| Cover |
1 |
| Title Page |
2 |
| Abstract |
4 |
| Acknowledgements |
6 |
| Table of Contents |
8 |
| List of Figures |
17 |
| List of Tables |
22 |
| Chapter I - Introduction |
24 |
| I.1 The Concept of Space Colonies |
24 |
| I.2: Projected Uses of Space Colonies |
25 |
| I.2.1: General Remarks |
25 |
| I.2.2: Manufacture: |
25 |
| I.2.3: Large Space Structures |
26 |
| I.2.4: Long-Term Uses |
26 |
| I.3: History |
27 |
| Chapter II - Summary of Results |
30 |
| II.l: Introduction |
30 |
| II.2: Overall Concept |
30 |
| II.3: Colony Configuration and Systems |
30 |
| II.3.1: Major Components |
30 |
| II.3.2: The Colony |
32 |
| II.4: Structural Design |
35 |
| II.4.1: Hulls and Compartments |
35 |
| II.4.2: Damage Tolerance: |
36 |
| II.5: Colony Construction |
38 |
| II.5.1: Materials and Refining |
38 |
| II.5.2: Manufacture and Fabrication |
38 |
| II.5.3: Assembly and Testing |
40 |
| II.6: Scheduling and Costs |
42 |
| II.6.1: Schedule |
42 |
| II.6.2: Costs |
42 |
| Chapter III - This Study |
46 |
| III.1: The Course |
46 |
| III.1.1: Course Announcement |
46 |
| III .1. 2: Course Personnel and Organiz·ation |
47 |
| III.1.3: Direction of Investigation |
47 |
| III.2: The Report |
47 |
| Chapter IV - Assumptions |
52 |
| IV.1: Location |
52 |
| IV.2 : Materials and Transportation |
52 |
| Chapter V - Environments |
56 |
| V.1: Introduction |
56 |
| V.2: Life Requierments |
56 |
| V.2.1: Radiation |
56 |
| V.2.2: Atmosphere |
58 |
| V.2.3: Temperature and Humidity |
62 |
| V.2.4: Food |
62 |
| V.2.5: Waste Recycling |
63 |
| V.2.6: Light |
63 |
| V.2.7: Rotation of Environment |
66 |
| V.2.8: Acoustic Levels |
66 |
| V.3 : Operation and Comfort Requirements |
67 |
| V.3.1: Pseudogravity |
67 |
| V.3.2: Living Space |
68 |
| Chapter VI - Systems |
72 |
| VI.1: Introduction |
72 |
| VI.2: Design Method |
72 |
| VI.3: The First Hull |
73 |
| VI.3.1: General Remarks |
73 |
| VI.3.2: Assumptions: |
73 |
| VI.3.3: Design Philosophy |
75 |
| VI.3.4: Candidate Hulls |
76 |
| VI.3.5: Dimensions of Hull |
78 |
| VI.4: Shielding, Sunlight and Windows |
85 |
| VI.4.1: General Remarks |
85 |
| VI.4.2: Shielding Requirement |
85 |
| VI.4.3: Sunlight, Windows, and Cutouts |
88 |
| VI.4.4: Shield Configuration |
89 |
| VI.4.5: The Sunlight Beam |
92 |
| VI.5: The Precession/Nutation Problem |
97 |
| VI.5.1: General Remarks |
97 |
| VI.5.2: The Hull as Gyroscope |
97 |
| VI .5.3 : Uncontrolled Variations in the Hull Spin Axis |
102 |
| VI.5.4: The Shield Around the Hull |
103 |
| VI.5.5: The Despun Shield Option |
103 |
| VI.5.6: The Slowly Spun Shield Option |
107 |
| VI .5 .7: Shield Option Decision |
115 |
| VI .5 .8: Docking System |
115 |
| VI.6: First Overall Configuration |
115 |
| VI.6.1 : General Remarks |
115 |
| VI.6.2: The Hull |
118 |
| VI.6.3: The Shield |
118 |
| VI.7: Air Composition and Pressure |
121 |
| VI.7.1: General Remarks |
121 |
| VI.7.2: Advantages to Low Pressure |
121 |
| VI.7.3: Inert Gas Content |
121 |
| VI.7.4: Risk of Fire |
121 |
| VI.7.5: Decision |
121 |
| VI.7.6: Leakdown Analysis |
122 |
| VI.8: Energy Flow in the First Configuration |
124 |
| VI.8.1: General Remarks |
124 |
| VI.8.2: Description of Inputs |
124 |
| VI.8.3: Output by Passive Radiation through the Shield |
126 |
| VI.8.4: Output by Passive External Radiator |
128 |
| VI.8.5: Output by Active External Radiator |
136 |
| VI.8.6: Heat Pipes through the Shield |
138 |
| VI.9: Configuration Change |
139 |
| VI.9.1: Reasons for Changes |
139 |
| VI.9.2 : Changes |
143 |
| VI.9.3: Parabolic Mirror and Electrical Generating System |
148 |
| VI.9.4 : Docking System |
152 |
| VI.9.5: Flat Mirror and Shadow Reflector |
155 |
| VI.10: Temperature and Humidity Control |
157 |
| VI.10.1: General Remarks |
157 |
| VI.10.2: Solar Heat Gain - Sensible and Latent Heat |
158 |
| VI.10.3: Electrical Heat Gain - Sensible and Latent |
162 |
| VI .10.4: Environment al Control Process |
166 |
| VI.11 : Food Production and Waste Recycling |
180 |
| VI.11.1: Summary |
180 |
| VI.11.2: Nutritional Requirements |
181 |
| VI.11.3: Food Production - Nutrients and Growth Medium |
181 |
| VI.11.4 : Food Production - Temperature, Light , and Humidity |
182 |
| VI.11.5: Food Production - Yields |
185 |
| VI .11.5.1: Grain |
185 |
| VI.11.5.2: Fruits and Vegetables |
185 |
| VI.11.5.3: Animal Protein |
186 |
| VI .11.6: Agricultural Area Design |
190 |
| VI.11.7: Waste Recycling |
190 |
| VI.12: Living Space Design |
191 |
| VI.12.1: Summary |
191 |
| VI .12.2: Image of the Prototype Community |
192 |
| VI.12.3: Activities and Facilities Program |
194 |
| VI.12.4: Habitable Space Program |
195 |
| VI.12.5: Landuse Plan |
205 |
| VI.12.6: Building Systems |
207 |
| Appendix VI.A - Radiation Sheilding |
216 |
| VI.A.l: The Problem |
216 |
| VI.A.2: The Radiation Environment |
216 |
| VI.A.2.1: The Solar Wind |
217 |
| VI.A.2.2: Solar Particle Events |
217 |
| VI.A.2.3: The Galactic Background Radiation |
217 |
| VI.A.3: Dosimetry |
222 |
| VI.A.4: Sheilding |
229 |
| VI.A.5 : Simpleminded Calculationof Sheilding Mass |
231 |
| Appendix VI.B - The Gyroscope |
234 |
| Appendix VI.C - Estimates of Moment of Inertia |
242 |
| VI.C.1: Estimate of Moment of Intertia About Spin Axix of First Hull Design |
242 |
| VI.C.2: Estimate of Moment of Inertia About Transverse Axis of First Hull Design |
245 |
| VI.C.3 : Estimate of Moment of Intertia of First Sheild Design About Its Axis of Symmetry |
248 |
| VI.C.4: Estimate of Moment of Inertia of First Sheild Design About Transverse Axis |
250 |
| Appendix VI.D - Leakdown Analysis |
252 |
| VI.D.1: List of Symbols |
252 |
| VI.D.2: Analysis |
252 |
| Appendix VI.E - Estimate of the Electrical Energy Requirements of the Space Colony |
258 |
| Appendix VI.F - Power Flow from Hull through Sheild for First Configuration |
264 |
| VI.F.l: List of Symbols |
264 |
| VI.F.2: Analysis |
264 |
| Appendix VI.G - Densities of Typical Radiator Structures |
270 |
| Appendix VI.H - The Brayton Heat Pump Cycle |
272 |
| VI.H.l: List of Symbols and Constants |
272 |
| VI.H.2 : Description of Brayton Heat Pump Cycle |
274 |
| VI.H.3: Analysis |
277 |
| VI.H.4: Constraints on the Parameters |
282 |
| Appendix VI.I - The Rankine Heat Pump Cycle |
288 |
| VI.I.1: List of Symbols and Contants |
288 |
| VI.I.2: Description of Rankine Heat Pump Cycle |
289 |
| VI.I.3: Analysis |
291 |
| VI.I.4: Choice of Refrigerants |
296 |
| VI.I.6: Water |
298 |
| VI.I.7: Refrigerant 11 |
299 |
| VI.I.8: Refrigerant 12 |
301 |
| VI.I.9: Remarks |
303 |
| Appendix VI.2 - Transpiration of Plants |
304 |
| Chapter VII - Structural Design |
306 |
| VII.1: Operational Requirements of the Colony Structure |
306 |
| VII.2: Loads |
307 |
| VII.2.1: General Remarks |
307 |
| VII.2.2: Norma l Operations |
308 |
| VII.2.3: Construction and Spin-up |
309 |
| VII.2.4: Damage-Induced Loads |
310 |
| VII.3: Configuration and Materials-Alternatives |
314 |
| VII.3.1 : General Remarks |
314 |
| VII.3.2 : Materials |
314 |
| VII.3.3: Fabrication Techniques |
320 |
| VII.3.4: The Hull Concept |
322 |
| VII.4: Stress Analysis and Sizing |
327 |
| VII.4.1: List of Symbols |
327 |
| VII.4.2: General Remarks |
328 |
| VII.4.3: Inner Hull |
329 |
| VII.4.3.1: Calculations of the Normal Applied Stress - Hull ThicknessRelation |
329 |
| VI I.4.3.2: Calculation of the Applied Stress - Hull Thickness Relation with Outer Hull Failure |
330 |
| VII:4.4: Outer Hull |
332 |
| VII.4.5: Bulkheads |
333 |
| VII.4.5.1: Calculation of the Normal Interaction Stress - Bulkhead Thickness Relation |
335 |
| VII.4.S.2 : Calculation of Bulkhead Stress - Thickness Relation with Outer Hull Failure |
339 |
| VII.4.6: Interior Structure |
341 |
| VII.4.6.1: Buildings |
341 |
| VII.4.6.2: The Window |
342 |
| VII.5: Fatigue and Operational Safety Limits |
344 |
| VII.5.1: General Remarks |
344 |
| VII .5.2: Fracture Mechanics Considerations in Component Design |
346 |
| VII.5.2.1: Leak Before Break Design Considerations |
348 |
| VII.5.2.2: Component Design for Fatigue |
352 |
| VII.5.2.3: Minor Stiffener Sizing for Damage Containment |
355 |
| VII.5.2.4: Major Stiffener Design for Fastener Considerations |
357 |
| VII.5.3: Choice of Design Points |
361 |
| VII.6: General Configuration |
366 |
| VII.7: Conclusions and Recommendations |
373 |
| Appendix VII.A - Derivations of Hoop Stress Equations |
378 |
| VII.A.1: General Remarks |
378 |
| VII.A.2: Determination of Hoop Stresses in a Single Hull |
378 |
| Appendix VII.B - Dynamic Loads |
382 |
| VII.B.1: List of Symbols |
382 |
| VII.B.2: General Remarks |
382 |
| VII.B.3: Torsion |
383 |
| VII.B.4: Bending |
387 |
| VII.B.5: Conclusions |
391 |
| Appendix VII.C - Meteroid Impac |
392 |
| Appendix VII.D - Leak Before Break Design |
396 |
| VII.D.1: List of Symbols |
396 |
| VII.D.2: General Remarks |
397 |
| VII.D.3: Analysis |
397 |
| Appendix VII.E - Mass Per Unit Area of Hull, Bulkhead, Sheild and Agriculture |
406 |
| Appendix VII.F - Rayleigh-Ritz Analysis of Square Clamped Plate |
410 |
| VII.F.1: List of Symbols |
410 |
| VII.F.2: General Remarks |
411 |
| VII.F.3: Analysis |
411 |
| Appendix VII.G - Example of Interior Structure |
422 |
| VII.G.1: General Remarks |
422 |
| VII.G.2: Analysis |
422 |
| Appendix VII.H - Structural Analysis of Endcap Window |
426 |
| Chapter VIII - Construction and Maintenance |
428 |
| VIII.1: Introduction |
428 |
| VIII.2: Materials |
428 |
| VIII.3: Refining |
433 |
| VIII.3.1: Refining Processes |
433 |
| VIII.3.2: Process Mass, Power, and Labor |
433 |
| VIII.4: Manufacture |
436 |
| VIII.4.1: General Comments on Space Manufacture |
436 |
| VIII.4.2: Material Flow |
436 |
| VIII.4.3: Rolling Mills and Related Equipment |
438 |
| VIII.4.3.1: General Design and Function |
438 |
| VIII.4.3.2: The Blooming Mill |
440 |
| VIII.4.3.3: The Plate Mill |
440 |
| VIII.4.3.4: The Billet Mill |
442 |
| VIII.4.3.5: Light Section Mill |
442 |
| VIII.4.4: Light Machine Tools |
443 |
| VIII.4.4.1: General Design and Function |
443 |
| VIII.4.4.2: Plate Finishing Milling Machine |
444 |
| VIII.4.4.3: Fastener and Nut Machine |
444 |
| VIII.4.4.4: Milling Machine for Major Stiffeners |
445 |
| VIII.4.4.5: Milling Machine for Minor Stiffeners |
445 |
| VIII.4.5: Additional Manufacturing Equipment and Procedures |
445 |
| VIII.4.5.1: Automated Control |
445 |
| VIII.4.5.2: Manipulators and Conveyors |
446 |
| VIII.4.5.3: Refuse Disposal and Recycling |
446 |
| VIII.4.6: Conclusion |
446 |
| VIII.5: Fabrication |
447 |
| VIII.5.1: Outline of Fabrication Technique |
447 |
| VIII.5.2: Electron Beam Welding |
448 |
| VIII.5.2.1: Advantages of EB Welding |
448 |
| VIII.5.2.2: Disadvantages of EB Welding; Alternative Fastener Systems |
448 |
| VIII.5.3: Detail of Section and .Bulkhead Fabrication |
449 |
| VIII.5.3.1: Lay-up |
449 |
| VIII.5.3.2: EB Welding |
451 |
| VIII.5.3.3: Drilling and Attachment of Major Stiffeners |
451 |
| VIII.5.4: Conclusion |
453 |
| VIII.6: Work Environment and Summary |
454 |
| VIII.6.1: Work Shacks |
454 |
| VIII .6.1.1: General Description |
454 |
| VIII.6.1.2: Design |
454 |
| VIII.6.2: Mass and Power Summary |
456 |
| VIII.7: Assembly |
457 |
| VIII.7.1: Overall Plan |
457 |
| VIII.7.2: The Construction Site |
457 |
| VIII.7.2.1: Elements of the Site |
457 |
| VIII.7.2.2: Local Transportation |
463 |
| VIII.7.2.3: Power Distribution Network |
465 |
| VIII.7.2.4: Local Navigation System |
466 |
| VIII.7.2.5: Initial Deployment Sequence |
466 |
| VIII.7.3 Colony Assembly Process |
467 |
| VIII.7.3.1: Assembly Tolerances and Choice of Technique |
467 |
| VIII.7.3.2: Assembly Sequence |
470 |
| VIII.7.3.3: Final Assembly |
471 |
| VIII.7.4: Design of Construction Site Structure |
472 |
| VIII.7.5: Conclusion |
474 |
| VIII.8: Inspection and Repair |
474 |
| VIII.8.1: Overall Scenario |
474 |
| VIII.8.2: Inspection Methods |
475 |
| VIII.8.2.1: Comparisons of NDE Methods: |
475 |
| 1. Visual/Optical |
475 |
| 2. Radiography |
475 |
| 3. Ultrasonics |
475 |
| 4. Magnetic Anomaly |
476 |
| 5. Acoustic Emission (8.18), (8.19), (8.20), (8.21) |
476 |
| 6. Eddy Current |
476 |
| VIII.8.2.2: Details of Selected Inspection Methods |
477 |
| VIII .8.3: Component Quality Assurance |
478 |
| VIII.8.3.1: Plate Inspection |
478 |
| VIII.8.3.2: Fastener Inspection |
479 |
| VIII.8.3.3: Plate Proof Testing |
479 |
| VIII.8.4: Assembly Inspection |
480 |
| VIII.8.5: Overall Structural Proof Testing |
480 |
| VIII.8.6: Structure Monitoring and Leak Detection |
482 |
| VIII.8.7: Repair |
483 |
| VIII.9: Work Force, Mass and Power |
484 |
| VIII.9.1: Work Force |
484 |
| VIII.9.2: Mass and Power Consumption |
485 |
| VIII.10: Conclusions and Recommendations |
485 |
| Appendix VIII.A - Characteristic Relations of Machine Tools |
490 |
| VIII.A.1: General Remarks |
490 |
| VIII.A.2: Light Machine Tools |
490 |
| VIII.A.3: Rolling Mills |
491 |
| Appendix VIII.B - EB Welding Rate |
496 |
| Chapter IX - Transportation, Scheduling and Cost |
498 |
| IX.1: Transport Systems |
498 |
| IX.1.1: Earth Surface-Low Earth Orbit Transportation |
498 |
| IX.1.2: Interorbital Transfer Vehicle |
501 |
| IX.1.3: Lunar Landing Vehicle |
514 |
| IX.1.4: Transport Linear Accelerator |
517 |
| IX.1.5: Interlibration Point Transfer Vehicle |
523 |
| IX.2: Transportation Costing Rationale |
524 |
| XI.3: Project Scheduling |
530 |
| IX.4: Transport Scheduling |
534 |
| IX.5: Program Cost Rationale |
534 |
| IX.6: Program Costs |
539 |
| Chapter X - Conclusions and Suggested Research |
546 |
| X.1: Conclusions |
546 |
| X.1.1: General Conclusion |
546 |
| X.1.2: Thermal Effects |
546 |
| X.1.3: Structures |
546 |
| X.1.4: Construction |
548 |
| X.1.5: Inspection and Repair |
548 |
| X.1.6: Cost |
549 |
| X.2 Suggested Research |
550 |
| X.2.1: General Remarks |
550 |
| X.2.2: Human Physiology |
550 |
| 1) Long-Term Effects of Rotation |
550 |
| 2) Long-Term Effects of Reduced Gravity |
550 |
| 3) Effects of Radiation |
551 |
| 4) Effects of Atmospheric Composition and Pressure |
551 |
| 5) Acoustics |
551 |
| X.2.3: Ecology |
551 |
| 1) Toxic Substances and Their Removal |
551 |
| 2) Food Production |
551 |
| 3) Closing the Food Cycle |
551 |
| 4) Water Balance |
551 |
| 5) Carbon Dioxide Balance |
551 |
| 6) Airflow Patterns |
551 |
| X.2.4: Location and Logistics |
552 |
| 1) Location Environment |
552 |
| 2) Orbital Mechanics |
552 |
| 3) Transportation Systems |
552 |
| 4) Transport Linear Accelerator |
552 |
| 5) Mass-catcher |
552 |
| 6) Materials Availability |
552 |
| X.2.5: Structures |
553 |
| 1) Properties of Space Alloys |
553 |
| 2) Cable Structures |
553 |
| 3) Vapor Deposition |
553 |
| X.2.6: Systems |
553 |
| 1) Enerqy Management |
553 |
| 2) Rotating Bearings |
553 |
| 3) Nutation and Uncontrolled Precession |
553 |
| X.2.7: Construction and Maintenance |
553 |
| 1) Human Productivity |
553 |
| 2) Refining |
554 |
| 3) Dynamics of the Construction Site |
554 |
| 4) Navigation Around Construction Sites |
554 |
| 5) Manufacturing Equipment Design |
554 |
| 6) Sealants |
554 |
| 7) Inspection Techniques |
554 |
| Chapter XI - References |
556 |
| Chapter I |
556 |
| Chapter IV |
556 |
| Chapter V |
556 |
| Chapter VI |
557 |
| Chapter VII |
562 |
| ChapterVIII |
564 |
| Chapter IX |
567 |