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NASA NTRS2007

TRL Assessment of Solar Sail Technology Development Following the 20-Meter System Ground Demonstrator Hardware Testing

The NASA In-Space Propulsion Technology (ISPT) Projects Office has been sponsoring 2 separate, independent system design and development hardware demonstration activities during 2002-2005. ATK Space Systems of Goleta, CA was the prime contractor for one development team and L'Garde, Inc. of Tustin, CA was the prime contractor for the other development team. The goal of these activities was to advance the technology readiness level (TRL) of solar sail propulsion from 3 towards 6 by the year 2006. Component and subsystem fabrication and testing were completed successfully, including the ground deployment of 10-meter and 20-meter ground demonstration hardware systems under vacuum conditions. The deployment and structural testing of the 20-meter solar sail systems was conducted in the 30 meter diameter Space Power Facility thermal-vacuum chamber at NASA Glenn Plum Brook in April though August, 2005. This paper will present the results of the TRL assessment following the solar sail technology development activities associated with the design, development, analysis and testing of the 20-meter system ground demonstrators. Descriptions of the system designs for both the ATK and L'Garde systems will be presented. Changes, additions and evolution of the system designs will be highlighted. A description of the modeling and analyses activities performed by both teams, as well as testing conducted to raise the TRL of solar sail technology will be presented. A summary of the results of model correlation activities will be presented. Finally, technology gaps identified during the assessment and gap closure plans will be presented, along with "lessons learned", subsequent planning activities and validation flight opportunities for solar sail propulsion technology.

Montgomery, Edward E.↗

NASA NTRS2007

TRL Assessment of Solar Sail Technology Development Following the 20-Meter System Ground Demonstrator Hardware Testing

Young, Roy M.↗

NASA NTRS2006

In-Vacuum Photogrammetry of a Ten-Meter Square Solar Sail

Solar sailing is a promising, future in-space propulsion method that uses the small force of reflecting sunlight to accelerate a large, reflective membrane without expendable propellants. One of two solar sail configurations under development by NASA is a striped net approach by L'Garde, Inc. This design uses four inflatably deployed, lightweight booms supporting a network of thin strings onto which four quadrants of ultrathin aluminized membranes are attached. The NASA Langley Research Center (LaRC) provided both experimental and analytical support to L'Garde for validating the structural characteristics of this unique, ultralightweight spacecraft concept. One of LaRC's responsibilities was to develop and apply photogrammetric methods to measure sail shape. The deployed shape provides important information for validating the accuracy of finite-element modeling techniques. Photogrammetry is the science and art of calculating 3D coordinates of targets or other distinguishing features on structures using images. A minimum of two camera views of each target is required for 3D determination, but having four or more camera views is preferable for improved reliability and accuracy. Using retroreflective circular targets typically provides the highest measurement accuracy and automation. References 3 and 4 provide details of photogrammetry technology, and reference 5 discusses previous experiences with photogrammetry for measuring gossamer spacecraft structures such as solar sails. This paper discusses the experimental techniques used to measure a L Garde 10-m solar sail test in vacuum with photogrammetry. The test was conducted at the NASA-Glenn Space Power Facility (SPF) located at Plum Brook Station in Sandusky, Ohio. The SPF is the largest vacuum chamber in the United States, measuring 30 m in diameter by 37 m in height. High vacuum levels (10(exp -6) torr) can be maintained inside the chamber, and cold environments (-195 C) are possible using variable-geometry cryogenic cold walls. This test used a vacuum level of approximately 1 torr (sufficient for structural static/dynamic characterization) and instead of using the cryogenic cold walls, used local LN2 cold plates underneath each of the four cold-rigidizable solar sail booms instead.

Pappa, Richard S.↗

NASA NTRS2008

Overview of the Orion Vibroacoustic Test Capability at NASA Glenn Research Center

In order to support the environmental test needs for our new Orion and Constellation program, NASA is developing unique world-class test facilities. To optimize this testing of spaceflight hardware while minimizing transportation issues, a one-stop, under one roof test capability is being developed at the Space Power Facility at the NASA Glenn Research Center's Plum Brook Station. This facility will provide the capability to perform the following environmental testing: (1) reverberation acoustic testing, (2) mechanical base-shake sine testing, (3) modal testing, (4) thermal-vacuum testing, and (5) EMI/EMC (electromagnetic interference and compatibility) testing. An overview of this test capability will be provided in this presentation, with special focus on the two new vibroacoustic test facilities currently being designed and built, the Reverberant Acoustic Test Facility (RATF) and the Mechanical Vibration Facility (MVF). Testing of the engineering developmental hardware and qualification hardware of the Orion (Crew Exploration Vehicle) will commence shortly after the facilities are commissioned.

Hughes, William O.↗

NASA NTRS2006

Solar Sails

The Solar Sail Propulsion investment area has been one of the three highest priorities within the In-Space Propulsion Technology (ISPT) Project. In the fall of 2003, the NASA Headquarters' Science Mission Directorate provided funding and direction to mature the technology as far as possible through ground research and development from TRL 3 to 6 in three years. A group of experts from government, industry, and academia convened in Huntsville, Alabama to define technology gaps between what was needed for science missions to the inner solar system and the current state of the art in ultra1ightweight materials and gossamer structure design. This activity set the roadmap for development. The centerpiece of the development would be the ground demonstration of scalable solar sail systems including masts, sails, deployment mechanisms, and attitude control hardware and software. In addition, new materials would be subjected to anticipated space environments to quantify effects and assure mission life. Also, because solar sails are huge structures, and it is not feasible to validate the technology by ground test at full scale, a multi-discipline effort was established to develop highly reliable analytical models to serve as mission assurance evidence in future flight program decision-making. Two separate contractor teams were chosen to develop the SSP System Ground Demonstrator (SGD). After a three month conceptual mission/system design phase, the teams developed a ten meter diameter pathfinder set of hardware and subjected it to thermal vacuum tests to compare analytically predicted structural behavior with measured characteristics. This process developed manufacturing and handling techniques and refined the basic design. In 2005, both contractor teams delivered 20 meter, four quadrant sail systems to the largest thermal vacuum chamber in the world in Plum Brook, Ohio, and repeated the tests. Also demonstrated was the deployment and articulation of attitude control mechanisms. In conjunction with these tests, the stowed sails were subjected to launch vibration and ascent vent tests. Other investments studied radiation effects on the solar sail materials, investigated spacecraft charging issues, developed shape measuring techniques and instruments, produced advanced trajectory modeling capabilities, and identified and resolved gossamer structure dynamics issues. Technology validation flight and application to a He1iophysics science mission is on the horizon.

Young, Roy↗

NASA NTRS2009

Advanced Distributed Measurements and Data Processing at the Vibro-Acoustic Test Facility, GRC Space Power Facility, Sandusky, Ohio - an Architecture and an Example

A large-scale, distributed, high-speed data acquisition system (HSDAS) is currently being installed at the Space Power Facility (SPF) at NASA Glenn Research Center s Plum Brook Station in Sandusky, OH. This installation is being done as part of a facility construction project to add Vibro-acoustic Test Capabilities (VTC) to the current thermal-vacuum testing capability of SPF in support of the Orion Project s requirement for Space Environments Testing (SET). The HSDAS architecture is a modular design, which utilizes fully-remotely managed components, enables the system to support multiple test locations with a wide-range of measurement types and a very large system channel count. The architecture of the system is presented along with details on system scalability and measurement verification. In addition, the ability of the system to automate many of its processes such as measurement verification and measurement system analysis is also discussed.

Hill, Gerald M.↗

NASA NTRS2009

Review of the Constellation Level II Safety, Reliability, and Quality Assurance (SR&QA) Requirements Documents during Participation in the Constellation Level II SR&QA Forum

At the request of the Exploration Systems Mission Directorate (ESMD) and the Constellation Program (CxP) Safety, Reliability; and Quality Assurance (SR&QA) Requirements Director, the NASA Engineering and Safety Center (NESC) participated in the Cx SR&QA Requirements forum. The Requirements Forum was held June 24-26; 2008, at GRC's Plum Brook Facility. The forums purpose was to gather all stakeholders into a focused meeting to help complete the process of refining the CxP to refine its Level II SR&QA requirements or defining project-specific requirements tailoring. Element prime contractors had raised specific questions about the wording and intent of many requirements in areas they felt were driving costs without adding commensurate value. NESC was asked to provide an independent and thorough review of requirements that contractors believed were driving Program costs, by active participation in the forum. This document contains information from the forum.

Cameron, Kenneth D.↗

NASA NTRS2009

Calibration Laboratory Capabilities Listing as of April 2009

This document reviews the Calibration Laboratory capabilities for various NASA centers (i.e., Glenn Research Center and Plum Brook Test Facility Kennedy Space Center Marshall Space Flight Center Stennis Space Center and White Sands Test Facility.) Some of the parameters reported are: Alternating current, direct current, dimensional, mass, force, torque, pressure and vacuum, safety, and thermodynamics parameters. Some centers reported other parameters.

Kennedy, Gary W.↗

NASA NTRS2010

TRL Assessment of Solar Sail Technology Development Following the 20-Meter System Ground Demonstrator Hardware Testing

The NASA In-Space Propulsion Technology (ISPT) Projects Office sponsored two separate, independent solar sail system design and development demonstration activities during 2002-2005. ATK Space Systems of Goleta, CA was the prime contractor for one development team and L' Garde, Inc. of Tustin, CA was the prime contractor for the other development team. The goal of these activities was to advance the technology readiness level (TRL) of solar sail propulsion from 3 towards 6 by the year 2006. Component and subsystem fabrication and testing were completed successfully, including the ground deployment of 10-meter and 20-meter demonstration hardware systems under vacuum conditions. The deployment and structural testing of the 20-meter solar sail systems was conducted in the 30 meter diameter Space Power Facility thermal-vacuum chamber at NASA Glenn Plum Brook in April though August, 2005. This paper will present the results of the TRL assessment following the solar sail technology development activities associated with the design, development, analysis and testing of the 20-meter system ground demonstrators.

Young, Roy M.↗

NASA NTRS2010

Status of Solar Sail Technology Within NASA

In the early 2000s, NASA made substantial progress in the development of solar sail propulsion systems for use in robotic science and exploration of the solar system. Two different 20-m solar sail systems were produced and they successfully completed functional vacuum testing in NASA Glenn Research Center's (GRC's) Space Power Facility at Plum Brook Station, Ohio. The sails were designed and developed by ATK Space Systems and L Garde, respectively. The sail systems consist of a central structure with four deployable booms that support the sails. These sail designs are robust enough for deployment in a one-atmosphere, one-gravity environment and were scalable to much larger solar sails perhaps as large as 150 m on a side. Computation modeling and analytical simulations were also performed to assess the scalability of the technology to the large sizes required to implement the first generation of missions using solar sails. Life and space environmental effects testing of sail and component materials were also conducted. NASA terminated funding for solar sails and other advanced space propulsion technologies shortly after these ground demonstrations were completed. In order to capitalize on the $30M investment made in solar sail technology to that point, NASA Marshall Space Flight Center (MSFC) funded the NanoSail-D, a subscale solar sail system designed for possible small spacecraft applications. The NanoSail-D mission flew on board the ill-fated Falcon-1 Rocket launched August 2, 2008, and due to the failure of that rocket, never achieved orbit. The NanoSail-D flight spare will be flown in the Fall of 2010. This paper will summarize NASA's investment in solar sail technology to-date and discuss future opportunities

Johnson, Les↗

NASA NTRS2010

The Testing Behind the Test Facility: the Acoustic Design of the NASA Glenn Research Center's World-Class Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC s Plum Brook Station in Sandusky, Ohio, U.S.A. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA s space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama, U.S.A. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent ongoing construction.

Hughes, William O.↗

NASA NTRS2011

The Testing Behind The Test Facility: The Acoustic Design of the NASA Glenn Research Center's World-Class Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC?s Plum Brook Station in Sandusky, Ohio, USA. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA?s space exploration program. T he large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world?s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada?s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama, USA. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic de-sign and subsequent on-going construction.

Hughes, William O.↗

NASA NTRS2011

The Testing Behind The Test Facility: The Acoustic Design of the NASA Glenn Research Center's World-Class Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC's Plum Brook Station in Sandusky, Ohio, USA. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA's space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 cu ft in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world's known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada's acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama, USA. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent on-going construction.

Hozman, Aron D.↗

NASA NTRS2011

The Development of the Acoustic Design of NASA Glenn Research Center's New Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC's Plum Brook Station in Sandusky, Ohio, USA. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA s space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama, USA. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent on-going construction.

Hughes, William O.↗

NASA NTRS2011

The Development of the Acoustic Design of NASA Glenn Research Center's New Reverberant Acoustic Test Facility

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) is leading the design and build of the new world-class vibroacoustic test capabilities at the NASA GRC s Plum Brook Station in Sandusky, Ohio. Benham Companies, LLC is currently constructing modal, base-shake sine and reverberant acoustic test facilities to support the future testing needs of NASA s space exploration program. The large Reverberant Acoustic Test Facility (RATF) will be approximately 101,000 ft3 in volume and capable of achieving an empty chamber acoustic overall sound pressure level (OASPL) of 163 dB. This combination of size and acoustic power is unprecedented amongst the world s known active reverberant acoustic test facilities. The key to achieving the expected acoustic test spectra for a range of many NASA space flight environments in the RATF is the knowledge gained from a series of ground acoustic tests. Data was obtained from several NASA-sponsored test programs, including testing performed at the National Research Council of Canada s acoustic test facility in Ottawa, Ontario, Canada, and at the Redstone Technical Test Center acoustic test facility in Huntsville, Alabama. The majority of these tests were performed to characterize the acoustic performance of the modulators (noise generators) and representative horns that would be required to meet the desired spectra, as well as to evaluate possible supplemental gas jet noise sources. The knowledge obtained in each of these test programs enabled the design of the RATF sound generation system to confidently advance to its final acoustic design and subsequent on-going construction.

Hughes, William O.↗

NASA NTRS2011

Capabilities, Design, Construction and Commissioning of New Vibration, Acoustic, and Electromagnetic Capabilities Added to the World's Largest Thermal Vacuum Chamber at NASA's Space Power Facility

NASA s human space exploration plans developed under the Exploration System Architecture Studies in 2005 included a Crew Exploration Vehicle launched on an Ares I launch vehicle. The mass of the Crew Exploration Vehicle and trajectory of the Ares I coupled with the need to be able to abort across a large percentage of the trajectory generated unprecedented testing requirements. A future lunar lander added to projected test requirements. In 2006, the basic test plan for Orion was developed. It included several types of environment tests typical of spacecraft development programs. These included thermal-vacuum, electromagnetic interference, mechanical vibration, and acoustic tests. Because of the size of the vehicle and unprecedented acoustics, NASA conducted an extensive assessment of options for testing, and as result, chose to augment the Space Power Facility at NASA Plum Brook Station, of the John H. Glenn Research Center to provide the needed test capabilities. The augmentation included designing and building the World s highest mass capable vibration table, the highest power large acoustic chamber, and adaptation of the existing World s largest thermal vacuum chamber as a reverberant electromagnetic interference test chamber. These augmentations were accomplished from 2007 through early 2011. Acceptance testing began in Spring 2011 and will be completed in the Fall of 2011. This paper provides an overview of the capabilities, design, construction and acceptance of this extraordinary facility.

Motil, Susan M.↗

NASA NTRS2011

Large Payload Transportation and Test Considerations

Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure - roads, bridges, airframes, and buildings - necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider how large spacecraft are designed, and where they are manufactured, tested, or launched, could result in unforeseen cost to modify/develop infrastructure, or incur additional risk due to increased handling or elimination of key verifications. During test and verification planning for the Altair project, a number of transportation and test issues related to the large payload diameter were identified. Although the entire Constellation Program - including Altair - was canceled in the 2011 NASA budget, issues identified by the Altair project serve as important lessons learned for future payloads that may be developed to support national "heavy lift" strategies. A feasibility study performed by the Constellation Ground Operations (CxGO) project found that neither the Altair Ascent nor Descent Stage would fit inside available transportation aircraft. Ground transportation of a payload this large over extended distances is generally not permitted by most states, so overland transportation alone would not have been an option. Limited ground transportation to the nearest waterway may be permitted, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA s Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing (which includes hypergolic fuels, pyrotechnic devices, and high pressure gasses).

Rucker, Michelle A.↗

NASA NTRS2010

A Risk Communication Success Story

A key success of the decommissioning effort at the National Aeronautics and Space Administration's (NASA's) Plum Brook Reactor Facility (PBRF) has been the public outreach program. The approach has been based on risk communications rather than a public relations approach. As a result it has kept the public feeling more involved in the process. It ensures they have the information needed to understand the project and its goals, and to make recommendations. All this is done so that NASA can better plan and execute the necessary work without delays or suprises.

Peecook, Keith↗