- private sector industry, universities, and the government- to spark a renaissance in American manufacturing and help our manufacturers develop the cutting-edge tools they need to compete with anyone in the world,” - Presidential Address at Carnegie Mellon University- June 24, 2011

Report to the President on Ensuring American Leadership in Advanced Manufacturing, President’s Council of Advisors on Science and Technology, June 2011

National Strategic Plan for Advanced Manufacturing

OSTP/NSTC/The Interagency Working Group on Advanced Manufacturing (IAM), February 2012

The strategy seeks to achieve five objectives through large number of Federal agencies

National Network for Manufacturing Innovation (NNMI)

The President announced a new proposal for the NNMI, March 9, 2012

Proposal to creating a network of up to 15 regional Institutes for Manufacturing Innovation (IMI’s). One-time $1 billion appropriation

Advanced Manufacturing Partnership (AMP) Steering Committee

Capturing Domestic Competitive Advantage in Advanced Manufacturing, July 12, 2012

President Obama

at Rolls-Royce Commonwealth

Center for Advanced

Manufacturing

Petersburg, VA

March 9, 2012



Why NASA?

NASA has state of the art advanced manufacturing capabilities and R&D projects

Industry scale equipment: during the technology to bring research into the manufacturing line.

Composite Processes: Polymer, Ceramic, Metal matrix, Insulations

World class weld development: Friction Stir and Fusion Weld processes

Nondestructive Evaluation methods that are integrated seamlessly into the welding processes

Manufacturing Modeling and Digital/Model based Manufacturing

Additive Manufacturing: a manufacturing process where materials is successively laid down to create the part, instead of removing material from a larger piece to create the part.

Supply Chain Management, green and sustainability initiatives, and full scale manufacturing development and production oversight.

NASA has a broad range of complimentary design, materials and processing capabilities

Design and analysis

Material Diagnostics and Failure Analysis

Mechanical Testing

Chemistry and Analytical Chemistry

Oxygen and Hydrogen testing

Space environment effects testing

Tribology and metrology

Corrosion and Cleaning

SLS: Being Built Today in the USA!



• Future long duration human space missions will be

challenged by mass and volume constraints for

spare parts

– Lengthy travel times with existing launch and

propulsion systems makes re-supply from Earth an

impossibility

• Monte Carlo simulations could not reproducibly predict

which parts may fail on extended missions, but mass of

failed parts was consistent

– Strongly supports on-demand fabrication

approach for supportability

– Replacement parts, new tools or repair damaged

components

– Additive manufacturing builds parts directly from

computer drawings with minimal tooling

• ISS is an ideal testbed for technology demonstration

Additive Manufacturing


“Additive manufacturing will be a $5.2B

industry by 2020” - Terry Wohlers

Additive Manufacturing is Disruptive


Cooperative Agreement Accelerated Award Schedule BAA-12-17-PKM release: 8 May 2012 Proposer’s Day: 16 May 2012 Proposal Due Date: 14 June 2012 Agreement Awarded: 15 August 2012 Public Announcement: 16 August 2012

• DoD-led award and management of a Cooperative

Agreement

• DoD, DOE, DOC (NIST), NSF and NASA

• $30 M of Federal Government funds, $40 M of private

industry, academic and local Government contribution

NAMII: National Additive Manufacturing Innovation Institute: A Pilot Institute for the National Network for Manufacturing Innovation



Description

• Rocket engine components are expensive to

manufacture and require long lead times;

additive manufacturing (AM) can reduce

part cost and manufacture time by an order

of magnitude.

Technical Goals

• Reduce injector manufacture time from

months to weeks

• Reduce full scale injector cost by nearly an

order of magnitude (~90% reduction)

• Demo sub-scale additively manufactured

rocket engine injectors under hot-fire

conditions


Rocket engine component

development via additive

manufacturing to reduce lead

time and cost.


Integrating Systems for Additive

Manufacturing Applications


Heat Sink Nozzle X 1

Heat Sink

Combustion

Chamber x 2

Water Cooled Nozzle x 2 (Pre-Braze)

Igniter Assembly x 3

Additive Manufacturing—Validation


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• The ECLSS for the International Space Station is currently designing and

building their second-generation Urine Processor Assembly (UPA)

demister

– Using additive manufactured parts decreases manufacturing time

• Machining from a solid block of Ti-6-4 takes a long time and eats up mill bits; intricate

passageways on the interior of the block are impossible to machine

• Manufacturing near net shape parts saves machining time and expense; intricate parts

can be manufactured easily



Benefits:

• High energy efficiency and feedstock usage efficiency compatible with space-based

operations

• Electron beam can be modulated to perform multiple operations (welding, deposition,

heating, surface modification, machining, etc.)

• Wire feedstock safely handled in reduced gravity

• Can process wide variety of metallic materials

Electron Beam Free Form Fabrication:

• Layer-additive process to build parts using CNC techniques

• Electron beam melts pool on substrate, metal wire added to

build up part

• Successfully demonstrated in 0-g during parabolic flight tests

• Demonstrating design and build of candidate replacement

part for finishing and testing in ground-system testbed

• Developing S-basis allowables and modeling to predict

properties for certification



GCD Challenge for Adaptive Structures

Problem: There is not enough volume available for large structures in the

payload stowage area within current launch vehicles

Challenge: Novel structures are required to achieve needed performance

Game Changing Goals:

• Develop concepts for ultra-large area (>1500 m2) deployable structures

• Mature hardware to enable long duration inflatable habitat structures

• Explore new mission needs:

1. An inflatable capture bag for asteroid retrieval

2. An inflatable airlock for Orion Multi Purpose Crew Vehicle

3. A hybrid-inflatable habitation module for Mars exploration

4. A large, deployable solar occulter for Exoplanet discovery

• Mature deployable electrodynamic tether technologies

• Advance human robotic structural designs


Summary

• Adaptive structures are great technology areas to be

pursuing

• STMD/GCD is very interested in these areas

• What are the partnership opportunities for technology

develop

• How to do business with us and find out more:

• Http://nasa.gov/spacetechnology

• Http://gameon.nasa.gov

• Contact the GCD PI in your technology domain

• Most likely Pete Lillehei or LaNetra Tate

Will you accept the challenge to discover radical new adaptive

structure ideas that will change the way NASA does business?

Http://nasa.gov/spacetechnology



Http://gameon.nasa.gov




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BACK UP


STMD Senior Leadership

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Associate Administrator Michael Gazarik

Deputy Associate Administrator for

Management

Dorothy Rasco

Deputy Associate Administrator for Programs James Reuther

Director for Communications and Operations /

Chief of Staff

G. Michael Green

Director for Resource Management Robert Carver

Director for Strategic Integration and Analysis Prasun Desai

Senior Technical Officer Harry Partridge

Executive Officer Natalie Simms


Program Executives

Program Program Executive

Center Innovation Fund &

NIAC

Jay Falker

Centennial Challenges Larry Cooper

Flight Opportunities LK Kubendran

Game Changing

Development Program

Tibor Balint

SBIR/STTR Rich Leshner

Small Spacecraft Technology

Program

Andy Petro

Space Technology Research

Grants

Claudia Meyer

Technology Demonstration

Missions

Randy Lillard

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New Capabilities

Launch Vehicle Structures

Habitats

Nanotechnology


Materials Genome

Large Area Structures

Tether Dynamics

Hot Structures

Radiation Protection

Cranes and Boom Structures

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HEO

SMD

Space Materials, Structures, and Manufacturing RoadmapMission Applications

Year:2012 2016 2020 2024 2028

Legend:= Interim Milestone= Technology at TRL 6= 1st Mission Potential= Missions Envisioned

Small Ultralightweight Nanocomposite Tension

Structures

Human Exploration Near-Earth Astroids

Integratewd, Lightweight Crew Module Concepts

ElectroDynamicTether PDR

BEAM

Ultra lightweight Structural Manipulator Concepts

Electrodynamic Tether Propulsion

NRL MINI-EDDE Flight Experiment

NRL Full EDDE Flight Experiment

SLS Block 2

Build and Test Structural Elements under Simul. Env. Conditions

Validated StructuralConcepts for Composite

Cryogenic Tank

Validated Concepts for Large Highly Loaded

Compression Structures

Nanocomposite Pressurte Vessel

CNT/BNNTUltralightweight Wiring

Nanocomposite Secondary Structures

FemtosattelitePathfinder

Ultralightweight Power and Data

Cables

FemtosatteliteSwarms

Validated StructuralConcepts for Inflatable

Structures

Habitat Structures with Integrated MMOD

5.5 m Composite Cryogenic Tank

8.4 m Composite Interstage Barrel

2.4 m Composite Cryogenic Tank

Large Complex Shape Structures

Multifuncional Habitat Structures

Lifetime Data on Inflatable Habitat Structures

Hot-Structure - Composite Structure Joint Pannels

ElectrodynamicTether

Propulsion Demonstration

Ultra Large DeployableStarshade Ground Tests

1500 m2 Deployable Structural Concepts

Thermal Protection Structural Reinforcement Concepts

Evaluation of Thick Passive Radiation Protection Materials

Integration of Modeling and Test on TPS Structures

Rocket Nozzel Made by AM

In-Space AM

Near Net Shape Metallic Structures

In-Space Manufacturing and Repair

Bulk Metallic Glasses

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