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Assembly Test Article (ATA)

The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.

Ricks, Glen A.↗

Structures and materials technology for hypersonic aerospacecraft

Major considerations in structural design of a transatmospheric aerospacecraft are discussed. The general direction of progress in structures and materials technology is indicated, and technical areas in structures and materials where further research and development is necessary are indicated. Various structural concepts under study and materials which appear to be most applicable are discussed. Structural design criteria are discussed with particular attention to the factor-of-safety approach and the probabilistic approach. Structural certification requirements for the aerospacecraft are discussed. The kinds of analyses and tests which would be required to certify the structural integrity, safety, and durability of the aerospacecraft are discussed, and the type of test facility needed to perform structural certification tests is identified.

Mccomb, Harvey G., Jr.↗

Design of lightning protection for a full-authority digital engine control

The steps and procedures are described which are necessary to achieve a successful lightning-protection design for a state-of-the-art Full-Authority Digital Engine Control (FADEC) system. The engine and control systems used as examples are fictional, but the design and verification methods are real. Topics discussed include: applicable airworthiness regulation, selection of equipment transient design and control levels for the engine/airframe and intra-engine segments of the system, the use of cable shields, terminal-protection devices and filter circuits in hardware protection design, and software approaches to minimize upset potential. Shield terminations, grounding, and bonding are also discussed, as are the important elements of certification and test plans, and the role of tests and analyses. Also included are examples of multiple-stroke and multiple-burst testing. A review of design pitfalls and challenges, and status of applicable test standards such as RTCA DO-160, Section 22, are presented.

Dargi, M.↗

Erosion, Corrosion and Foreign Object Damage Effects in Gas Turbines [Les consequences de l'endommagement des turbines I gaz par erosion, corrosion et objets étrangers]

The Conference Proceedings contains 31 papers presented at the Propulsion and Energetics Panel Symposium on Erosion, Corrosion and Foreign Object Damage Effects in Gas Turbines which was held from 25-28th April 1994, in Rotterdam, The Netherlands. The Technical Evaluation Report and the Keynote Address are included at the beginning and discussions follow most papers. The Symposium was arranged in the following Sessions: Operational Experience and Requirements (7); Deposition and Erosion (7); Foreign Object Damage (5); Coatings, Repairs and Materials Aspects - 1 (4); Coatings, Repairs and Materials Aspects - 2 (7); and Testing and Certification Procedures (1).

Deposition↗

Fire and Ice - Safety, Comfort, and Getting the Firefighters' Job Done

Daily life for firefighters consists of working with life-threatening hazards in hostile environments. A major hazard is excessive ambient heat. New hazards have arisen from protective gear that was intended to increase survival time of firefighters while finding and rescuing victims. The insulation is so good now that a firefighter's metabolic heat buildup cannot escape. This forces body core temperatures to life threatening levels in about 20 minutes of moderate activity. Using NASA space suit technology, Oceaneering Space Systems developed a liquid cooling garment prototype that will remove up to 250 watts of metabolic heat. After testing and certification as an approved accessory for firefighter use, this garment will be available for use by any individual encapsulated in protective clothing. This demonstration will present a high surface area circulated liquid cooling garment displayed on a mannequin and available for attendees to try on to experience the effects of active cooling.

Foley, Tico↗

The Dangers of Failure Masking in Fault-Tolerant Software: Aspects of a Recent In-Flight Upset Event

On 1 August 2005, a Boeing Company 777-200 aircraft, operating on an international passenger flight from Australia to Malaysia, was involved in a significant upset event while flying on autopilot. The Australian Transport Safety Bureau's investigation into the event discovered that an anomaly existed in the component software hierarchy that allowed inputs from a known faulty accelerometer to be processed by the air data inertial reference unit (ADIRU) and used by the primary flight computer, autopilot and other aircraft systems. This anomaly had existed in original ADIRU software, and had not been detected in the testing and certification process for the unit. This paper describes the software aspects of the incident in detail, and suggests possible implications concerning complex, safety-critical, fault-tolerant software.

Johnson, C. W.↗

Ares Launch Vehicles Lean Practices Case Study

The Ares launch vehicles team, managed by the Ares Projects Office (APO) at NASA Marshall Space Flight Center, has completed the Ares I Crew Launch Vehicle System Requirements Review and System Definition Review and early design work for the Ares V Cargo Launch Vehicle. This paper provides examples of how Lean Manufacturing, Kaizen events, and Six Sigma practices are helping APO deliver a new space transportation capability on time and within budget, while still meeting stringent technical requirements. For example, Lean philosophies have been applied to numerous process definition efforts and existing process improvement activities, including the Ares I-X test flight Certificate of Flight Readiness (CoFR) process, risk management process, and review board organization and processes. Ares executives learned Lean practices firsthand, making the team "smart buyers" during proposal reviews and instilling the team with a sense of what is meant by "value-added" activities. Since the goal of the APO is to field launch vehicles at a reasonable cost and on an ambitious schedule, adopting Lean philosophies and practices will be crucial to the Ares Project's long-term SUCCESS.

Doreswamy, Rajiv↗

IEEE/NASA Workshop on Leveraging Applications of Formal Methods, Verification, and Validation

This volume contains the Preliminary Proceedings of the 2005 IEEE ISoLA Workshop on Leveraging Applications of Formal Methods, Verification, and Validation, with a special track on the theme of Formal Methods in Human and Robotic Space Exploration. The workshop was held on 23-24 September 2005 at the Loyola College Graduate Center, Columbia, MD, USA. The idea behind the Workshop arose from the experience and feedback of ISoLA 2004, the 1st International Symposium on Leveraging Applications of Formal Methods held in Paphos (Cyprus) last October-November. ISoLA 2004 served the need of providing a forum for developers, users, and researchers to discuss issues related to the adoption and use of rigorous tools and methods for the specification, analysis, verification, certification, construction, test, and maintenance of systems from the point of view of their different application domains.

Margaria, Tiziana↗

Development and Certification of Ultrasonic Background Noise Test (UBNT) System for use on the International Space Station (ISS)

As a next step in the development and implementation of an on-board leak detection and localization system on the International Space Station (ISS), there is a documented need to obtain measurements of the ultrasonic background noise levels that exist within the ISS. This need is documented in the ISS Integrated Risk Management System (IRMA), Watch Item #4669. To address this, scientists and engineers from the Langley Research Center (LaRC) and the Johnson Space Center (JSC), proposed to the NASA Engineering and Safety Center (NESC) and the ISS Vehicle Office a joint assessment to develop a flight package as a Station Development Test Objective (SDTO) that would perform ultrasonic background noise measurements within the United States (US) controlled ISS structure. This document contains the results of the assessment

Prosser, William H.↗

Purpose, Principles, and Challenges of the NASA Engineering and Safety Center

NASA formed the NASA Engineering and Safety Center in 2003 following the Space Shuttle Columbia accident. It is an Agency level, program-independent engineering resource supporting NASA's missions, programs, and projects. It functions to identify, resolve, and communicate engineering issues, risks, and, particularly, alternative technical opinions, to NASA senior management. The goal is to help ensure fully informed, risk-based programmatic and operational decision-making processes. To date, the NASA Engineering and Safety Center (NESC) has conducted or is actively working over 600 technical studies and projects, spread across all NASA Mission Directorates, and for various other U.S. Government and non-governmental agencies and organizations. Since inception, NESC human spaceflight related activities, in particular, have transitioned from Shuttle Return-to-Flight and completion of the International Space Station (ISS) to ISS operations and Orion Multi-purpose Crew Vehicle (MPCV), Space Launch System (SLS), and Commercial Crew Program (CCP) vehicle design, integration, test, and certification. This transition has changed the character of NESC studies. For these development programs, the NESC must operate in a broader, system-level design and certification context as compared to the reactive, time-critical, hardware specific nature of flight operations support.

Gilbert, Michael G.↗

Cryo-Vacuum Testing of the JWST Integrated Science Instrument Module

In late 2015 early 2016, a major cryo-vacuum test was carried out for the Integrated Science Instrument Module (ISIM) of the James Webb Space Telescope. This test comprised the final cryo-certification and calibration test of the ISIM before its delivery for integration with the rest of the JWST observatory. Over the roughly 100-day period of the round-the-clock test program, the full complement of ISIM flight instruments, structure, harness radiator, and electronics were put through a comprehensive program of thermal, optical, electrical, and operational tests. We briefly summarize the goals, setup, execution, and key results for this critical JWST milestone.

cryo-vacuum test↗

Mars Sample Return: Grand Challenge for EDL

A year ago, I gave a talk in anticipation of a Mars Sample Return effort at the 9th Ablation Workshop. Since then a lot has happened. "April of this year, after a year of study phase, NASA and ESA (European Space Agency) signed a Statement of Intent (SOI) to jointly develop a Mars Sample Return plan to be submitted to their respective authorities by the end of 2019. This signing is historic, as it signals the desire, the readiness, and the willingness to work together to execute this inspiring mission, we all have the opportunity to tackle this grand challenge. We have the scientific and engineering maturity to identify the critical technologies ready to be applied, and with discipline this campaign can be executed affordably," Jim Watzin, Mars Program Executive, NASA. NASA Centers with JPL (Jet Propulsion Laboratory) leading the charge is in the midst of a pre-formulation phase for executing a Mars Sample Return before the end of next decade. The proposed talk builds on the previous year talk. In light of the agreement between NASA and ESA, NASA has assumed the responsibilities for developing the earth entry vehicle (EEV) that will fly along with a European Spacecraft and return with the sample from Mars. EEV will be deployed for entry into earth. The EEV design, development, testing and certification have to result in a highly reliable sample return system. The entire architecture has to be demonstrated to meet the planetary protection requirement. NASA is considering two distinctly different earth entry vehicle architectures and with each choice, many different ablative TPS (Thermal Protective Shield) candidates. As a result of the NASA-ESA ongoing studies, some of the key entry conditions and design requirements are better understood today and more are being scoped out. The heat-shield ablative TPS choice need to be done with a good understanding as it plays a very significant role in determining the robustness of the EEV. Knowledge about how materials and system perform, and how the features could become flaws and how flaws lead to failure, etc. need to be clearly understood and the knowledge then need to be used to down select the TPS. This proposed talk will provide greater insight into the progress being made and the challenges that need to be tackled.

Mars Sample Return: Grand Challenge for EDL↗

RCA: Modeling Tools for CLmax Prediction

TACP06 is aimed at further research in maturing eddy-resolving modeling tools, in their accuracy and efficiency, and demonstrating the tools for application to the prediction of aircraft maximum lift (CLmax). The goal is to achieve CLmaxprediction accuracy of the same level as in aircraft certification flight tests. This will require comparison of various modeling approaches against experimental results from the planned wind tunnel tests, down selecting an approach, further maturing the technology and validating against flight test data. Advances in computational fluid dynamics (CFD) over the last several decadeshas fundamentally changed the aerospace design process. Advanced simulation capabilities not only enable reductions in ground-based and in-flight testing requirements, but also provide added physical insight, enable superior designs at reduced cost and risk, and open upnew frontiers in aerospace vehicle design and performance. The NASA sponsored CFD Vision 2030 Study, while highlighting these accomplishments, brought out several challenges and deficiencies in the computational technology and developed a research roadmap for advancing the state-of-the-art required for enabling NASA missions in aeronautics and space applications. Based on TC TACP01 research completed in May 2018, it became clear that unsteady flow simulation capability is needed for expanding the role of CFD across the entire flight envelope to enable design of future advanced aircraft and space vehicles, and that capability will be the primary outcome of this technical challenge.

Mujeeb R Malik↗

EVA Swab Kit: Tools and Techniques for Collecting Aseptic Samples from Crewed Space Missions

Introduction: When we send humans to search for life on other planets, we'll need to know what we brought with us versus what may already be there. To ensure our crewed spacecraft meet planetary protection requirements—and to protect our science from human contamination—we'll need to assess and verify whether micro-organisms may be leaking/venting from our spacesuits. This requires collecting samples under Extravehicular Activity (EVA) conditions. Detailed, systematic research on forward contamination from robotic spacecraft has been steadily progressing since the Viking missions, but systematic studies of contamination from space suits has not been conducted in many years. The modern EMU (Extravehicular Mobility Unit) suit used by NASA is designed to leak at rates as high as 100 cc/min. Before humans land on Mars there is a critical need to understand the types and quantities of microbes that could be introduced via space suits. The Human Forward Contamination Assessment team at NASA’s Johnson Space Center (JSC) has developed a prototype EVA swab tool [1,2,3,4] designed for use in space to sample cleaned and uncleaned space suits to determine the present day microbial load and eventually the rate of leakage. The ability to assess microbial leakage early in advanced space suit and life support system design cycles will help avoid costly hardware redesign later. Test Objectives: The primary objective of EMU testing was to characterize the type of micro-organisms typically found on or near selected suit pressure joints under suit differential pressure conditions. Most human-borne microbes can fit through a 0.5 to 1.0 µm gap. Knowing which joints are more likely to leak will inform hardware design decisions. Knowing which types of micro-organisms may leak from EVA suits provides a basis for subsequent studies to characterize the viability of those organisms under destination conditions, as well as how far they might spread through natural or human-influenced processes. That data, in turn, will inform exploration mission operations and hardware design. The secondary objective of testing was to evaluate the interface between a fully suited test subject and the EVA swab tool at vacuum. Bulky EVA suits can restrict movement and limit visibility through the helmet visor. Fully suited testing is important for identifying tool design issues prior to flight. At exploration destinations, such as Mars, suited crew may be required to periodically sample their suits as part of an environmental monitoring protocol. Suit Microbial Sampling Results: This report details results of microbial swabs collected from current flight suit configurations worn by crew members assigned to upcoming ISS expedition missions as well as swabs collected from prototype suits intended for use on the Orion spacecraft. These tests were intended to characterize the types of contaminants found on flight suits under current, typical handling conditions. No attempt was made to change suit handling procedures, provide additional sterilization, or to limit typical potential contaminant sources. Using culture based techniques, we cultivated 235 CFU (colony forming units) comprised of 26 bacterial species and one fungal species on the outside of the suits. The fungal species and 14 of the bacterial species were unique to the suit surfaces and were not detected in any of the background samples collected within the chambers. We sequenced 755,434 ribosomal fragments on all of the suit surfaces from swab samples. 557,016 of these sequences represent DNA that survived at least 4 hours at vacuum. These sequences formed 2,464 OTU's (Operational Taxonomic Units, 97% similarity) showing low diversity in the samples. The most abundant sequences that survived vacuum belong to the genera Staphyloccocus, Ralstona, Bacillus and Rhodobacter all of which are common to the human microbiome. [5] See Danko et al., (2021) for more complete details of these first analyses. Further analysis of EVA suit materials with respect to the efficacy of various cleaning protocols and engineered containment solutions is planned to inform suit design for NASA’s Artemis Moon to Mars program crew testing. Swab Tool Function Results: The kit was demonstrated for fit and function in suited subject vacuum tests to determine how well the tool worked as an aseptic microbial sampling device as well as to identify any design elements that could be upgraded for EVA task specific improvement. It was found that sample acquisition efficacy could be enhanced by redesign of the sample canister to end-effector interface. Several modifications of the sample caddy assemblies to optimize EVA safety and functionality were also identified. Consequently, fabrication of the redesigned sample canister to end-effector assembly interfaces and and the sample caddy assemblies are required. Fabrication of sixteen flight sample canister assemblies (8 per each of two EVA Swab Kits) and two sample caddy assemblies are in process to be followed by hardware testing and certification to produce two flight-certified EVA Swab Kits for transport to ISS no earlier than summer of 2022. Sampling Strategy: The International Space Station is an ideal testbed for systematic studies of contamination from crewed vehicles since it has been continuously occupied for 20 years and exposed to non-terrestrial conditions. We will sample the exterior of the ISS during EVA using a purpose-built swab tool capable of maintaining sterility while undergoing temperature changes from -151 to +121°C under hard vacuum. Prior to each EVA, the project team will work with ISS mission managers to identify precise sampling locations, which will vary by EVA based on the translation paths and worksites scheduled for that particular EVA. Ideally, translation path handrails and areas near ECLSS (Environmental Control and Life Support System) external vent openings on a spacecraft would be assessed. There are currently more than a dozen ECLSS external vents on the ISS. Some are connected to systems that vent waste products, while others are intended to equalize cabin pressure. As EVA opportunity allows, microbial samples from any of these external vents would provide a valuable data point, though some will be more useful than others. Four criteria have been identified to help prioritize sampling sites near vents: • EVA Accessibility: To minimize cost, it is desired to piggy-back onto a planned EVA. Therefore, the sampling location must be readily accessible by an EVA crew • Type of Vented Products: Vent products that have been in direct contact with crew, such as cabin air, are more likely to contain microorganisms than vent products associated with isolated systems, such as experiment module combustion products. • Mass of Vented Products: Higher-flow vents are more likely to contain detectible levels of microbial contaminants than lower-flow vents. • Local Environment: Sample locations with relatively benign local conditions, such as warm surfaces shielded from direct ultraviolet (UV) radiation exposure, may be more likely to support microbial growth than locations with harsher local environmental conditions. Because EVA accessibility is the most important criteria, the proposal team worked with an astronaut and flight controllers using the Dynamic Onboard Ubiquitous Graphics (DOUG) tool. The DOUG virtual environment allows an operator to “fly” around the current ISS vehicle configuration to assess EVA translation paths, attach points, and keep-out zones. While analysis on station or rapid return to Earth would be preferable, samples collected from the exterior of the ISS have already been exposed to temperature variations between -157 and +121 °C as well as hard vacuum. Therefore, they should be fairly stable and robust. We hypothesize that samples collected from the ISS exterior could be stored for up to 6 months at -80°C without degradation. Sample canisters will be returned to Earth while frozen at -80°C for analysis, and sterilized canisters can be re-flown back to ISS to support additional sampling opportunities Relevance to NASA Exploration Objectives: These data will allow us to identify new or improved methods, technologies, and procedures for spacecraft sterilization and leakage mitigation to minimize the amount of contamination introduced to the environment by human explorers. This work is funded by NASA research grant: NNH18ZDA001N-PPR References: [1] Bell, M.S. et al. (2015) LPS XLVI, Abst. #1832 [2] Rucker et al. (2018) 42nd COSPAR (PPP.3) [3] Bell, M.S. et al. (2019) Mars Extant Life Conference, Abst. #5096.[4] Bell, M.S. et al., (2020) 43rd COSPAR (BO.2).[5] Danko D, et.al.,(2021)Front.Microbiol.12:608478.

Mary Suzanne Bell↗

Space Launch System Day of Launch Loads for Artemis I

NASA’s Space Launch System (SLS) was successfully launched on November 16, 2022. During the years leading up to the first flight, Artemis I, a DOLILU (Day of Launch I-Load Update) process was developed to design, verify, and upload the first stage flight trajectory on day-of-launch to ensure a safe flight. The evaluation of integrated vehicle loads is a key component of the DOLILU process. The SLS Artemis I DOL loads project has involved methodology development, software development, software testing and certification, operator training, and simulation and launch support. The resulting DOL process successfully calculated loads for all launch opportunities within the window, with the robust nature of the process contributing to all opportunities being go for loads.

SLS↗

Demonstrations: A Path to the Future of Aviation

These slides were given as part of Panel 7: “Electric Flight Demonstrations: Test Results, Upcoming Tests, and Certification” a part of iTEC+EATS 2026 held in Novi MI. The presentation represents NASA’s recent and current investments in demonstrating megawatt and multi-megawatt electrified aircraft propulsion

demonstrator↗

Radon Considerations at Environmental Remediation Sites - 19469

Radon and how it is regulated poses many challenges to the U.S. Army Corps of Engineers (USACE) in executing the Formerly Utilized Sites Remedial Action Program (FUSRAP). These challenges include:, terminology; radon measurement methods and limitations; state certification and testing requirements; limited and potentially conflicting federal guidance; background considerations; and limited experience regarding application of guidance; among others. These challenges and others are discussed in detail. The FUSRAP Maywood Superfund Site (FMSS) is presented as a case study demonstrating these challenges and considerations to mitigate or address the challenges. The USACE, U.S. Environmental Protection Agency (USEPA), and the New Jersey Department of Environmental Protection (NJDEP) (NJDEP) have spent several years working on and continue to work through the radon issues at FMSS. The FMSS experience, information, and solutions presented in this paper will be helpful to other environmental sites with radium and thorium contamination. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗