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NASA NTRS2019

Trends in Human Spaceflight: Failure Tolerance, High Reliability and Correlated Failure History

In a half century of human spaceflight, NASA has continuously refined agency safety and reliability requirements in response to mission demands, critical failures, and technology development. Early spacecraft, including Mercury, Gemini and Apollo vehicles, were highly reliant on dissimilar redundancy and demonstrated test margins. Later programs, such as the reusable Space Transportation System (STS) and International Space Station (ISS), introduced probabilistic studies and isolated two-failure tolerance to improve robustness at the expense of added complexity. More recently, the Orion Multi-Program Crew Vehicle (MPCV) program adopted universal single-failure tolerance with two categorical exceptions; Zero-Failure Tolerant (0FT) and Design for Minimum Risk (DFMR) hardware. Failure tolerance variances are defined and managed in accordance with agency human-rating requirements, and require concurrence from program Technical Authorities (TA) as well as the MPCV Safety and Mission Assurance Safety and Engineering Review Panel (MSERP). To understand and reaffirm standards applied to Apollo, Space Shuttle and Orion vehicles, Orion and Deep Space Gateway Safety and Mission Assurance (S&MA) representatives conducted accelerated research to compare unique safety and reliability criteria against ground and flight anomalies, based on information contained in post-mission reports and the Problem Reporting and Corrective Action (PRACA) database. In some cases, high-profile failures and narrow escapes have reinforced decisions to maintain or adapt safety requirements. In others, empirical trends have highlighted the need for vigilance and innovative safety guidelines. Given the inability to achieve absolute compliance with evolving safety and reliability requirements, the team conducted a targeted review of DFMR and 0FT propulsion elements within the framework of changing system design, inspection, materials and process developments to formulate conclusions on technological maturity, failure density, and net changes in safety risk. Based on the aggregate performance of high-reliability and failure-tolerant systems, the authors have attempted to establish best practices and guidelines to inform future program decisions. On a somewhat cautionary note, this study is not intended to direct a universal set of requirements for future missions based on prior lessons learned. Spacecraft safety is a multi-variable problem, and attempts to mitigate past failures will not guarantee future success. However, this assessment offers a retrospective review of policy changes, implementation and effectiveness. In the future, NASA, European Space Agency (ESA) and industry partners may benefit from a more robust correlation between requirements and performance, as space-faring nations work toward more challenging, complex and long-duration commercial and deep-space ventures.

Green, Carrie↗

NASA NTRS1993

Numerical Simulation of a High Mach Number Jet Flow

The recent efforts to develop accurate numerical schemes for transition and turbulent flows are motivated, among other factors, by the need for accurate prediction of flow noise. The success of developing high speed civil transport plane (HSCT) is contingent upon our understanding and suppression of the jet exhaust noise. The radiated sound can be directly obtained by solving the full (time-dependent) compressible Navier-Stokes equations. However, this requires computational storage that is beyond currently available machines. This difficulty can be overcome by limiting the solution domain to the near field where the jet is nonlinear and then use acoustic analogy (e.g., Lighthill) to relate the far-field noise to the near-field sources. The later requires obtaining the time-dependent flow field. The other difficulty in aeroacoustics computations is that at high Reynolds numbers the turbulent flow has a large range of scales. Direct numerical simulations (DNS) cannot obtain all the scales of motion at high Reynolds number of technological interest. However, it is believed that the large scale structure is more efficient than the small-scale structure in radiating noise. Thus, one can model the small scales and calculate the acoustically active scales. The large scale structure in the noise-producing initial region of the jet can be viewed as a wavelike nature, the net radiated sound is the net cancellation after integration over space. As such, aeroacoustics computations are highly sensitive to errors in computing the sound sources. It is therefore essential to use a high-order numerical scheme to predict the flow field. The present paper presents the first step in a ongoing effort to predict jet noise. The emphasis here is in accurate prediction of the unsteady flow field. We solve the full time-dependent Navier-Stokes equations by a high order finite difference method. Time accurate spatial simulations of both plane and axisymmetric jet are presented. Jet Mach numbers of 1.5 and 2.1 are considered. Reynolds number in the simulations was about a million. Our numerical model is based on the 2-4 scheme by Gottlieb & Turkel. Bayliss et al. applied the 2-4 scheme in boundary layer computations. This scheme was also used by Ragab and Sheen to study the nonlinear development of supersonic instability waves in a mixing layer. In this study, we present two dimensional direct simulation results for both plane and axisymmetric jets. These results are compared with linear theory predictions. These computations were made for near nozzle exit region and velocity in spanwise/azimuthal direction was assumed to be zero.

Hayder, M. Ehtesham↗

NASA NTRS2008

Titan's Atmospheric Dynamics and Meteorology

Titan, after Venus, is the second example of an atmosphere with a global cyclostrophic circulation in the solar system, but a circulation that has a strong seasonal modulation in the middle atmosphere. Direct measurement of Titan's winds, particularly observations tracking the Huygens probe at 10degS, indicate that the zonal winds are generally in the sense of the satellites rotation. They become cyclostrophic approx. 35 km above the surface and generally increase with altitude, with the exception of a sharp minimum centered near 75 km, where the wind velocity decreases to nearly zero. Zonal winds derived from the temperature field retrieved from Cassini measurements, using the thermal wind equation, indicate a strong winter circumpolar vortex, with maximum winds at mid northern latitudes of 190 ms-' near 300 km. Above this level, the vortex decays. Curiously, the zonal winds and temperatures are symmetric about a pole that is offset from the surface pole by approx.4 degrees. The cause of this is not well understood, but it may reflect the response of a cyclostrophic circulation to the offset between the equator, where the distance to the rotation axis is greatest, and the solar equator. The mean meridional circulation can be inferred from the temperature field and the meridional distribution of organic molecules and condensates and hazes. Both the warm temperatures in the north polar region near 400 km and the enhanced concentration of several organic molecules suggests subsidence there during winter and early spring. Stratospheric condensates are localized at high northern latitudes, with a sharp cut-off near 50degN. Titan's winter polar vortex appears to share many of the same characteristics of winter vortices on Earth-the ozone holes. Global mapping of temperatures, winds, and composition in he troposphere, by contrast, is incomplete. The few suitable discrete clouds that have bee found for tracking indicate smaller velocities than aloft, consistent with the Huygens measurements. At low latitudes the zonal winds near the surface appear not to be westward as on Earth, but eastward. Because the net zonal-mean time-averaged torq exerted by the surface on the atmosphere should vanish, this implies westward flow o part of the surface; the question is where. The latitude contrast in tropospheric temperatures, deduced from radio occultations at low, mid, and high latitudes, is small approx.5 K at the tropopause and approx.3 K at the surface.

Flasar, F. M.↗

NASA NTRS2009

Chapter 13. Atmospheric Dynamics and Meteorology

Titan, after Venus, is the second example in the solar system of an atmosphere with a global cyclostrophic circulation, but in this case a circulation that has a strong seasonal modulation in the middle atmosphere. Direct measurement of Titan's winds, particularly observations tracking the Huygens probe at 10 deg S, indicate that the zonal winds are mostly in the sense of the satellite's rotation. They generally increase with altitude and become cyclostrophic near 35 km above the surface. An exception to this is a sharp minimum centered near 75 km, where the wind velocity decreases to nearly zero. Zonal winds derived from temperatures retrieved from Cassini orbiter measurements, using the thermal wind equation, indicate a strong winter circumpolar vortex, with maximum winds of 190 m/s at mid northern latitudes near 300 km. Above this level, the vortex decays. Curiously, the stratospheric zonal winds and temperatures in both hemispheres are symmetric about a pole that is offset from the surface pole by about 4 deg. The cause of this is not well understood, but it may reflect the response of a cyclostrophic circulation to the onset between the equator, where the distance to the rotation axis is greatest, and the seasonally varying subsolar latitude. The mean meridional circulation can be inferred from the temperature field and the meridional distribution of organic molecules and condensates and hazes. Both the warm temperatures near 400 km and the enhanced concentration of several organic molecules suggest subsidence in the north polar region during winter and early spring. Stratospheric condensates are localized at high northern latitudes, with a sharp cut-off near 50 deg N. Titan's winter polar vortex appears to share many of the same characteristics of isolating high and low-latitude air masses as do the winter polar vortices on Earth that envelop the ozone holes. Global mapping of temperatures, winds, and composition in the troposphere, by contrast, is incomplete. The few suitable discrete clouds that have been found for tracking indicate smaller velocities than aloft, consistent: with the Huygens measurements, Along the descent trajectory, the Huygens measurements indicate eastward zonal winds down to 7 km, where they shift westward, and then eastward again below 1 km dawn to the surface. The low-latitude dune fields seen in Cassini RADAR images have been interpreted as longitudinal dunes occurring in a mean eastward zonal wind. This is not like Earth, where the low-latitude winds are westward above the surface. Because the net zonal-mean time-averaged torque exerted by the surface on the atmosphere should vanish, there must be westward flow over part of the surface; the question is where and when. The meridional contrast in tropospheric temperatures deduced from radio occultations at low, mid, and high latitudes. is small, approximately 5 K at the tropopause and approximately 3 K at the surface. This implies efficient heat transport, probably by axisymmetric meridional circulations. The effect of the methane "hydrological" cycle on the atmospheric circulation is not well constrained by existing measurements, Understanding the mature of the surface-atmosphere coupling will be critical to elucidating the atmospheric transports of momentum, heat, and volatiles.

Flasar, F. M.↗

NASA NTRS2022

Analysis of Base Metal Microstructures and Mechanical Properties of a Single-Piece, Spin-Formed Forward Pressure Vessel Bulkhead

In 2012, a pathfinder forward pressure vessel bulkhead (FPVBH) for the Orion Multi-Purpose Crew Vehicle (MPCV) was fabricated using aluminum (Al) alloy 2219. The demonstration article was offered as a replacement for the baseline configuration, which at that time was a multi-piece welded construction using aluminum-lithium (Al-Li) alloy 2195. In 2014, the NASA Engineering and Safety Center (NESC) funded a Phase I effort to explore spin-forming as a manufacturing method to produce a complex-shaped, single-piece FPVBH for the crew module (CM) [1]. The primary focus of the NESC effort was to expand spin-forming technology to the fabrication of an Al-Li 2195 FPVBH. As a result, limited testing and analysis was performed on the original Al 2219 article. In this study, a sufficiently large plate of Al 2219 was not available for the fabrication of a FPVBH. Therefore, the forming blank comprised two plates (from different lots) butt welded together using a single friction stir weld. The welded forming blank was then spin formed into the FPVBH configuration and heat treated to the T62 temper. Mechanical property testing of the spin-formed 2219-T62 FPVBH revealed that the tensile properties were comparable to the Metallic Material Properties Development and Standardization (MMPDS) A-basis allowable for Al 2219-T6 wrought products. However, post-spin forming application of the standard heat treatment produced large, recrystallized grains in the material. The response varied within the two plates; one plate lot exhibited nearly complete recrystallization, while the other lot contained bands of recrystallization. Although no reduction in tensile properties was observed due to these microstructural variations, a more detailed investigation was recommended to better understand the effect of spin forming on the recrystallization mechanism and the impact on other material properties. The current study examined the microstructure and mechanical properties of the fully processed Al 2219-T62 FPVBH with emphasis on comparing differences between the two plates. Testing was limited to the cone region of the FPVBH. The two specific tasks in this study were: a) Characterization of the microstructure and mechanical properties in the two plates used in the FPVBH. b) Isolation of the impact of each step in the thermo-mechanical processing (TMP) sequence of the FPVBH on recrystallization and grain growth. Mechanical property testing sampled regions containing both large, recrystallized and small, unrecrystallized grains. Tensile strengths and elongations were equivalent in both regions and exceeded MMPDS A-basis allowables. Fracture toughness was equivalent in both regions and fracture morphology was typical of aluminum alloys. The fatigue precrack region of the fracture toughness specimens appeared more faceted in the recrystallized plate. This suggests that property testing that is more sensitive to grain size, such as fatigue crack growth rate and stress corrosion cracking, may be warranted. Alcoa reviewed the production records for the two plate lots and confirmed that composition of both plates was within the allowable range for Al 2219 and that plate processing steps were all performed within production limits. However, the Fe content was notably higher in the fully recrystallized plate, resulting in a greater volume fraction of large Fe-bearing inclusions and Al-Cu constituent particles. Alcoa did not provide details regarding plate processing variables for the two plate lots. It was surmised that deformation by hot rolling was the most accurate TMP simulation of commercial spin forming within a laboratory setting. Both hot rolling and spin forming comprise combinations of shear and compressive deformation. The through-thickness strain caused by hot rolling is symmetrical about the mid-plane, as the rollers contact both sides of the material. Shear strains are maximum at the inner and outer surfaces and trend toward zero at the mid-thickness. In contrast, spin forming utilizes a single roller on the outer surface, producing a gradient in shear stress through the thickness. Shear strains in spin-formed material are highest at the outer surface due to direct contact with the roller, and trend toward zero at the inner surface. Consequently, there will undoubtedly be some discrepancies in the mechanical response of hot-rolled and spin-formed products in the through-thickness direction. Interrupted TMP simulations were performed on remnant plate from the FPVBH forming blank in order to isolate the effects of a post-weld anneal, spin-forming deformation/thermal cycling, and solution heat treatment (SHT) on development of the recrystallized microstructures. Analysis confirmed that large, recrystallized grains formed exclusively during SHT and only after a certain deformation level was exceeded. Remnant plate from both lots that received thermal processing only did not exhibit recrystallization but exhibited fully recrystallized microstructures when processed by hot rolling. This indicates that (1) the level of deformation exceeded the critical level for recrystallization in both plates and (2) that the level of deformation during hot rolling was greater than that which accumulated during spin forming of the FPVBH. Comparison of the hot-rolled plate with the spin-formed material showed that the recrystallized grain size was larger in the FPVBH, providing further evidence that deformation levels were lower in the FPVBH. The most plausible explanation for the differing degrees of recrystallization in the two plates is particle stimulated nucleation (PSN) at the Fe-bearing inclusions and large Al-Cu constituent particles. In the plate with higher solute content, the greater volume fraction of these particles reduces the deformation level required to promote recrystallization. During spin forming the critical deformation level was likely exceeded for the higher Fe content plate resulting in a fully recrystallized microstructure. The lower Fe content plate developed a microstructure that exhibited bands of recrystallization due to the combination of a non-uniform distribution of particles and deformation. The critical deformation required for recrystallization was likely only exceeded during spin forming in regions of higher particle content. While there were differences in Fe content between these lots of Al 2219 plate, the composition of both was within defined alloy limits and Alcoa reported no anomalies during plate production. The observed differences in recrystallization after spin forming may reflect the inherent variability between these two lots of plate. The spin-forming vendor, Spincraft, reported that similar variations in recrystallized microstructures have been observed during examination of multiple spin-forming trials of a different 2xxx series aluminum alloy. Hence, tighter chemical specification limits on impurity levels in Al 2219 plate may help ensure uniform, predictable microstructures. Finally, the tensile and fracture toughness properties were not affected by the microstructural variations noted.

single-piece↗