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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Use of Raman Spectroscopy and Delta Volume Growth from Void Collapse to Assess Overwrap Stress Gradients Compromising the Reliability of Large Kevlar/Epoxy COPVs

Composite Overwrapped Pressure Vessels (COPVs) are frequently used for storing pressurized gases aboard spacecraft and aircraft when weight saving is desirable compared to all-metal versions. Failure mechanisms in fibrous COPVs and variability in lifetime can be very different from their metallic counterparts; in the former, catastrophic stress-rupture can occur with virtually no warning, whereas in latter, a leak before burst design philosophy can be implemented. Qualification and certification typically requires only one burst test on a production sample (possibly after several pressure cycles) and the vessel need only meet a design burst strength (the maximum operating pressure divided by a knockdown factor). Typically there is no requirement to assess variability in burst strength or lifetime, much less determine production and materials processing parameters important to control of such variability. Characterizing such variability and its source is crucial to models for calculating required reliability over a given lifetime (e.g. R = 0.9999 for 15 years). In this paper we present a case study of how lack of control of certain process parameters in COPV manufacturing can result in variations among vessels and between production runs that can greatly increase uncertainty and reduce reliability. The vessels considered are 40-inch ( NASA Glenn Research center, Cleveland, OH, 44135 29,500 in3 ) spherical COPVs with a 0.74 in. thick Kevlar49/epoxy overwrap and with a titanium liner of which 34 were originally produced. Two burst tests were eventually performed that unexpectedly differed by almost 5%, and were 10% lower than anticipated from burst tests on 26-inch sister vessels similar in every detail. A major observation from measurements made during proof testing (autofrettage) of the 40-inch vessels was that permanent volume growth from liner yielding varied by a factor of more than two (150 in3 to 360 in3 ), which suggests large differences in the residual stress gradient through their overwraps. This resulted in large uncertainty in true fiber stress ratio (fiber stress at operating pressure divided by fiber stress at burst) which governs lifetime. The vessels were originally designed with tight safety margins, so it became crucial to develop a non-destructive evaluation (NDE) technique to directly measure the overwrap residual stress state of each vessel, and to identify those vessels at highest risk of having poor reliability. This paper describes a Raman Spectroscopy technique for measuring certain patterns of fluctuation in fiber elastic strains over the outside vessel surface (where all but one wrap is exposed at certain locations) that are shown to directly correlate to increased fiber stress ratios and reduced reliability.

Kezirian, Michael T.↗
NASA NTRS2011

Assessment of an Automated Touchdown Detection Algorithm for the Orion Crew Module

Orion Crew Module (CM) touchdown detection is critical to activating the post-landing sequence that safe?s the Reaction Control Jets (RCS), ensures that the vehicle remains upright, and establishes communication with recovery forces. In order to accommodate safe landing of an unmanned vehicle or incapacitated crew, an onboard automated detection system is required. An Orion-specific touchdown detection algorithm was developed and evaluated to differentiate landing events from in-flight events. The proposed method will be used to initiate post-landing cutting of the parachute riser lines, to prevent CM rollover, and to terminate RCS jet firing prior to submersion. The RCS jets continue to fire until touchdown to maintain proper CM orientation with respect to the flight path and to limit impact loads, but have potentially hazardous consequences if submerged while firing. The time available after impact to cut risers and initiate the CM Up-righting System (CMUS) is measured in minutes, whereas the time from touchdown to RCS jet submersion is a function of descent velocity, sea state conditions, and is often less than one second. Evaluation of the detection algorithms was performed for in-flight events (e.g. descent under chutes) using hi-fidelity rigid body analyses in the Decelerator Systems Simulation (DSS), whereas water impacts were simulated using a rigid finite element model of the Orion CM in LS-DYNA. Two touchdown detection algorithms were evaluated with various thresholds: Acceleration magnitude spike detection, and Accumulated velocity changed (over a given time window) spike detection. Data for both detection methods is acquired from an onboard Inertial Measurement Unit (IMU) sensor. The detection algorithms were tested with analytically generated in-flight and landing IMU data simulations. The acceleration spike detection proved to be faster while maintaining desired safety margin. Time to RCS jet submersion was predicted analytically across a series of simulated Orion landing conditions. This paper details the touchdown detection method chosen and the analysis used to support the decision.

Gay, Robert S.↗
NASA NTRS1988

Spacecraft flight simulation: A human factors investigation into the man-machine interface between an astronaut and a spacecraft performing docking maneuvers and other proximity operations

The anticipated increase in rendezvous and docking activities in the various space programs in the Space Station era necessitates a renewed interest in manual docking procedures. Ten test subjects participated in computer simulated docking missions in which the influence of initial velocity was examined. All missions started from a resting position of 304.8 meters (1000 feet) along the space station's +V-bar axis. Test subjects controlled their vehicle with a translational hand controller and digital auto pilot which are both virtually identical to their space shuttle counterparts. While the 0.1 percent rule (range rate is equal to 0.1 percent of the range) used by space shuttle pilots is comfortably safe, it is revealed to be extremely inefficient in terms of time and not justifiable in terms of marginal safety. Time is worth money, not only because of training and launch costs, but because the sooner a pilot and spacecraft return from a mission, the sooner they can begin the next one. Inexperienced test subjects reduced the costs of simulated docking by close to a factor of 2 and achieved safe dockings in less than 4 percent of the time the baseline approach would entail. This reduction in time can be used to save lives in the event of an accident on orbit, and can tremendously reduce docking costs if fuel is produced from waste water on orbit.

Brody, Adam R.↗
NASA NTRS2005

RSRM TP-H1148 Main Grain Propellant Crack Initiation Evaluation

Pressurized TP-HI 148 propellant fracture toughness testing was performed to assess the potential for initiation of visually undetectable cracks in the RSRM forward segment transition region during motor ignition. Two separate test specimens were used in this evaluation. Testing was performed in cold-gas and hot-fire environments, and under both static and dynamic pressurization conditions. Analysis of test results demonstrates safety factors against initiation of visually undetectable cracks in excess of 8.0. The Reusable Solid Rocket Motor (RSRM) forward segment is cast with PBAN propellant (TP-HI 148) to form T an 1 1-point star configuration that transitions to a tapered center perforated bore (see Figure 1). The geometry of the transition region between the fin valleys and the bore causes a localized area of high strain during horizontal storage. Updated analyses using worst-case mechanical properties at 40 F and improved modeling techniques indicated a slight reduction in safety margins over previous predictions. Although there is no history of strain induced cracks or flaws in the transition region propellant, a proactive test effort was initiated to better understand the implications of the new analysis, primarily the resistance of TP-H1148 propellant to crack initiation' during RSRM ignition.

Earnest, Todd E.↗
NASA NTRS2005

Intelligent Life-Extending Controls for Aircraft Engines Studied

Current aircraft engine controllers are designed and operated to provide desired performance and stability margins. Except for the hard limits for extreme conditions, engine controllers do not usually take engine component life into consideration during the controller design and operation. The end result is that aircraft pilots regularly operate engines under unnecessarily harsh conditions to strive for optimum performance. The NASA Glenn Research Center and its industrial and academic partners have been working together toward an intelligent control concept that will include engine life as part of the controller design criteria. This research includes the study of the relationship between control action and engine component life as well as the design of an intelligent control algorithm to provide proper tradeoffs between performance and engine life. This approach is expected to maintain operating safety while minimizing overall operating costs. In this study, the thermomechanical fatigue (TMF) of a critical component was selected to demonstrate how an intelligent engine control algorithm can significantly extend engine life with only a very small sacrifice in performance. An intelligent engine control scheme based on modifying the high-pressure spool speed (NH) was proposed to reduce TMF damage from ground idle to takeoff. The NH acceleration schedule was optimized to minimize the TMF damage for a given rise-time constraint, which represents the performance requirement. The intelligent engine control scheme was used to simulate a commercial short-haul aircraft engine.

Guo, Ten-Huei↗
NASA NTRS2017

Evaluating the Stability of NASA's Space Launch System with Adaptive Augmenting Control

NASA's baseline Space Launch System (SLS) flight control system (FCS) design includes an adaptive augmenting control (AAC) component that modifies the attitude control system response to provide the classical gain-scheduled control architecture with additional performance and robustness. The NASA Engineering and Safety Center (NESC) teamed with the Space Launch System (SLS) Program to perform a comprehensive assessment of the stability and robustness of the FCS with AAC. This paper provides an overview of the approach, specific analysis techniques, and outcomes that were particularly relevant for the SLS Program. Multiple analysis techniques that specifically target the nonlinear AAC were commissioned as part of this assessment, which was completed outside of the Program's standard design analysis cycle. The following analyses were included, with each technique adding its own valuable insights: Lyapunov-based stability analysis, classical stability analysis with static AAC gain variations, circle criterion-based analysis of the FCS with a time-varying element, time-domain stability margin assessment, Monte Carlo simulations with expanded dispersions, and an extensive set of stressing cases. Several of the completed analyses focused on determining whether the inclusion of AAC introduced risk to the FCS, while others quantified the benefits of the adaptive augmentation.

Tannen S Vanzwieten↗
NASA NTRS2010

Projection Operator: A Step Towards Certification of Adaptive Controllers

One of the major barriers to wider use of adaptive controllers in commercial aviation is the lack of appropriate certification procedures. In order to be certified by the Federal Aviation Administration (FAA), an aircraft controller is expected to meet a set of guidelines on functionality and reliability while not negatively impacting other systems or safety of aircraft operations. Due to their inherent time-variant and non-linear behavior, adaptive controllers cannot be certified via the metrics used for linear conventional controllers, such as gain and phase margin. Projection Operator is a robustness augmentation technique that bounds the output of a non-linear adaptive controller while conforming to the Lyapunov stability rules. It can also be used to limit the control authority of the adaptive component so that the said control authority can be arbitrarily close to that of a linear controller. In this paper we will present the results of applying the Projection Operator to a Model-Reference Adaptive Controller (MRAC), varying the amount of control authority, and comparing controller s performance and stability characteristics with those of a linear controller. We will also show how adjusting Projection Operator parameters can make it easier for the controller to satisfy the certification guidelines by enabling a tradeoff between controller s performance and robustness.

Larchev, Gregory V.↗
NASA NTRS1977

Integration of remote sensing and surface geophysics in the detection of faults

Remote sensing was included in a comprehensive investigation of the use of geophysical techniques to aid in underground mine placement. The primary objective was to detect faults and slumping, features which, due to structural weakness and excess water, cause construction difficulties and safety hazards in mine construction. Preliminary geologic reconnaissance was performed on a potential site for an underground oil shale mine in the Piceance Creek Basin of Colorado. LANDSAT data, black and white aerial photography and 3 cm radar imagery were obtained. LANDSAT data were primarily used in optical imagery and digital tape forms, both of which were analyzed and enhanced by computer techniques. The aerial photography and radar data offered supplemental information. Surface linears in the test area were located and mapped principally from LANDSAT data. A specific, relatively wide, linear pointed directly toward the test site, but did not extend into it. Density slicing, ratioing, and edge enhancement of the LANDSAT data all indicated the existence of this linear. Radar imagery marginally confirmed the linear, while aerial photography did not confirm it.

Jackson, P. L.↗
NASA NTRS2009

Stability and Control Analysis of the F-15B Quiet SpikeTM Aircraft

The primary purpose of the Quiet Spike(TradeMark) flight research program was to analyze the aerodynamic, structural, and mechanical proof-of-concept of a large multi-stage telescoping nose spike installed on the National Aeronautics and Space Administration Dryden Flight Research Center (Edwards, California) F-15B airplane. This report describes the preflight stability and control analysis performed to assess the effect of the spike on the stability, controllability, and handling qualities of the airplane; and to develop an envelope expansion approach to maintain safety of flight. The overall flight test objective was to collect flight data to validate the spike structural dynamics and loads model up to Mach 1.8. Other objectives included validating the mechanical feasibility of a morphing fuselage at operational conditions and determining the near-field shock wave characterization. The two main issues relevant to the stability and control objectives were the effects of the spike-influenced aerodynamics on the F-15B airplane flight dynamics, and the air data and angle-of-attack sensors. The analysis covered the sensitivity of the stability margins, and the handling qualities due to aerodynamic variation and the maneuvering limitations of the F-15B Quiet Spike configuration. The results of the analysis and the implications for the flight test program are also presented.

McWherter, Shaun C.↗
NASA NTRS1978

Evaluation of the SSRCT engine with a hydrazine as a fuel, phase 1

The performance parameters for the space shuttle reaction control thruster (SSRCT) when the fuel is changed from monomethylhydrazine to hydrazine were predicted. Potential problems are higher chamber wall temperature during steady state operation and explosive events during pulse mode operation. Solutions to the problems are suggested. To conduct the analysis, a more realistic film cooling model was devised which considers that hydrazine based fuels are reactive when used as a film coolant on the walls of the combustion chamber. Hydrazine based fuels can decompose exothermally as a monopropellant and also enter into bipropellant reactions with any excess oxidizer in the combustion chamber. It is concluded that the conversion of the thruster from MMH to hydrazine fuel is feasible but that a number of changes would be required to achieve the same safety margins as the monomethylhydrazine-fueled thruster.

Minton, S. J.↗
NASA NTRS2000

Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners while maintaining the superior CuCrNb properties are also presented.

Zimmerman, Frank↗
NASA NTRS2020

Unsupervised Anomaly Detection in High-Dimensional Flight Data Using Convolutional Variational Auto-Encoder

The modern National Airspace System (NAS) is an extremely safe system and the aviation industry has experienced a steady decrease in fatalities over the years. This can be attributed to both improved flight critical systems with redundant hardware and software protections, as well as an increased focus on active monitoring and response to real time and historically identified vulnerabilities by implementing more resilient procedures and protocols. The main approach for identifying vulnerabilities in operations leverages domain expertise using knowledge about how the system should behave within the expected tolerances to known safety margins. This approach works well when the system has a well-defined operating condition. However, the operations in the NAS can be highly complex with various nuances that render it difficult to clearly pre-define all known safety vulnerabilities. With the advancement of data science and machine learning techniques, the potential to automatically identify emerging vulnerabilities in the observed operations has become more practical in recent years. The state-of-the-art anomaly detection approaches in aerospace data usually rely on supervised or semi-supervised learning. However, in many real-world problems such as flight safety, creating labels for the data requires huge amount of effort and is largely impractical. To address this challenge, we developed a Convolutional Variational Auto-Encoder (CVAE), which is an unsupervised learning approach for anomaly detection in high-dimensional heterogeneous time-series data. We validate performance of CVAE compared to the state-of-the-art supervised learning approach as well as unsupervised clustering-based approach using KMeans++ and kernel-based approach using One-Class Support Vector Machine (OC-SVM) on Yahoo!'s benchmark time series anomaly detection data. Finally, we showcase performance of CVAE on a case study of identifying anomalies in the first 60 seconds of commercial flights' take-offs using Flight Operational Quality Assurance (FOQA) data.

Memarzadeh, Milad↗
NASA NTRSDate not supplied

Unsupervised Anomaly Detection in High-Dimensional Flight Data Using Convolutional Variational Auto-Encoder

The modern National Airspace System (NAS) is an extremely safe system. The industry has experienced a steady decrease in fatalities over the years. This can be contributed to both improved flight critical systems with redundant hardware and software protections as well as an increased focus on active monitoring and response to real time and historically identified vulnerabilities by implementing more resilient procedures and protocols. The main practice for identifying vulnerabilities in operations leverages domain expertise using knowledge about how the system should behave with the expected tolerances to known safety margins. This approach works well when the system has a well-defined operating condition. However, the operations in the NAS can be highly complex with various nuances that render it difficult to clearly pre-define all known safety vulnerabilities. With the advancement of data science and machine learning techniques, the potential to automatically identify emerging vulnerabilities in the observed operations has become more practical in recent years. The state-of-the-art anomaly detection approaches in aerospace data usually rely on supervised or semi-supervised learning. However, in many real-world problems such as flight safety creating labels for the data requires huge amount of efforts and is largely expensive. As a result, in this article, we develop a Convolutional Variational Auto-Encoder (CVAE), an unsupervised learning approach for anomaly detection in high-dimensional heterogeneous time-series data. We validate performance of CVAE compared to the state-of-the-art supervised learning approach (as an upper bound) as well as an supervised clustering based on K-Means (as a lower bound) on Yahoo!'s benchmark time series anomaly detection data. Finally, we showcase performance of CVAE on a case study of identifying anomalies in the first 60 seconds of commercial flights' take-offs using Flight Operational Quality Assurance (FOQA) data.

Milad Memarzadeh↗
NASA NTRS2008

Structural Design and Analysis of the Upper Pressure Shell Section of a Composite Crew Module

This paper presents the results of the structural design and analysis of the upper pressure shell section of a carbon composite demonstration structure for the Composite Crew Module (CCM) Project. The project is managed by the NASA Engineering and Safety Center with participants from eight NASA Centers, the Air Force Research Laboratory, and multiple aerospace contractors including ATK/Swales, Northrop Grumman, Lockheed Martin, Collier Research Corporation, Genesis Engineering, and Janicki Industries. The paper discusses details of the upper pressure shell section design of the CCM and presents the structural analysis results using the HyperSizer structural sizing software and the MSC Nastran finite element analysis software. The HyperSizer results showed that the controlling load case driving most of the sizing in the upper pressure shell section was the internal pressure load case. The regions around the cutouts were controlled by internal pressure and the main parachute load cases. The global finite element analysis results showed that the majority of the elements of the CCM had a positive margin of safety with the exception of a few hot spots around the cutouts. These hot spots are currently being investigated with a more detailed analysis. Local finite element models of the Low Impact Docking System (LIDS) interface ring and the forward bay gussets with greater mesh fidelity were created for local sizing and analysis. The sizing of the LIDS interface ring was driven by the drogue parachute loads, Trans-Lunar Insertion (TLI) loads, and internal pressure. The drogue parachute loads controlled the sizing of the gusset cap on the drogue gusset and TLI loads controlled the sizing of the other five gusset caps. The main parachute loads controlled the sizing of the lower ends of the gusset caps on the main parachute fittings. The results showed that the gusset web/pressure shell and gusset web/gusset cap interfaces bonded using Pi-preform joints had local hot spots in the Pi-preform termination regions. These regions require a detailed three-dimensional analysis, which is currently being performed, to accurately address the load distribution near the Pi-preform termination in the upper and lower gusset caps.

Sleight, David W.↗
NASA NTRS2013

Mars Sample Return Using Commercial Capabilities: ERV Trajectory and Capture Requirements

Mars Sample Return was presented as the highest priority planetary science mission of the next decade [1]. Lemke et al. [2] present a Mars Sample Return mission concept in which the sample is returned directly from the surface of Mars to an Earth orbit. The sample is recovered in Earth Orbit instead of being transferred between spacecraft in Mars Orbit. This paper provides the details of this sample recovery in Earth orbit and presents as such a sub-element of the overall Mars sample return concept given in [2]. We start from the assumption that a Mars Ascent Vehicle (MAV), initially landed on Mars using a modified SpaceX Dragon capsule, has successfully delivered the sample, already contained within an Earth Return Vehicle (ERV), to a parking orbit around Mars. From the parking orbit, the ERV imparts sufficient Delta-V to inject itself into an earthbound trajectory and to be captured into an Earth orbit eventually. We take into account launch window and Delta-V considerations as well as the additional constraint of increased safety margins imposed by planetary protection regulations. We focus on how to overcome two distinct challenges of the sample return that are driven by the issues of planetary protection: (1) the design of an ERV trajectory meeting all the requirements including the need to avoid contamination of Earth's atmosphere; (2) the concept of operations for retrieving the Martian samples in Earth orbit in a safe way. We present an approach to retrieve the samples through a rendezvous between the ERV and a second SpaceX Dragon capsule. The ERV executes a trajectory that brings it from low Mars orbit (LMO) to a Moon-trailing Earth orbit at high inclination with respect to the Earth-Moon plane. After a first burn at Trans-Earth Injection (TEI), the trajectory uses a second burn at perigee during an Earth flyby maneuver to capture the ERV in Earth orbit. The ERV then uses a non-propulsive Moon flyby to come to a near-circular Moon-trailing orbit. To perform the Earth Orbit Rendezvous (EOR), a second Dragon capsule is then launched from Earth and a similar lunar flyby is performed to rendezvous with the ERV. The requirements for rendezvous, close proximity operations and capture of the sample canister are described. A concept of operations for sample retrieval is presented along with design specifications of the ERV, the required modifications to the Dragon capsule, as well as the hardware, software, sensors, actuators, and capture mechanisms used. In our concept, a container is mounted to the front hatch of Dragon, capable of accommodating the sample canister and sealing it from the rest of the capsule. The sample canister is captured using a robotic arm with a magnetic grappling mechanism. Dragon then performs a propulsive maneuver to return to Earth for a controlled re-entry while the ERV (sans sample container) is left in the Moon trailing orbit. Contingency cases and related mitigation strategies are also discussed, including the advantages and disadvantages of performing the ERV rendezvous with a crew.

Faber, Nicolas F.↗
NASA NTRS2014

Service Life Extension of the Propulsion System of Long-Term Manned Orbital Stations

One of the critical non-replaceable systems of a long-term manned orbital station is the propulsion system. Since the propulsion system operates beginning with the launch of station elements into orbit, its service life determines the service life of the station overall. Weighing almost a million pounds, the International Space Station (ISS) is about four times as large as the Russian space station Mir and about five times as large as the U.S. Skylab. Constructed over a span of more than a decade with the help of over 100 space flights, elements and modules of the ISS provide more research space than any spacecraft ever built. Originally envisaged for a service life of fifteen years, this Earth orbiting laboratory has been in orbit since 1998. Some elements that have been launched later in the assembly sequence were not yet built when the first elements were placed in orbit. Hence, some of the early modules that were launched at the inception of the program were already nearing the end of their design life when the ISS was finally ready and operational. To maximize the return on global investments on ISS, it is essential for the valuable research on ISS to continue as long as the station can be sustained safely in orbit. This paper describes the work performed to extend the service life of the ISS propulsion system. A system comprises of many components with varying failure rates. Reliability of a system is the probability that it will perform its intended function under encountered operating conditions, for a specified period of time. As we are interested in finding out how reliable a system would be in the future, reliability expressed as a function of time provides valuable insight. In a hypothetical bathtub shaped failure rate curve, the failure rate, defined as the number of failures per unit time that a currently healthy component will suffer in a given future time interval, decreases during infant-mortality period, stays nearly constant during the service life and increases at the end when the design service life ends and wear-out phase begins. However, the component failure rates do not remain constant over the entire cycle life. The failure rate depends on various factors such as design complexity, current age of the component, operating conditions, severity of environmental stress factors, etc. Development, qualification and acceptance test processes provide rigorous screening of components to weed out imperfections that might otherwise cause infant mortality failures. If sufficient samples are tested to failure, the failure time versus failure quantity can be analyzed statistically to develop a failure probability distribution function (PDF), a statistical model of the probability of failure versus time. Driven by cost and schedule constraints however, spacecraft components are generally not tested in large numbers. Uncertainties in failure rate and remaining life estimates increase when fewer units are tested. To account for this, spacecraft operators prefer to limit useful operations to a period shorter than the maximum demonstrated service life of the weakest component. Running each component to its failure to determine the maximum possible service life of a system can become overly expensive and impractical. Spacecraft operators therefore, specify the required service life and an acceptable factor of safety (FOS). The designers use these requirements to limit the life test duration. Midway through the design life, when benefits justify additional investments, supplementary life test may be performed to demonstrate the capability to safely extend the service life of the system. An innovative approach is required to evaluate the entire system, without having to go through an elaborate test program of propulsion system elements. Evaluating every component through a brute force test program would be a cost prohibitive and time consuming endeavor. ISS propulsion system components were designed and built decades ago. There are no representative ground test articles for some of the components. A 'test everything' approach would require manufacturing new test articles. The paper outlines some of the techniques used for selective testing, by way of cherry picking candidate components based on failure mode effects analysis, system level impacts, hazard analysis, etc. The type of testing required for extending the service life depends on the design and criticality of the component, failure modes and failure mechanisms, life cycle margin provided by the original certification, operational and environmental stresses encountered, etc. When specific failure mechanism being considered and the underlying relationship of that mode to the stresses provided in the test can be correlated by supporting analysis, time and effort required for conducting life extension testing can be significantly reduced. Exposure to corrosive propellants over long periods of time, for instance, lead to specific failure mechanisms in several components used in the propulsion system. Using Arrhenius model, which is tied to chemically dependent failure mechanisms such as corrosion or chemical reactions, it is possible to subject carefully selected test articles to accelerated life test. Arrhenius model reflects the proportional relationship between time to failure of a component and the exponential of the inverse of absolute temperature acting on the component. The acceleration factor is used to perform tests at higher stresses that allow direct correlation between the times to failure at a high test temperature to the temperatures to be expected in actual use. As long as the temperatures are such that new failure mechanisms are not introduced, this becomes a very useful method for testing to failure a relatively small sample of items for a much shorter amount of time. In this article, based on the example of the propulsion system of the first ISS module Zarya, theoretical approaches and practical activities of extending the service life of the propulsion system are reviewed with the goal of determining the maximum duration of its safe operation.

Kamath, Ulhas↗
NASA NTRS2017

Extraction-Separation Performance and Dynamic Modeling of Orion Test Vehicles with Adams Simulation: 3rd Edition

NASA's Orion Capsule Parachute Assembly System (CPAS) Project is now in the qualification phase of testing, and the Adams simulation has continued to evolve to model the complex dynamics experienced during the test article extraction and separation phases of flight. The ability to initiate tests near the upper altitude limit of the Orion parachute deployment envelope requires extractions from the aircraft at 35,000 ft-MSL. Engineering development phase testing of the Parachute Test Vehicle (PTV) carried by the Carriage Platform Separation System (CPSS) at altitude resulted in test support equipment hardware failures due to increased energy caused by higher true airspeeds. As a result, hardware modifications became a necessity requiring ground static testing of the textile components to be conducted and a new ground dynamic test of the extraction system to be devised. Force-displacement curves from static tests were incorporated into the Adams simulations, allowing prediction of loads, velocities and margins encountered during both flight and ground dynamic tests. The Adams simulation was then further refined by fine tuning the damping terms to match the peak loads recorded in the ground dynamic tests. The failure observed in flight testing was successfully replicated in ground testing and true safety margins of the textile components were revealed. A multi-loop energy modulator was then incorporated into the system level Adams simulation model and the effect on improving test margins be properly evaluated leading to high confidence ground verification testing of the final design solution.

Varela, Jose G.↗
NASA NTRS2007

NASA's Decadal Planning Team Mars Mission Analysis Summary

In June 1999 the NASA Administrator chartered an internal NASA task force, termed the Decadal Planning Team, to create new integrated vision and strategy for space exploration. The efforts of the Decadal Planning Team evolved into the Agency-wide team known as the NASA Exploration Team (NEXT). This team was also instructed to identify technology roadmaps to enable the science-driven exploration vision, established a cross-Enterprise, cross-Center systems engineering team with emphasis focused on revolutionary not evolutionary approaches. The strategy of the DPT and NEXT teams was to "Go Anywhere, Anytime" by conquering key exploration hurdles of space transportation, crew health and safety, human/robotic partnerships, affordable abundant power, and advanced space systems performance. Early emphasis was placed on revolutionary exploration concepts such as rail gun and electromagnetic launchers, propellant depots, retrograde trajectories, nano structures, and gas core nuclear rockets to name a few. Many of these revolutionary concepts turned out to be either not feasible for human exploration missions or well beyond expected technology readiness for near-term implementation. During the DPT and NEXT study cycles, several architectures were analyzed including missions to the Earth-Sun Libration Point (L2), the Earth-Moon Gateway and L1, the lunar surface, Mars (both short and long stays), one-year round trip Mars, and near-Earth asteroids. Common emphasis of these studies included utilization of the Earth-Moon Libration Point (L1) as a staging point for exploration activities, current (Shuttle) and near-term launch capabilities (EELV), advanced propulsion, and robust space power. Although there was much emphasis placed on utilization of existing launch capabilities, the team concluded that missions in near-Earth space are only marginally feasible and human missions to Mars were not feasible without a heavy lift launch capability. In addition, the team concluded that missions in Earth s neighborhood, such as to the Moon, can serve as stepping-stones toward further deep-space missions in terms of proving systems, technologies, and operational concepts. The material contained in this presentation was compiled to capture the work performed by the Mars Sub-Team of the DPT NEXT efforts in the late 1999-2001 timeframe.

Drake, Bret G.↗