Demonstrated technology goals for cryogenics include reducing specific mass from the current level of 15 kg/W_cooling to 8 kg/W_cooling by FY00 and 5 kg/W_cooling by FY05; reducing specific power (watts of input power per watt of cooling) from the current level of 70 W/W_cooling to 50 W/W_cooling by FY00 and 40 W/W_cooling by FY05; increasing life expectancy from the current 2-year level to 5 years in FY00 and to 7.5 years by FY05; and reducing induced vibrations from the current level of 1.0 Nrms to 0.1 Nrms by FY00 and 0.01 Nrms by FY05. Technology payoffs are increased payload mass fraction, extended on-orbit life, and improved sensor resolution due to a reduced vibration environment.

These technologies will be demonstrated through the development of protoflight engineering models and laboratory testing. Milestones include delivery of an Advanced 35 K/60 K Cryocooler in FY99 and demonstration of the No Moving Parts Advanced Cryocooler in FY01.

Technology barriers/challenges include: availability of lightweight components for use in cryogenic temperatures; excessive friction and material stresses in miniature-sized, high-frequency cycles; contamination of seals and orifices; lack of effective design and materials for cryogenic regenerators; poorly understood thermodynamic loss mechanisms; and ineffective vibration isolation control electronics and techniques.

Customers for cryogenic technologies include those who use sensors for space surveillance and missile warning and tracking missions, specifically the SBIRS program, NASA, and NPOESS environmental sensors. This technology also supports development of low-temperature superconducting electronics pervasive to all DoD space vehicles, as well as USSPACECOM, NASA, and other space programs.

Demonstrated technology goals for space thermal management include increasing heat flux from the current level of 2.9 W/cm² to 3.8 W/cm² by FY00, and to 5.2 W/cm² in FY05; increasing heat transport from the current level of 2.5 kW-m to 4.5 kW-m by FY00, and to 9.0 kW-m by FY05; decreasing thermal subsystem mass from the current 0.04 kg/W to 0.038 kg/W by FY00, and to 0.034 kg/W by FY05; decreasing electronic component temperatures from the current level of 125°C to 120°C by FY00, and to 115°C by FY05; and decreasing space vehicle heater power from the current level of 0.11 W/W to 0.088 W/W by FY00, and further to 0.072 W/W by FY05. Technology payoffs are increased payload fraction and extended on-orbit lifetimes.

The program includes extensive ground testing. For two-phase fluid systems, final demonstration is accomplished on dedicated space missions, due to the inability to simulate the zero-g environment on Earth and possible significant effects on performance due to the gravity field. Milestones include delivery of one micron CPL wicks for characterization in FY99, delivery of a carbon-carbon radiator for flight test on New Millennium in FY97, and delivery of the Advanced Lightweight Thermal Bus protoflight model in FY02.

Technology barriers for space thermal management include rapid, reliable startup and long-term operation of capillary-pumped loop systems and loop heat pipes; and development of (1) low-cost, advanced composite materials and devices capable of dissipating high heat fluxes from microelectronics devices, (2) sub-micron wicks (1-micron pore size) for capillary-pumped loop applications, and (3) flexible or rotatable joints that allow for the efficient transportation of heat from the space vehicle bus outboard to a deployable radiator.

Thermal management is considered a pervasive technology area, applicable to all space vehicle program offices. The technologies are essential for those missions with either high-power dissipation (SMC or SAF/SP space-based radar) or concentrated power dissipation on reduced area payloads (next-generation military and commercial communication space vehicles such as MILSTAR III, as well as the NPOESS program with a multitude of weather sensors).

Note: Totals may not add due to rounding.

Specific demonstrated capabilities and milestones for advanced structural control technology concepts, techniques, and production approaches are to reduce satellite structural mass by 35% and reduce cost by more than 10% by FY01 (70% and 25%, respectively, by FY11); to reduce ELV launch vehicle structural subsystem mass by 40% and cost by 40% by FY01 (75% and 75%, respectively, by FY11); decrease satellite dynamic launch loads by a factor of 5 by FY01 (a factor of 10 by FY11); demonstrate flight-qualified, fiber-optic sensors by FY00; and decrease on-orbit disturbances experienced by payloads by a factor of 10 by FY01 (a factor of 50 by FY11).

Technical challenges include developing rapid and less costly manufacturing techniques for large launch vehicle structures; accounting for the synergistic effects of the combined aspects of the space environment; developing high-fidelity simulations; reducing EMI effects and increasing the reliability/durability of multifunctional structures; ensuring satellite structural isolation without constraints on rattle space (clearance), weight, power, and volume, as well as interaction between the isolator control system and the launch vehicle control system; developing rapid nonpyrotechnic release mechanisms; and integrating neural network technology into structural control systems during operation. The technical approaches are focused on researching new structural concepts and construction methods to decrease the weight and cost. This technology improves the conductivity and radiation shielding capability of satellite bus and secondary structures. The project encompasses investigating new techniques to better understand and predict the effects of the space environment on spacecraft structures; and integrating power, communication, and electrical paths into the structure thus eliminating the need for wiring harnesses, connectors, and electronic boxes.

Note: Totals may not add due to rounding.

Key technology challenges and developments include extremely lightweight large apertures such as dilute and inflatable optics, space-erectable structures, nonconventional wavefront compensation for maintaining good image quality, and smart sensor technologies for on-board processing. Specifically, dilute aperture phasing, nonlinear optical techniques, biomemonics for on board processing, and phase diversity will be evaluated. The integrated performance of deployable space structures, ultra lightweight optics, and nonconventional compensation systems will be evaluated using image quality, information delivery, and packaging efficiency as metrics.

Demonstrated technology goals for an integrated space power system include increased subsystem conversion efficiency from current level of 18.5% to a level of 28% by FY00 and to 35% by FY05; increased solar array specific power from the current level of 50 W/kg to 100 W/kg in FY00, and further to 120 W/kg in FY05 (LEO); and increased LEO satellite energy-storage-specific energy density from the current 40 Wh/kg to 100 Wh/kg by FY00, and 150 Wh/kg in FY05. Technology payoffs are increased payload mass fraction, increased available usable power, and increased space vehicle on-orbit life using weight savings which may be applied to the station-keeping propulsion system.

Milestones for space power system technologies include: in FY00, development of a solar thermal power generation system, demonstration of high efficiency solar cell manufacturing techniques, and protoflight testing of nonelectrochemical energy storage devices; and in FY02, development of concepts for the Advanced Concentrator Follow-on Program. Space flight demonstrations are planned on the STRV-2 Program STP-5 and MightySat I in FY97.

Technical barriers include growth and compatibility of advanced semiconductor materials (GaInP₂, GaAs, ZnGeAs₂, CuInSe₂) for multijunction and low-cost, ultra-thin solar cells; feasibility of high-efficiency solar thermal conversion through a combination of devices, concentrators, and power distribution systems; inability to predict the effects of battery cell design and electrochemical processes on optimum operating conditions, battery performance, and cycling lifetime; availability of high-voltage (70-130 Vdc), space-qualified, silicon-based, solid-state components and circuits; and availability of higher efficiency wide-bandgap (GaAs and SiC), solid-state devices.

Space power generation is a pervasive technology area, applicable to all space vehicle program offices. The technologies are essential for those missions with either high-power level or concentrated power usage payloads (next-generation military and commercial communication space vehicles such as MILSTAR III, as well as the NPOESS program.)

Note: Totals may not add due to rounding.

These technologies provide for a reduction in instructor manpower requirements of 50% by FY00, a further reduction of 75% by FY05, a reduction in control costs (with an increase in capability) by 30% in FY00, and 40% by FY05 and 60% in FY10. Decision support for anomalies will be added in phases through FY99; on-board autonomous satellite health and status capability will be flight tested in FY02, machine learning systems in FY04, and immersive operator environments in FY05.

Technology challenges include the verification of the correctness and safety of automated anomaly detection and resolution based on artificial intelligence techniques such a neural networks; the development of reliable, verifiable, self-learning computer systems; reducing the processing and storage requirements of autonomous systems so they can be used on-board the satellite; developing generic intelligent systems that can be used on more than one satellite family; verifying correct performance of highly intelligent ground and space systems; and developing technologies that will satisfy acquisition and O&M cost constraints. Users include USAF Space Command, USAF Space and Missile Systems Center SPOs, and select Navy, BMDO, and other agencies.

Note: Totals may not add due to rounding.

Technical challenges for liquid systems include improving material compatibility, reducing component weight and volume through the incorporation of advanced materials, increasing rotodynamic speeds (to decrease turbo pump assembly size), increasing turbine blade/disk capability of withstanding thermal shocks and high stresses at high temperatures, reducing composite processing costs, utilizing advanced bearing concepts, and identifying advanced bearing concept limitations. Solid system technical challenges include adapting polymeric materials for use in manufacturing reduced weight components, eliminating bondlines, and identifying high-strength case materials for decreased component mass/volume.

Note: Totals may not add due to rounding.

Specific demonstrated capabilities for chemical orbit transfer systems include an increased payload capability of 10% in FY00 and 20% in FY05. Solar thermal orbit transfer systems will demonstrate, by FY00, life and repositioning capabilities leading to $60 million in launch and lifespan cost savings. FY00 chemical/solar thermal orbit transfer propulsion demonstrations will achieve specific improvements of +10% Isp, and +15% mass fraction. Specific demonstrated capabilities for solar electric orbit transfer propulsion systems include increased repositioning capabilities doubling that of current systems, or life and payload increases leading to a $60 million launch cost savings. FY00 solar electric orbit transfer propulsion demonstrations will achieve specific improvements of +15% mass fraction and +15% thruster efficiency in FY00.

Milestones for orbit transfer propulsion include chemical thrust chamber assembly proof testing and hardware completion in FY97 for integration into the FY00 chemical upper-stage/orbit-transfer demonstration, Argos spacecraft launch for the ESEX high-power (30 kW) arcjet demonstration in FY97, and solar thermal propulsion system design complete in FY99 for balloon flight test in FY00.

Technical challenges/barriers include chemical combustion and mixing improvements for increased combustion efficiency, lightweight material developments to improve mass fraction in chemical systems, solar thermal concentrator (and absorber) design and deployment improvements to enhance reliability, refined solar thermal tracking capabilities, and increased solar electric power processing and thruster efficiency to reduce weight, increase performance, and increase reliability.

Note: Totals may not add due to rounding.

Specific demonstrated capabilities for all tactical rocket propulsion systems include a 10% increase in warhead size or range, or a 20% decrease in time-to-target, by FY00. Divert propulsion systems will demonstrate a 26% reduction in the number of interceptors required (per theater) by FY00. FY00 tactical rocket propulsion demonstrations will achieve specific improvements of +3% delivered energy, +10% mass fraction (with TVC), and +2% mass fraction (without TVC), while maintaining current cost/safety/survivability standards.

Milestones for tactical rocket propulsion include formulating and testing a GAP/AN/CL20 propellant by FY97, evaluating a low-cost carbon-carbon nozzle by FY97, and integrating the nozzle and propellant for testing in FY97. Once successful, these components will be scaled up for integration into the IHPRPT program's FY00 high-performance, increased-range tactical propulsion demonstration.

Technical barriers revolve around two primary areas: propellant developments and component developments. Propellant technical challenges/barriers include reducing detonability while increasing performance in high-energy propellants, enhancing burn-rate control, and investigating high-energy smokeless ingredients. Component technical challenges/barriers involve adapting polymeric materials for use as reduced weight components, eliminating bondlines, and identifying high-strength case materials for decreased component mass/volume. Hybrid concepts are advantageous with respect to throttling and combustion control issues but are currently limited by their bulky, lower performing designs. Advanced materials will allow for new hybrid designs to be investigated. High-energy-fuel/-oxidizer developments are also required for hybrid tactical missiles to be exploited.

Note: Totals may not add due to rounding.

The technical approach includes definition of the threat (hostile and natural—including space debris); developing program protection requirements with users; performance of susceptibility and vulnerability experiments at various levels of integration; development of models or analytic techniques for extrapolating data to higher levels of system interaction; performance of survivability enhancement options trades; development of protection techniques based on those performance trades; and demonstration of those techniques on appropriate subsystems.

Specific milestones for protection technologies include a reduced radiation safety factor for current COTS components from a factor of 10 to a factor of 5 by FY00, a factor of 4 by FY05, and a factor of 3 by FY10; laser threat protection increased by a factor of 2 by FY00, a factor of 5 by FY05, and a factor of 10 by FY10; RF high-power microwave susceptibility from a current level of 40 dB to 15 dB in FY00, 10 dB in FY05, and 6 dB by FY10; increased knowledge of space debris from the current shuttle baseline by a factor of 5 by FY00, a factor of 10 by FY05, and a factor of 25 by FY10. Demonstration of the laser microbolometer and RF detector will occur in FY01.

Technical barriers include accuracy of the threat/subsystem interaction modules; accuracy of space debris prediction models; integration of threat-specific modules into multithreat prediction models; minimization of performance impact of threat countermeasures; and integration of balanced multithreat protection capability.

Note: Totals may not add due to rounding.

The technical approach includes definition of the warfighter requirements by working with USSPACECOM; characterization of the threat environment as a function of time; investigation of candidate sensor and microelectronics technologies; and development and demonstration of candidate technologies which can be transitioned to SPOs.

Given the current technology baseline (135 lb and 110 W), specific demonstrated capabilities for a threat warning and attack reporting on-board system include a brassboard of a microbolometer laser detector in FY99 and a space demonstration in FY01 with weight reduction by a factor of 4 and power reduction by a factor of 3 in the RF sensor with associated electronics. This system will geolocate a threat. Follow-on activities to achieve an integrated laser/RF sensor suite with a weight and power reduction of a factor of 10 and a factor of 5, respectively, will commence in FY04.

Technical barriers include the use of a single laser detector (microbolometer) to achieve required bandwidth and dynamic range for pulsed and counter weapon sources; use of a cross-correlation receiver for RF threat detection; and miniaturization of the antennas and associated electronics to meet stringent weight and power goals.

Note: Totals may not add due to rounding.

The objectives of these efforts are to develop a class 1.3 solid propellant that meets all ballistic missile propulsion requirements—as well as the associated propulsion system components that are compatible with that propellant—by FY01; extend the "look ahead" window 10 years by FY00 and 20 years by FY10 with a 90% confidence level; reduce the time and cost for nondestructive evaluation (NDE) data processing by 50% by FY05; and develop and demonstrate PBV control system component technologies using commercially available materials by FY04.

The technologies being developed address critical component/ingredient availability; sustaining critical design, test, and manufacturing capabilities; and increasing system life, availability, and affordability. The technical challenges include developing non-shock-sensitive, high-energy propellant ingredients that will yield the required Trident ballistic performance while meeting the strategic missile service life requirements; identifying commercially available, high-temperature/high-strength materials that meet the Trident PBV operational requirements and can be manufactured using commercially available techniques; identifying effective seal materials for the Minuteman PBV propulsion system; and developing a better understanding of propulsion system chemical kinetics that can be linked with NDE techniques and service life prediction codes to increase missile propulsion service life prediction confidence by 100%.