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Russell, Richard W.

Publications and source records attributed to Russell, Richard W..

15 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Nasa's Plans for Development of a Standard for Additively Manufactured Components

The current version of NASA standards for manned spaceflight hardware do not contain sufficient detail for the certification of additively manufactured components. The development of additively manufactured standards is currently in work by several standards organizations. However, NASA cannot wait on these organizations to develop such standards. NASA and its program partners in manned spaceflight (Commercial Crew, Space Launch System and the Orion Multi-Purpose Crew Vehicle) are actively developing additively manufactured components for flight as early as 2019.

Russell, Richard W.↗
NASA NTRS2018

NASA’s Plans for Development of Standards for Additive Manufactured Components

There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its program partners in manned spaceflight (the Commercial Crew Program, the Space Launch System and the Orion Multi-purpose Crew Vehicle) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) has authored a center-level standard (MSFC-STD-3716)1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the manned space flight programs. The development of an Agency-level standard is proposed, which based upon the principles of MSFC-STD-3716, would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs.

Russell, Richard W.↗
NASA NTRS2014

The History of Orbiter Corrosion Control (1981 - 2011)

After 135 missions and 30 years the Orbiter fleet was retired in 2011. Working with Orbiter project management and a world class engineering team the CCRB was successful in providing successful sustaining engineering support for approximately 20 years. Lessons learned from the Orbiter program have aided NASA and contractor engineers in the design and manufacture of new spacecraft so that exploration of space can continue. The Orbiters are proudly being displayed for all the public to see in New York City, Washington D.C., Los Angeles, and at the Kennedy Space Center in Florida.

Corrosion↗
NASA NTRS2013

NASA's Beachside Corrosion Test Site and Current Environmentally Friendly Corrosion Control Initiatives

NASA began corrosion studies at the Kennedy Space Center (KSC) in 1966 during the Gemini/Apollo Programs with the evaluation of long-term corrosion protective coatings for carbon steel. KSC's Beachside Corrosion Test Site (BCTS), which has been documented by the American Society of Materials (ASM) as one of the most corrosive, naturally occurring, environments in the world, was established at that time. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acid ic exhaust from the solid rocket boosters. In the years that followed, numerous studies have identified materials, coatings, and maintenance procedures for launch hardware and equipment exposed to the highly corrosive environment at the launch pad. This paper presents a historical overview of over 45 years of corrosion and coating evaluation studies and a description of the BCTS's current capabilities. Additionally, current research and testing programs involving chromium free coatings, environmentally friendly corrosion preventative compounds, and alternates to nitric acid passivation will be discussed.

Russell, Richard W.↗
NASA NTRS2011

Commercial Crew Development Program Overview

NASA's Commercial Crew Development Program is designed to stimulate efforts within the private sector that will aid in the development and demonstration of safe, reliable, and cost-effective space transportation capabilities. With the goal of delivery cargo and eventually crew to Low Earth Orbit (LEO) and the International Space Station (ISS) the program is designed to foster the development of new spacecraft and launch vehicles in the commercial sector. Through Space Act Agreements (SAAs) in 2011 NASA provided $50M of funding to four partners; Blue Origin, The Boeing Company, Sierra Nevada Corporation, and SpaceX. Additional, NASA has signed two unfunded SAAs with ATK and United Space Alliance. This paper will give a brief summary of these SAAs. Additionally, a brief overview will be provided of the released version of the Commercial Crew Development Program plans and requirements documents.

Russell, Richard W.↗
NASA NTRS2010

The Reconstruction and Failure Analysis of The Space Shuttle Columbia

This viewgraph presentation describes a very detailed reconstruction plan and failure analysis of The Space Shuttle Columbia accident. The contents include: 1) STS-107 Timeline; 2) Foam Impact; 3) Recovery; 4) Reconstruction; 5) Reconstruction Plan; 6) Reconstruction Hanger; 7) Pathfinders; 8) Aluminum Pathfinder; 9) Early Analysis - Left MLG Door Area; 10) Emphasis Switched to Left Hand Wing Leading Edge; 11) Wing Leading Edge Subsystem (LESS); 12) 3D Reconstruction of Left WLE; 13) Left Wing Tile Table; 14) LESS Observations; 15) Left Hand Wing Debris Points to RCC 8/9 - Slumped Tile; 16) Reconstructed View of LC/P 9 tile with I/B Tile; 17) Reconstructed View of Lower C/P 9 Tile; 18) Carrier Panel 8 - Upper; 19) Left Hand Wing Debris Points to RCC 8/9 - Erosion and RCC with attach hole intact; 20) Erosion on Panel 8 Upper Outboard Rib; 21) RCC Panels 8 & 9 Erosion Features; 22) Slumping Source for Carrier Panel 9 Tile was Revealed; 23) Debris Indicated Highest Probability Initiation Site; 24) Left Hand Wing Debris Points to RCC 8/9- Metallic Deposits; 25) Relative Metallic Deposition on L/H Wing Materials; 26) Metallic Deposit Example, LH RCC 8; 27) High Level Questions; 28) Analysis Plan Challenges; 29) Analysis Techniques; 30) Analysis Approach; 31) RCC Panel 8 Erosion Features; 32) Radiographic Features; 33) Radiography WLE LH Panel 8; 34) LH RCC 8 Upper Apex; 35) LH RCC 8 - Deposit Feature: Thick Tear Shaped; 36) LH RCC 8 - Deposit Feature: Thick Globules; 37) LH RCC 8 - Deposit Feature: Spheroids; 38) LH RCC 8 - Deposit Feature: Uniform Deposit; 39) Significant Findings - Sampling All Other panels; 40) Proposed Breach Location and Plasma Flow; 41) Corroborating Information - RCC Panel Debris Locations; 42) Corroborating Information - LH OMS Pod Analysis; 43) Corroborating Information - Impact Testing; and 44) Overall Forensic Conclusions.

Russell, Richard W.↗
NASA NTRS2008

Kevlar 49/Epoxy COPV Aging Evaluation

NASA initiated an effort to determine if the aging of Kevlar 49/Epoxy composite overwrapped pressure vessels (COPV) affected their performance. This study briefly reviews the history and certification of composite pressure vessels employed on NASA Orbiters. Tests to evaluate overwrap tensile strength changes compared 30 year old samples from Orbiter vessels to new Kevlar/Epoxy pressure vessel materials. Other tests include transverse compression and thermal analyses (glass transition and moduli). Results from these tests do not indicate a noticeable effect due to aging of the overwrap materials.

Sutter, James K.↗
NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Kemmerer, Catherine C.↗
NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The United States Space Operational Space Shuttle Fleet Consists of three shuttles with an average age of 19.7 years. Shuttles are exposed to corrosive conditions while undergoing final closeout for missions at the launch pad and extreme conditions during ascent, orbit, and descent that may accelerate the corrosion process. Structural corrosion under TPS could progress undetected (without tile removal) and eventually result in reduction in structural capability sufficient to create negative margins of . safety and ultimate loss of local structural capability.

Kammerer, Catherine C.↗
NASA NTRS2007

Terahertz NDE Application for Corrosion Detection and Evaluation under Shuttle Tiles

Pulsed Terahertz NDE is being examined as a method to inspect for possible corrosion under Space Shuttle Tiles. Other methods such as ultrasonics, infrared, eddy current and microwave technologies have demonstrable shortcomings for tile NDE. This work applies Terahertz NDE, in the frequency range between 50 GHz and 1 THz, for the inspection of manufactured corrosion samples. The samples consist of induced corrosion spots that range in diameter (2.54 to 15.2 mm) and depth (0.036 to 0.787 mm) in an aluminum substrate material covered with tiles. Results of these measurements are presented for known corrosion flaws both covered and uncovered and for blind tests with unknown corrosion flaws covered with attached tiles. The Terahertz NDE system is shown to detect all artificially manufactured corrosion regions under a Shuttle tile with a depth greater than 0.13 mm.

Anastasi, Robert F.↗
NASA NTRS2007

An Overview of the Space Shuttle Orbiter's Aging Aircraft Program

The Space Shuttle Orbiter has well exceeded its original design life of 10 years or 100 missions. The Orbiter Project Office (OPO) has sponsored several activities to address aging vehicle concerns, including a Corrosion Control Review Board (CCRB), a mid-life certification program, and most recently the formation of the Aging Orbiter Working Group (AOWG). The AOWG was chartered in 2004 as a proactive group which provides the OPO oversight for aging issues such as corrosion, non-destructive inspection, non-metallics, wiring and subsystems. The core team consists of mainly representatives from the Materials and Processes Problem Resolution Team (M&P PRT) and Safety and Mission Assurance (S&MA). Subsystem engineers and subject matter experts are called in as required. The AOWG has functioned by forming issues based sub-teams. Examples of completed sub-teams include adhesives, wiring and wing leading edge metallic materials. Current sub-teams include Composite Over-Wrapped Pressure Vessels (COPV), elastomeric materials and mechanisms.

Russell, Richard W.↗
NASA NTRS2007

Application of Terahertz Radiation to the Detection of Corrosion under the Shuttle's Thermal Protection System

There is currently no method for detecting corrosion under Shuttle tiles except for the expensive process of tile removal and replacement; hence NASA is investigating new NDE methods for detecting hidden corrosion. Time domain terahertz radiation has been applied to corrosion detection under tiles in samples ranging from small lab samples to a Shuttle with positive results. Terahertz imaging methods have been able to detect corrosion at thicknesses of 5 mils or greater under 1" thick Shuttle tiles and 7-12 mils or greater under 2" thick Shuttle tiles.

Madaras, Eric I.↗