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NASA Accident Precursor Analysis Handbook, Version 1.0

Catastrophic accidents are usually preceded by precursory events that, although observable, are not recognized as harbingers of a tragedy until after the fact. In the nuclear industry, the Three Mile Island accident was preceded by at least two events portending the potential for severe consequences from an underappreciated causal mechanism. Anomalies whose failure mechanisms were integral to the losses of Space Transportation Systems (STS) Challenger and Columbia had been occurring within the STS fleet prior to those accidents. Both the Rogers Commission Report and the Columbia Accident Investigation Board report found that processes in place at the time did not respond to the prior anomalies in a way that shed light on their true risk implications. This includes the concern that, in the words of the NASA Aerospace Safety Advisory Panel (ASAP), "no process addresses the need to update a hazard analysis when anomalies occur" At a broader level, the ASAP noted in 2007 that NASA "could better gauge the likelihood of losses by developing leading indicators, rather than continue to depend on lagging indicators". These observations suggest a need to revalidate prior assumptions and conclusions of existing safety (and reliability) analyses, as well as to consider the potential for previously unrecognized accident scenarios, when unexpected or otherwise undesired behaviors of the system are observed. This need is also discussed in NASA's system safety handbook, which advocates a view of safety assurance as driving a program to take steps that are necessary to establish and maintain a valid and credible argument for the safety of its missions. It is the premise of this handbook that making cases for safety more experience-based allows NASA to be better informed about the safety performance of its systems, and will ultimately help it to manage safety in a more effective manner. The APA process described in this handbook provides a systematic means of analyzing candidate accident precursors by evaluating anomaly occurrences for their system safety implications and, through both analytical and deliberative methods used to project to other circumstances, identifying those that portend more serious consequences to come if effective corrective action is not taken. APA builds upon existing safety analysis processes currently in practice within NASA, leveraging their results to provide an improved understanding of overall system risk. As such, APA represents an important dimension of safety evaluation; as operational experience is acquired, precursor information is generated such that it can be fed back into system safety analyses to risk-inform safety improvements. Importantly, APA utilizes anomaly data to predict risk whereas standard reliability and PRA approaches utilize failure data which often is limited and rare.

Groen, Frank↗

Physics in NASA Exploration

The primary focus of the workshop was NASA's new concentration on sending crewed missions to the Moon by 2020, and then on to Mars and beyond. Several speakers, including JPL s Fred O Callaghan and NASA's Mark Lee, broached the problem that there is now a serious reduction of capability to perform experiments in the ISS, or to fly significant mass in microgravity by other means. By 2010, the shuttle fleet will be discontinued and Russian craft will provide the only access to the ISS. O Callaghan stated that the Fundamental Physics budget is being reduced by 70%. LTMPF and LCAP are slated for termination. However, ground-based experiments are continuing to be funded at present, and it will be possible to compete for $80-90 million in new money from the Human Research Initiative (HRI). The new program thrust is for exploration, not fundamental physics. Fundamental, we were told by Lee, does not ring well in Washington these days. Investigators were advised to consider how their work can benefit missions to the Moon and Mars. Work such as that regarding atomic clocks is looked upon with favor, for example, because it is considered important to navigation and planetary GPS. Mark Lee stressed that physicists must convey to NASA senior management that they are able and willing to contribute to the new exploration research programs. The new mentality must be we deliver products, not do research. This program needs to be able to say that it is doing at least 50% exploration-related research. JPL s Ulf Israelsson discussed the implications to OBPR, which will deliver methods and technology to assure human health and performance in extraterrestrial settings. The enterprise will provide advanced life-support systems and technology that are reliable, capable, simpler, less massive, smaller, and energy-efficient, and it may offer other necessary expertise in areas such as low-gravity behavior. Like Dr. Lee, he stated that the focus must be on products, not research. While there is not yet a formal direction, he said, LTMPF and PARCS ISS flight projects are slated to terminate in October 2004. All flight investigations are being returned to ground programs and phased out by the end of FY07. Physics ground programs are intact for now, but to survive we must shift about 50% of research to supporting exploration. Basic research programs in other disciplines are being cancelled. Product lines will support human health, safety and life-support, including countermeasures against radiation and other hazards, as well as advances in time-keeping, navigation and communications technologies. Israelsson said that the new Fundamental Physics for Exploration Roadmap points to how fundamental physics research can and does support exploration. JPL will use the roadmap to argue for support for fundamental physics research under several codes. Nicholas Bigelow of the University of Rochester encouraged attendees not to become discouraged, but rather to embrace the opportunities presented by NASA's new direction.

O'Callaghan, Fred↗

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗

Technology Candidates for Air-to-Air and Air-to-Ground Data Exchange

Technology Candidates for Air-to-Air and Air-to-Ground Data Exchange is a two-year research effort to visualize the U. S. aviation industry at a point 50 years in the future, and to define potential communication solutions to meet those future data exchange needs. The research team, led by XCELAR, was tasked with identifying future National Airspace System (NAS) scenarios, determining requirements and functions (including gaps), investigating technical and business issues for air, ground, & air-to-ground interactions, and reporting on the results. The project was conducted under technical direction from NASA and in collaboration with XCELAR's partner, National Institute of Aerospace, and NASA technical representatives. Parallel efforts were initiated to define the information exchange functional needs of the future NAS, and specific communication link technologies to potentially serve those needs. Those efforts converged with the mapping of each identified future NAS function to potential enabling communication solutions; those solutions were then compared with, and ranked relative to, each other on a technical basis in a structured analysis process. The technical solutions emerging from that process were then assessed from a business case perspective to determine their viability from a real-world adoption and deployment standpoint. The results of that analysis produced a proposed set of future solutions and most promising candidate technologies. Gap analyses were conducted at two points in the process, the first examining technical factors, and the second as part of the business case analysis. In each case, no gaps or unmet needs were identified in applying the solutions evaluated to the requirements identified. The future communication solutions identified in the research comprise both specific link technologies and two enabling technologies that apply to most or all specific links. As a result, the research resulted in a new analysis approach, viewing the underlying architecture of ground-air and air-air communications as a whole, rather than as simple "link to function" paired solutions. For the business case analysis, a number of "reference architectures" were developed for both the future technologies and the current systems, based on three typical configurations of current aircraft. Current and future costs were assigned, and various comparisons made between the current and future architectures. In general, it was assumed that if a future architecture offers lower cost than the current typical architecture, while delivering equivalent or better performance, it is likely that the future solution will gain industry acceptance. Conversely, future architectures presenting higher costs than their current counterparts must present a compelling benefit case in other areas or risk a lack of industry acceptance. The business case analysis consistently indicated lower costs for the proposed future architectures, and in most cases, significantly so. The proposed future solutions were found to offer significantly greater functionality, flexibility, and growth potential over time, at lower cost, than current systems. This was true for overall, fleet-wide equipage for domestic and oceanic air carriers, as well as for single, General Aviation (GA) aircraft. The overall research results indicate that all identified requirements can be met by the proposed solutions with significant capacity for future growth. Results also illustrate that the majority of the future communication needs can be met using currently allocated aviation RF spectrum, if used in more effective ways than it is today. A combination of such optimized aviation-specific links and commercial communication systems meets all identified needs for the 50-year future and beyond, with the caveat that a new, overall function will be needed to manage all information exchange, individual links, security, cost, and other factors. This function was labeled "Delivery Manager" (DM) within this research. DM employs a distributed client/server architecture, for both airborne and ground communications architectures. Final research results included identifying the most promising candidate technologies for the future system, conclusions and recommendations, and identifying areas where further research should be considered.

Communications↗

Additional Aviation Sustainability Strategies

Emissions from the aviation sector are expected to grow significantly in the next few decades due to growing demand for aviation. The U.S. fleet size has increased significantly in the past 20 years, growing from 2,132 aircraft to 5,485 aircraft. Similarly from 1990 to 2019, aviation emissions more than doubled, growing faster than any other transportation mode. These emissions include carbon dioxide (CO2), as well as non-CO2 sources including nitrogen oxides (NOx), sulfur dioxide (SO2), water (H2O), and particulate matter (soot). However, this report focuses specifically on CO2 emissions because the impacts from CO2 are well-understood and long-lived. There are also many climate goals tied to CO2 emissions, including the US Aviation Climate Action Plan which is pushing for net-zero in 2050. CO2 is a greenhouse, or heat-trapping, gas that comes from the extraction and burning of fossil fuels, from wildfires, and natural processes like volcanoes. Greenhouse gases absorb heat radiating from the Earth’s surface and release it in all directions, including back toward Earth’s surface. By adding more CO2 to the atmosphere, humans amplify the natural greenhouse effect, causing global temperature to rise. Since the onset of industrial times in 1750, human activities have raised atmospheric CO2 by 50%. Considering this challenge, the United States has set a climate goal to achieve net-zero CO2 emissions in the U.S. aviation sector by 2050 to reduce the environmental impact of aviation. Net-zero emissions refers to the amount of greenhouse gases (GHGs), such as CO2, methane or SO2, that are removed from the atmosphere being equal to those emitted by human activity. This contrasts with carbon-neutrality, which refers to no net release of carbon dioxide to the atmosphere, especially through offsetting emissions, that could be accomplished through a series of actions. As of 2022, the goal of net-zero has been adopted by much of the aviation industry including multiple airlines and countries. To reach net-zero by 2050, sustainable aviation fuels (SAFs) are identified as the technology that could provide the greatest impact within this timeframe. However, certain challenges may limit the production and/or adoption of SAFs in the marketplace, such as competition for feedstocks, production capacity, and high cost. In this case, SAFs would be insufficient to meet the net-zero CO2 emission goals. Therefore, in addition to SAFs, other strategies will be needed to close the gap on emissions produced as a result of SAF shortfalls or to enhance the impact of SAFs on reducing emissions. NASA’s Aeronautics Research Mission Directorate (ARMD) aims to examine these additional pathways to explore how its research may best contribute to the realization of net-zero emissions by 2050. Specifically, this effort considers strategies that can reduce emissions in the aviation sector in combination with the use of SAFs and carbon offsets while still meeting projected passenger demand. The strategies considered are not only feasible but also could be operationally scalable by 2050. The goal of this report is to investigate additional strategies such as alternative flight and ground operations, providing insight into the CO2 emission reduction potential and feasibility of strategy implementation by 2050.

Carbon Emissions↗