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Naflex seals have long history of use in launch vehicle components, including Saturn stages and Space Shuttle External Tank. Ares-I Upper Stage tank pressures are higher than ET pressures, requiring performance verification of heritage seal design in new manhole cover configurations. Heritage external tank analyses are reviewed for potential application to Upper Stage.
NASA selected the J-2X Upper Stage Engine in 2006 to power the upper stages of the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Based on the proven Saturn J-2 engine, this new engine will provide 294,000 pounds of thrust and a specific impulse of 448 seconds, making it the most efficient gas generator cycle engine in history. The engine's guiding philosophy emerged from the Exploration Systems Architecture Study (ESAS) in 2005. Goals established then called for vehicles and components based, where feasible, on proven hardware from the Space Shuttle, commercial, and other programs, to perform the mission and provide an order of magnitude greater safety. Since that time, the team has made unprecedented progress. Ahead of the other elements of the Constellation Program architecture, the team has progressed through System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of February 2010, more than 100,000 development engine parts have been ordered and more than 18,000 delivered. Approximately 1,300 of more than 1,600 engine drawings were released for manufacturing. A major factor in the J-2X development approach to this point is testing operations of heritage J-2 engine hardware and new J-2X components to understand heritage performance, validate computer modeling of development components, mitigate risk early in development, and inform design trades. This testing has been performed both by NASA and its J-2X prime contractor, Pratt & Whitney Rocketdyne (PWR). This body of work increases the likelihood of success as the team prepares for testing the J-2X powerpack and first development engine in calendar 2011. This paper will provide highlights of J-2X testing operations, engine test facilities, development hardware, and plans.
In 2006, NASA selected an evolved variant of the proven Saturn/Apollo J-2 upper stage engine to power the Ares I crew launch vehicle upper stage and the Ares V cargo launch vehicle Earth departure stage (EDS) for the Constellation Program. Any design changes needed by the new engine would be based where possible on proven hardware from the Space Shuttle, commercial launchers, and other programs. In addition to the thrust and efficiency requirements needed for the Constellation reference missions, it would be an order of magnitude safer than past engines. It required the J-2X government/industry team to develop the highest performance engine of its type in history and develop it for use in two vehicles for two different missions. In the attempt to achieve these goals in the past five years, the Upper Stage Engine team has made significant progress, successfully passing System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of spring 2010, more than 100,000 experimental and development engine parts have been completed or are in various stages of manufacture. Approximately 1,300 of more than 1,600 engine drawings have been released for manufacturing. This progress has been due to a combination of factors: the heritage hardware starting point, advanced computer analysis, and early heritage and development component testing to understand performance, validate computer modeling, and inform design trades. This work will increase the odds of success as engine team prepares for powerpack and development engine hot fire testing in calendar 2011. This paper will provide an overview of the engine development program and progress to date.
The new ARES space flight program has presented many challenges to aerospace engineers and designers. One of the areas for consideration are the seals in the turbopumps that supply cryogenic propellants to the combustion chamber in the upper stage. Heritage face seals that worked in the past might not be sufficient in the newer turbopumps with increased speeds, pressures across the seals, and loads. New seal materials, engineering designs, and analysis techniques have been developed since the early use of these heritage seals, however, rub conditions and surface degradation at the sliding contact cannot be reliably predicted. Testing is required to determine the safe operating limits and verify seal wear life over the operating range. Rocketdyne in Canoga Park California entered into a task agreement with MSFC to design, fabricate, build, test, disassemble, and inspect hardware after tests of carbon materials and wear resistant coatings. The purpose of testing would be to determine the safe operating limits, empirically iterate the design, and select the best combination of materials for face seals and mating rings. This paper summarizes the many hours and efforts of individuals and teams to get the program operating successfully and presents the test results that were obtained.
NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;
The development of more efficient thermoelectric couple technology capable of operating with high-grade heat sources up to 1,275 K is key to improving the performance of radioisotope thermoelectric generators. Lanthanum telluride La3-xTe4 and 14-1-11 Zintls (Yb14MnSb11) have been identified as very promising materials. The fabrication of advanced high-temperature thermoelectric couples requires the joining of several dissimilar materials, typically including a number of diffusion bonding and brazing steps, to achieve a device capable of operating at elevated temperatures across a large temperature differential (up to 900 K). A thermoelectric couple typically comprises a heat collector/ exchanger, metallic interconnects on both hot and cold sides, n-type and ptype conductivity thermoelectric elements, and cold-side hardware to connect to the cold-side heat rejection and provide electrical connections. Differences in the physical, mechanical, and chemical properties of the materials that make up the thermoelectric couple, especially differences in the coefficients of thermal expansion (CTE), result in undesirable interfacial stresses that can lead to mechanical failure of the device. The problem is further complicated by the fact that the thermoelectric materials under consideration have large CTE values, are brittle, and cracks can propagate through them with minimal resistance. The inherent challenge of bonding brittle, high-thermal-expansion thermoelectric materials to a hot shoe material that is thick enough to carry the requisite electrical current was overcome. A critical advantage over prior art is that this device was constructed using all diffusion bonds and a minimum number of assembly steps. The fabrication process and the materials used are described in the following steps: (1) Applying a thin refractory metal foil to both sides of lanthanum telluride. To fabricate the n-type leg of the advanced thermoelectric couple, the pre-synthesized lanthanum telluride coupon was diffusion bonded to the metal foil using a thin adhesion layer. (2) Repeating a similar process for the 14-1-11 Zintl p-type leg of the advanced thermoelectric couple. (3) Bonding thick CTE-matched metal plates on the metallized lanthanum telluride and Yb14MnSb11 to form the hot and cold sides of the thermoelectric couple. The calculated conversion efficiency of such an advanced couple would be about 10.5 percent, about 35 percent better than heritage radioisotope thermoelectric technology that relies on Si-Ge alloys. In addition, unlike Si-Ge alloys, these materials can be combined with many other thermoelectric materials optimized for operation at lower temperatures to achieve conversion efficiency in excess of 15 percent (a factor of 2 increase over heritage technology).
The microphysical structure of clouds is of fundamental importance for understanding a variety of cloud radiation and physical processes. With the advent of MODIS (Moderate Resolution Imaging Spectroradiometer) on the NASA EOS Terra and Aqua platforms, simultaneous global/daily 1km retrievals of cloud effective particle size are available using the heritage 3.7 an band from AVHRR as well as the 1.6 and 2.1 m shortwave IR bands. The MODIS cloud product (MOD06/MYD06 for MODIS Terra and Aqua, respectively) provides separate effective radii results using each of these spectral bands. It has been found that significant differences can occur between the three size retrievals, mainly for liquid water marine boundary layer clouds and especially in broken (low cloud fraction) regimes. In particular, for such regimes, effective radii derived from the MODIS 2.1 lim band can be substantially larger than retrievals from the Heritage 3.7 lam band. In this paper, we present global and regional results of the differences, including correlations, view angle dependencies, and algorithm sensitivities for the existing MODIS Collection 5 product.
This presentation covers an overview of NASA Glenn s history and heritage in the development of electrochemical systems for aerospace applications. Specific areas of focus are Li-ion batteries and their development for future Exploration missions. Current component development efforts for high energy and ultra high energy Li-ion batteries are addressed. Electrochemical systems are critical to the success of Exploration, Science and Space Operations missions. NASA Glenn has a long, successful heritage with batteries and fuel cells for aerospace applications. GRC Battery capabilities and expertise span basic research through flight hardware development and implementation. There is a great deal of synergy between energy storage system needs for aerospace and terrestrial applications.
A study was performed to identify the current and historical trends in the capability of solid rocket motor testing in the United States. The study focused on test positions capable of testing solid rocket motors of at least 10,000 lbf thrust. Top-level information was collected for two distinct data points plus/minus a few years: 2000 (Y2K) and 2010 (Present). Data was combined from many sources, but primarily focused on data from the Chemical Propulsion Information Analysis Center s Rocket Propulsion Test Facilities Database, and heritage Chemical Propulsion Information Agency/M8 Solid Rocket Motor Static Test Facilities Manual. Data for the Rocket Propulsion Test Facilities Database and heritage M8 Solid Rocket Motor Static Test Facilities Manual is provided to the Chemical Propulsion Information Analysis Center directly from the test facilities. Information for each test cell for each time period was compiled and plotted to produce a graphical display of the changes for the nation, NASA, Department of Defense, and commercial organizations during the past ten years. Major groups of plots include test facility by geographic location, test cells by status/utilization, and test cells by maximum thrust capability. The results are discussed.
The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.
The Phoenix Mars mission involves delivering a stationary science lander on to the surface of Mars in the polar region within the latitude band 65 deg N to 72 deg N. Its primary objective is to perform in-situ and remote sensing investigations that will characterize the chemistry of the materials at the local surface, subsurface, and atmosphere. The Phoenix spacecraft was launched on August 4, 2007 and will arrive at Mars in May 2008. The lander includes a suite of seven (7) science instruments. This mission is baselined for up to 90 sols (Martian days) of digging, sampling, and analysis. Operating at the Mars polar region creates a challenging environment for the Phoenix landed subsystems and instruments with Mars surface temperature extremes between -120 deg C to 25 deg C and diurnal thermal cycling in excess of 145 deg C. Some engineering and science hardware inside the lander were qualification tested up to 80 deg C to account for self heating. Furthermore, many of the hardware for this mission were inherited from earlier missions: the lander from the Mars Surveyor Program 2001 (MSP'01) and instruments from the MSP'01 and the Mars Polar Lander. Ensuring all the hardware was properly qualified and flight acceptance tested to meet the environments for this mission required defining and implementing an environmental assurance program that included a detailed heritage review coupled with tailored flight acceptance testing. A heritage review process with defined acceptance success criteria was developed and is presented in this paper together with the lessons learned in its implementation. This paper also provides a detailed description of the environmental assurance program of the Phoenix Mars mission. This program includes assembly/subsystem and system level testing in the areas of dynamics, thermal, and electromagnetic compatibility, as well as venting/pressure, dust, radiation, and meteoroid analyses to meet the challenging environment of this mission.
Single event upsets (SEUs) are a threat to any computing system running on hardware that has not been physically radiation hardened. In addition to mandating the use of performance-limited, hardened heritage equipment, prior techniques for dealing with the SEU problem often involved hardware-based error detection and correction (EDAC). With limited computing resources, software- based EDAC, or any more elaborate recovery methods, were often not feasible. Synthetic aperture radars (SARs), when operated in the space environment, are interesting due to their relevance to NASAs objectives, but problematic in the sense of producing prodigious amounts of raw data. Prior implementations of the SAR data processing algorithm have been too slow, too computationally intensive, and require too much application memory for onboard execution to be a realistic option when using the type of heritage processing technology described above. This standard C-language implementation of SAR data processing is distributed over many cores of a Tilera Multicore Processor, and employs novel Radiation Hardening by Software (RHBS) techniques designed to protect the component processes (one per core) and their shared application memory from the sort of SEUs expected in the space environment. The source code includes calls to Tilera APIs, and a specialized Tilera compiler is required to produce a Tilera executable. The compiled application reads input data describing the position and orientation of a radar platform, as well as its radar-burst data, over time and writes out processed data in a form that is useful for analysis of the radar observations.
The NASA Earth Observing System (EOS) mission includes the construction and launch of two nearly identical Moderate Resolution Imaging Spectroradiometer (MODIS) instruments. The MODIS proto-flight model (PFM) is onboard the EOS Terra satellite (formerly EOS AM-1) launched on December 18, 1999 and hereafter referred to as Terra MODIS. Flight model-1 (FM1) is onboard the EOS Aqua satellite (formerly EOS PM-1) launched on May 04, 2002 and referred to as Aqua MODIS. MODIS was developed based on the science community s desire to collect multiyear continuous datasets for monitoring changes in the Earth s land, oceans and atmosphere, and the human contributions to these changes. It was designed to measure discrete spectral bands, which includes many used by a number of heritage sensors, and thus extends the heritage datasets to better understand both long- and short-term changes in the global environment (Barnes and Salomonson 1993; Salomonson et al. 2002; Barnes et al. 2002). The MODIS development, launch, and operation were managed by NASA/Goddard Space Flight Center (GSFC), Greenbelt, Maryland. The sensors were designed, built, and tested by Raytheon/ Santa Barbara Remote Sensing (SBRS), Goleta, California. Each MODIS instrument offers 36 spectral bands, which span the spectral region from the visible (0.41 m) to long-wave infrared (14.4 m). MODIS collects data at three different nadir spatial resolutions: 0.25, 0.5, and 1 km. Key design specifications, such as spectral bandwidths, typical scene radiances, required signal-to-noise ratios (SNR) or noise equivalent temperature differences (NEDT), and primary applications of each MODIS spectral band are summarized in Table 7.1. These parameters were the basis for the MODIS design. More details on the evolution of the NASA EOS and development of the MODIS instruments are provided in Chap. 1. This chapter focuses on the MODIS sensor design, radiometry, and geometry as they apply to land remote sensing. With near-daily coverage of the Earth's surface, MODIS provides comprehensive measurements that enable scientists and policy makers to better understand and effectively manage the natural resources on both regional and global scales. Terra, the first large multisensor EOS satellite, is operated in a 10:30 am (local equatorial crossing time, descending southwards) polar orbit. Aqua, the second multisensor EOS satellite is operated in a 1:30 pm (local equatorial crossing time, ascending northwards) polar orbit. With complementing morning and afternoon observations, the Terra and Aqua MODIS, together with other sensors housed on both satellites, have greatly improved our understanding of the dynamics of the global environmental system.
The quadrupole mass spectrometer (QMS) has over 30 years of spaceflight heritage in making important neutral gas and low energy ion observations. Given their geometrical constraints, these instruments are currently operated at the extreme limit of their capabilities. However, a technique called higher order auxiliary excitation provides a set of novel, robust, electronics-based solutions for improving the performance of these sensors. By driving the quadrupole rods with an additional frequency nearly twice that of the normal RF operating frequency, substantially increased abundance sensitivity, maximum attainable mass resolution, and peak stability can be achieved through operation of voltage scan lines through the center of formed upper stability islands. Such improvements are modeled using numerical simulations of ion trajectories in a quadrupole field with and without applied higher order auxiliary excitation. When compared to a traditional QMS with a mass range up to 500Da, sensors can be designed with the same precision electronics to have expected mass ranges beyond 1500Da with a power increase of less than twice that of its heritage implementations.
Deployable subsystems are essential to mission success of most spacecraft. These subsystems enable critical functions including power, communications and thermal control. The loss of any of these functions will generally result in loss of the mission. These subsystems and their components often consist of unique designs and applications for which various standardized data sources are not applicable for estimating reliability and for assessing risks. In this study, a two stage sequential Bayesian framework for reliability estimation of spacecraft deployment was developed for this purpose. This process was then applied to the James Webb Space Telescope (JWST) Sunshield subsystem, a unique design intended for thermal control of the Optical Telescope Element. Initially, detailed studies of NASA deployment history, "heritage information", were conducted, extending over 45 years of spacecraft launches. This information was then coupled to a non-informative prior and a binomial likelihood function to create a posterior distribution for deployments of various subsystems uSing Monte Carlo Markov Chain sampling. Select distributions were then coupled to a subsequent analysis, using test data and anomaly occurrences on successive ground test deployments of scale model test articles of JWST hardware, to update the NASA heritage data. This allowed for a realistic prediction for the reliability of the complex Sunshield deployment, with credibility limits, within this two stage Bayesian framework.
In August 2011, the Environmental Control and Life Support Systems (ECLSS) technical community, along with associated stakeholders, held a workshop to review NASA s plans for Exploration missions and vehicles with two objectives: revisit the Exploration Atmospheres Working Group (EAWG) findings from 2006, and discuss preliminary ECLSS architecture concepts and technology choices for Exploration vehicles, identifying areas for potential common hardware or technologies to be utilized. Key considerations for selection of vehicle design total pressure and percent oxygen include operational concepts for extravehicular activity (EVA) and prebreathe protocols, materials flammability, and controllability within pressure and oxygen ranges. New data for these areas since the 2006 study were presented and discussed, and the community reached consensus on conclusions and recommendations for target design pressures for each Exploration vehicle concept. For the commonality study, the workshop identified many areas of potential commonality across the Exploration vehicles as well as with heritage International Space Station (ISS) and Shuttle hardware. Of the 36 ECLSS functions reviewed, 16 were considered to have strong potential for commonality, 13 were considered to have some potential commonality, and 7 were considered to have limited potential for commonality due to unique requirements or lack of sufficient heritage hardware. These findings, which will be utilized in architecture studies and budget exercises going forward, are presented in detail.
The Advanced Concepts Office (ACO) at the NASA Marshall Space Flight Center (MSFC) in conjunction with Pratt & Whitney Rocketdyne conducted a study to evaluate potential in-space applications for the Rocketdyne produced RS-34 propulsion system. The existing RS-34 propulsion system is a remaining asset from the decommissioned United States Air Force Peacekeeper ICBM program; specifically the pressure-fed storable bipropellant Stage IV Post Boost Propulsion System, renamed Phoenix. MSFC gained experience with the RS-34 propulsion system on the successful Ares I-X flight test program flown in October 2009. RS-34 propulsion system components were harvested from stages supplied by the USAF and used on the Ares I-X Roll control system (RoCS). The heritage hardware proved extremely robust and reliable and sparked interest for further utilization on other potential in-space applications. Subsequently, MSFC is working closely with the USAF to obtain all the remaining RS-34 stages for re-use opportunities. Prior to pursuit of securing the hardware, MSFC commissioned the Advanced Concepts Office to understand the capability and potential applications for the RS-34 Phoenix stage as it benefits NASA, DoD, and commercial industry. Originally designed, the RS-34 Phoenix provided in-space six-degrees-of freedom operational maneuvering to deploy multiple payloads at various orbital locations. The RS-34 Phoenix Utilization Study sought to understand how the unique capabilities of the RS-34 Phoenix and its application to six candidate missions: 1) small satellite delivery (SSD), 2) orbital debris removal (ODR), 3) ISS re-supply, 4) SLS kick stage, 5) manned GEO servicing precursor mission, and an Earth-Moon L-2 Waypoint mission. The small satellite delivery and orbital debris removal missions were found to closely mimic the heritage RS-34 mission. It is believed that this technology will enable a small, low-cost multiple satellite delivery to multiple orbital locations with a single boost. For both the small satellite delivery and the orbital debris mission candidates, the RS-34 Phoenix requires the least amount of modification to the existing hardware. The results of the RS-34 Phoenix Utilization Study show that the system is technically sufficient to successfully support all of the missions analyzed
The Geostationary Lightning Mapper (GLM) on the next generation Geostationary Operational Environmental Satellite-R (GOES-R) will not have onboard calibration capability to monitor its performance. The Lightning Imaging Sensor (LIS) onboard the Tropical Rainfall Measuring Mission (TRMM) satellite has been providing observations of total lightning over the Earth's Tropics since 1997. The GLM design is based on LIS heritage, making it a good proxy dataset. This study examines the performance of LIS throughout its time in orbit. This was accomplished through application of the Deep Convective Cloud Technique (DCCT) (Doelling et al., 2004) to LIS background pixel radiance data. The DCCT identifies deep convective clouds by their cold Infrared (IR) brightness temperatures and using them as invariant targets in the solar reflective portion of the solar spectrum. The GLM and LIS operate in the near-IR at a wavelength of 777.4 nm. In the present study the IR data is obtained from the Visible Infrared Sensor (VIRS) which is collocated with LIS onboard the Tropical Rainfall Measuring Mission (TRMM) satellite. The DCCT is applied to LIS observations for July and August of each year from 1998-2010. The resulting distributions of LIS background DCC pixel radiance for each July August are very similar, indicating stable performance. The mean radiance of the DCCT analysis does not show a long term trend and the maximum deviation of the July August mean radiance for each year is within 0.7% of the overall mean. These results demonstrate that there has been no discernible change in LIS performance throughout its lifetime. A similar approach will used for monitoring the performance of GLM, with cold clouds identified using IR data from the Advanced Baseline Imager (ABI) which will also be located on GOES-R. Since GLM is based on LIS design heritage, the LIS results indicate that GLM should also experience stable performance over its lifetime.