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Materials and processes for shuttle engine, external tank, and solid rocket booster

The Shuttle flight system is composed of the Orbiter, an External Tank (ET) that contains the ascent propellant to be used by the Space Shuttle Main Engines (SSME), and two Solid Rocket Boosters (SRB). The ET is expended on each launch; the Orbiter and SRB's are reusable. It is the requirement for reuse which poses the exciting new materials and processes challenges in the development of the Space Shuttle. A brief description of the Space Shuttle and the mission profile is given. The Shuttle configuration is then described with emphasis on the SSME, ET, and SRB. The materials selection, tracking, and control system used to assure reliability and to minimize cost are described, and salient features and challenges in materials and processes associated with the SSME, ET, and SRB are subsequently discussed.

Schwinghamer, R. J.↗

Revised estimates for ozone reduction by shuttle operation

Previous calculations by five different modeling groups of the effect of space shuttle operations on the ozone layer yielded an estimate of 0.2 percent ozone reduction for the Northern Hemisphere at 60 launches per year. Since these calculations were made, the accepted rate constant for the reaction between hydroperoxyl and nitric oxide to yield hydroxyl and nitrogen dioxide, HO2 + NO yields OH + NO2, was revised upward by more than an order of magnitude, with a resultant increase in the predicted ozone reduction for chlorofluoromethanes by a factor of approximately 2. New calculations of the shuttle effect were made with use of the new rate constant data, again by five different modeling groups. The new value of the shuttle effect on the ozone layer was found to be 0.25 percent. The increase resulting from the revised rate constant is considerably less for space shuttle operations than for chlorofluoromethane production, because the new rate constant also increases the calculated rate of downward transport of shuttle exhaust products out of the stratosphere.

Potter, A. E.↗

Space Shuttle - A personal view

A typical flight profile for the Space Shuttle is reviewed, and the operation of the Spacelab, as well as deployment of a satellite from the Shuttle, is considered. Selection of crews for a Space Shuttle mission, which may include as many as four payload specialists, is also discussed. Since medical requirements and flight training standards need not be as high for payload specialists as for the three members of the flight crew, the Shuttle may provide an opportunity for many scientists to perform experiments in space. Investigations of the critical opalescence of fluids and laser holography are proposed for Shuttle missions; X-ray astronomy is another likely candidate for inclusion in the program.

Mark, H.↗

Shuttle carrier aircraft flight tests

Since the Space Shuttle will need to be transported from its place of assembly to the launch site, a method has been developed whereby the Shuttle rides piggyback on a modified Boeing 747, called the Shuttle carrier aircraft (SCA). This paper describes tests of the SCA in its mated configuration. Tests include: flutter, found to decrease when fiberglass and wood fairings were added to the base of each supporting pylon; stability and control, found to be acceptable after damping with control pulses; noise and buffet, found high but acceptable; and climb, in which drag was marked but acceptable with the special rated thrust (SRT) power setting. Simulated launch maneuvers were undertaken at an airspeed of 273 KCAS. Transport of the Shuttle takes place with the Shuttle tail cone on, at a cruise speed of 288 KCAS at an altitude of 22,000 feet.

Fulton, F. L., Jr.↗

Legal issues inherent in Space Shuttle operations

The National Aeronautics and Space Act of 1958 (NASAct) is discussed with reference to its relevance to the operation of the Space Shuttle. The law is interpreted as giving NASA authority to regulate specific Shuttle missions, as well as authority to decide how much space aboard the Shuttle gets rented to whom. The Shuttle will not, however, be considered a 'common carrier' either in terms of NASAct or FAA regulations, because it will not be held available to the public-at-large, as are the flag carriers of various national airlines, e.g., Lufthansa, Air France, Aeroflot, etc. It is noted that the Launch Policy of 1972, which ensures satellite launch assistance to other countries or international organizations, shall not be interpreted as conferring common carrier status on the Space Shuttle.

Mossinghoff, G. J.↗

EDIN design study alternate space shuttle booster replacement concepts. Volume 1: Engineering analysis

The use of a recoverable liquid rocket booster (LRB) system to replace the existing solid rocket booster (SRB) system for the shuttle was studied. Historical weight estimating relationships were developed for the LRB using Saturn technology and modified as required. Mission performance was computed using February 1975 shuttle configuration groundrules to allow reasonable comparison of the existing shuttle with the study designs. The launch trajectory was constrained to pass through both the RTLS/AOA and main engine cut off points of the shuttle reference mission 1. Performance analysis is based on a point design trajectory model which optimizes initial tilt rate and exoatmospheric pitch profile. A gravity turn was employed during the boost phase in place of the shuttle angle of attack profile. Engine throttling add/or shutdown was used to constrain dynamic pressure and/or longitudinal acceleration where necessary. Four basic configurations were investigated: a parallel burn vehicle with an F-1 engine powered LRB; a parallel burn vehicle with a high pressure engine powered LRB; a series burn vehicle with a high pressure engine powered LRB. The relative sizes of the LRB and the ET are optimized to minimize GLOW in most cases.

Demakes, P. T.↗

Space Shuttle Program description and status

The main reason for the development of the Space Shuttle is related to the aim to achieve a major reduction in the cost of placing a payload into space. Such a reduction is to be obtained by using a reusable in place of an expendable launch vehicle. Developments concerning launch vehicles show a steady reduction in launching expenses. From a cost of about $500,000 a pound in the late 1950's, launching expenses were reduced to $600 a pound for payloads on the Saturn V. With the Space Shuttle the cost will drop to approximately $150 a pound. The Space Shuttle Program is discussed, taking into account a system description, a typical mission profile, aspects of mission design, launch costs, and Space Shuttle characteristics. The Space Shuttle Program status is also examined, giving attention to orbital flight schedules, flight hardware tests, launch area facilities, the mission control center, and details of flight crew training.

Macleod, J. B.↗

Direct simulation Monte Carlo technique for modeling of the environment in the vicinity of the Space Shuttle Orbiter

A program for analyzing the flowfield parameters in the neighborhood of the Space Shuttle Orbiter has been developed. The program uses the direct simulation Monte Carlo method, which is a completely probabilistic Monte Carlo technique capable of analyzing 3-dimensional steady or unsteady flow with prescribed internal and external boundary conditions. The freestream flux densities incident on the external flowfield boundaries are calculated from the drifting Maxwellian gas properties of the freestream. The flux entering the flowfield from the internal boundary is calculated from the outgassing flux density distribution over the Shuttle external surface and the prescribed discrete source fluxes. This technique produces a numerical flowfield solution which is the probabilistic equivalent of a complete solution of the time-dependent, 3-dimensional Boltzmann equation. Flowfield results are presented for the following configurations: (1) Shuttle angles of attack of 0 and 90 deg, (2) freestream density 10 to the 9th - 10 to the 11th per cu cm, (3) Shuttle outgassing flux density, and (4) operation of the aft downfiring vernier Reaction Control System (RCS) engine. Results are presented for column density distribution of outgassed and engine species and for the flux density of outgassed and engine species incident on the Shuttle bay and the windshield.

Melfi, L. T., Jr.↗

A method for determining the flight readiness of the integrated Space Shuttle system

The Space Shuttle Dynamic Integrated Test (DIT) system is described. The DIT is an open-loop system which makes no attempt to simulate Shuttle sensors, and by which the Shuttle redundancy management system is left unmodified. Open-loop operation is shown to inherently require less computing capacity during a test than the closed-loop alternative. DIT tests have generated a high degree of confidence in the Shuttle hardware, allowing the identification of such problems as a sluggish main fuel valve, which caused a countdown hold seconds before the simulated T-zero, and Main Engine Controller software malfunctions. Attention is given to the combination and substitution of sensor data, the modification of nominal flight software, and the preparation of simulation data. It is noted that greater performance would have been achieved if the interface with DIT had been a design requirement from the outset of Space Shuttle development.

Bacon, I.↗

Shuttle navigation overview

Space Shuttle onboard navigation system tasks are related to position and velocity determination, attitude determination, sensor management, sensor Redundancy Management (RM), and navigation-related functions such as transformations, timing system utilization, and user processing for displays, guidance, and flight control. It is pointed out that Shuttle navigation is different in at least two areas from previous manned space flight navigation. The differences are related to the use of multiple units to provide protection from increased risk of failure of off-the-shelf-type equipment used for more than one flight, and the need to land at a runway. Attention is given to the navigation sensor system, the Shuttle Inertial Measurement Units, the Shuttle Star Tracker, the Crew Optical Alinement Sight, the Shuttle Tacan, the Air Data Subsystem, and aspects of navigation system mechanization.

Savely, R. T.↗

Space flight experience with the Shuttle Orbiter control system

Experience gained through the Shuttle Orbital Flight Test program has matured the engineering understanding of the Shuttle on-orbit control system. The geneology of the control systems (called digital autopilots, or DAPs, and used by the Shuttle for on-orbit operations) is reviewed, the flight experience gained during the flight test program is examined within the context of preflight analysis and test results, and issues for the operational phase of the Shuttle, including constraints upon both operations and analysis still required to increase confidence in the Shuttle's ability to handle capabilities not experienced during the flight test program are addressed. Two orbital autopilots have resulted from computer memory and time constraints on a flight control system, with many different, flight phase unique requirements. The transition DAP, used for insertion and deorbit, has more active sensors and redundancy but a less complex data processing scheme excluding state estimation with fewer choices of operational mode.

Cox, K. J.↗

Use of the Space Shuttle for remote sensing research - Recent results and future prospects

The successful November 1981 test flight of the Space Shuttle Orbiter Columbia has demonstrated the Shuttle's utility and versatility for earth resources-related research. A series of remote sensing experiments is planned for the mid-1980s which will more fully exploit the Shuttle's earth observation capability. The OSTA-1 experiment package of the mission mentioned incorporated the Shuttle Imaging Radar, a synthetic aperture, side-looking device which artificially illuminated the earth's surface with horizontally polarized microwave radiation transmitted at L-band frequency, the Shuttle Multispectral IR Radiometer, which measured the intensity of solar radiation reflected from the earth's surface, the Measurement of Air Pollution from Satellites experiment, which determined the concentration of CO in the earth's atmosphere, the proof-of-concept Feature Identification and Location Experiment, and the Night/Day Optical Survey of Lightning experiment.

Settle, M.↗

High angle of attack inviscid flow calculations over a Shuttle-like vehicle with comparisons to flight data

Recent advances in computational techniques and computer hardware have made it possible to attack the problem of computing steady-state inviscid flowfields over complex three-dimensional bodies such as the Space Shuttle Orbiter. Certain problems have arisen in connection with cases involving high angles of attack. Weilmuenster et al. (1981, 1982) have, therefore, presented a time asymptotic computational method, HALIS, designed to handle the high angle-of-attack problem for the inviscid flow over the Space Shuttle vehicle. The code was modified to include all of the Shuttle vehicle forward of the wing root. Body surface pressures generated by the HALIS code were shown to be in excellent agreement with flight pressures measured on the Shuttle vehicle. In the present investigation, results from the HALIS code, which has been extended to cover the first 1212 inches of the Shuttle vehicle, are compared with flight surface pressures. Shock shapes at several angles of attack are also presented.

Weilmuenster, K. J.↗

Satellite drag prediction effects on Shuttle mission planning

Long-term factors, along with Shuttle performance limitations, are considered in order to illustrate the need for more reliable long-term drag (meaning 'solar cycle') prediction techniques. Such techniques would make it possible to confidently plan dual-objective Shuttle flights, which maximize Shuttle cargo loadings and thus reduce costs. In describing the coupled mission concept, it is pointed out that by deploying one payload while retrieving or servicing another, the Space Transportation System can maximize the usefulness of the Shuttle and reduce the cost per customer. It is shown here that the proposed mission coupling LDEF (Long Duration Exposure Facility) with ST (Space Telescope) must be rejected since the Shuttle performance limitations prohibit deployment of the ST at even 315 n mi with a subsequent LDEF retrieval. If, however, it were possible to predict solar cycles, then, depending on the prediction, a mission of this type could be feasible.

Young, K. A.↗

The use of the Space Shuttle for land remote sensing

The use of the Space Shuttle for land remote sensing will grow significantly during the 1980's. The main use will be for general land cover and geological mapping purposes by worldwide users employing specialized sensors such as: high resolution film systems, synthetic aperture radars, and multispectral visible/IR electronic linear array scanners. Because these type sensors have low Space Shuttle load factors, the user's preference will be for shared flights. With this strong preference and given the present prognosis for Space Shuttle flight frequency as a function of orbit inclination, the strongest demand will be for 57 deg orbits. However, significant use will be made of lower inclination orbits. Compared with freeflying satellites, Space Shuttle mission investment requirements will be significantly lower. The use of the Space Shuttle for testing R and D land remote sensors will replace the free-flying satellites for most test programs.

Thome, P. G.↗

Space Shuttle wind tunnel testing program

A major phase of the Space Shuttle Vehicle (SSV) Development Program was the acquisition of data through the space shuttle wind tunnel testing program. It became obvious that the large number of configuration/environment combinations would necessitate an extremely large wind tunnel testing program. To make the most efficient use of available test facilities and to assist the prime contractor for orbiter design and space shuttle vehicle integration, a unique management plan was devised for the design and development phase. The space shuttle program is reviewed together with the evolutional development of the shuttle configuration. The wind tunnel testing rationale and the associated test program management plan and its overall results is reviewed. Information is given for the various facilities and models used within this program. A unique posttest documentation procedure and a summary of the types of test per disciplines, per facility, and per model are presented with detailed listing of the posttest documentation.

Whitnah, A. M.↗

Earth resources research using the Shuttle Imaging Radar system

The Shuttle Imaging Radar (SIR) is an L-band synthetic radar that transmits and receives horizontally polarized microwave radiation. It was originally launched on the second Shuttle test flight (STS-2) in November 1981 with the antenna depression angle fixed at 43 deg. In this configuration, the radar system was referred to as SIR-A, and it collected more than then a million square kilometers of Earth imagery in a variety of areas situated between 38 deg north and south latitude. SIR-A data was optically recorded onboard the Shuttle, and it was subsequently correlated on the ground to produce imagery with a 50 kilometer swath width and a surface resolution of approximately 40 meters. The SIR is presently being upgraded into a new configuration termed SIR-B, in which the radar's antenna can be mechanically rotated in the Shuttle's payload bay during an orbital mission. SIR-B is currently scheduled for flight on the seventeenth Shuttle mission (STS-17) that is tentatively planned for August 1984. In its new configuration, the SIR-B can be used to image selected regions at different angles of incidence ranging from 15 deg to 60 deg (as measured from the local vertical). In principle, multiple incidence angle radar imagery of selected areas can be coregistered and used to differentiate surficial materials on the basis of their roughness characteristics. This procedure is conceptually similar to the use of multispectral imagery acquired at shorter wavelengths to discriminate surficial materials on the basis of their pigmentation.

Monson, R.↗

Space shuttle molecular and wake vacuum measurements

The wake environment of the space shuttle is analyzed to determine whether it is feasible to perform ultrahigh vacuum experiments in or near the payload bay with the shuttle oriented such that the payload bay faces the antivelocity direction. Several mechanisms were considered by which molecules could approach the payload bay from this direction and their relative contributions to the wake environment are estimated. These mechanisms include ambient atmospheric molecules that have velocities in excess of the orbital velocity which can overtake the shuttle, ambient atmospheric molecules that are backscattered by collisions with the shuttle induced atmosphere, and self scattering from the induced atmosphere. These estimates are compared with the measurements made with the collimated mass spectrometer which was part of the Induced Environment Contamination Monitor flown on several of the early shuttle flights. Although the collimated mass spectrometer was not designed for this purpose and the instrument background for the species for which the collimator is effective is above the expected levels, upper limits can be established for these species in the wake environment which are consistent with the analysis. There was considerably more helium and argon observed in the wake direction than was predicted, however. Possible origins of these gases are discussed.

Naumann, R. J.↗