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This viewgraph presentation describes the Rapid Vacuum Plasma Spray (VPS) and its rapid closeout of combustion chamber cooling channels for reduced time and reduced costs.
The Integrated Partial Payload Lifting Assembly (IPPLA) is currently used to transport and load experimental payloads into the cargo bay of the Space Shuttle. It is unable to carry the astronaut/passenger tunnel without a structural modification. The purpose of this design is to create a removalbe modification that will allow the IPPLA to lift and carry the passenger tunnel. Modifications evaluated were full-length insert beams which would extend through the existing strongback arms. These beam proposals were eliminated because of high cost and weight. Other proposals evaluated were attachments of cantilever beams to the existing strongback areas. The cantilever proposals reduced cost and weight compared to the full-length modifications. A third method evaluated was to simply make modifications to one side of the IPPLA therefore reducing the materials of the cantilever proposals by 40 percent. The design of the modification selected was completed with two channel beams jointly welded to a centered steel plate. The extension arm modification is inserted into the existing strongback channel beams and bolted into place. Two extension arms are added to one side of the IPPLA to provide the extra length needed to accommodate the passenger tunnel. The center counterbalance will then be offset about 20 inches to center gravity and therefore maintain horizontal status. The extension arm modification was selected because of minimum cost, low weight, and minimal installation time.
New method for finishing and plating machined surfaces for collimating mirrors holds surface tolerances within accepted limits. Technique reduces costs to less than one-tenth that of conventional methods.
The accelerating trend toward faster, better, cheaper missions places increasing emphasis on the trade-offs between requirements and risk to reduce cost and development times, while still improving quality and reliability. The Risk/Requirement Trade-off Guidelines discussed in this paper are part of an integrated approach to address the main issues by focusing on the sum of prevention, analysis, control, or test (PACT) processes.
This effort demonstrates that by focusing only on properties of relevance, composite interstage and shroud structures can be placed on the Space Launch System vehicle that simultaneously reduces cost, improves reliability, and maximizes performance, thus providing the Advanced Development Group with a new methodology of how to utilize composites to reduce weight for composite structures on launch vehicles. Interstage and shroud structures were chosen since both of these structures are simple in configuration and do not experience extreme environments (such as cryogenic or hot gas temperatures) and should represent a good starting point for flying composites on a 'man-rated' vehicle. They are used as an example only. The project involves using polymer matrix composites for launch vehicle structures, and the logic and rationale behind the proposed new methodology.
The cost of space plasma sensors is high for several reasons: (1) Most are one-of-a-kind and state-of-the-art, (2) the cost of launch to orbit is high, (3) ruggedness and reliability requirements lead to costly development and test programs, and (4) overhead is added by overly elaborate or generalized spacecraft interface requirements. Possible approaches to reducing costs include development of small 'sensors' (defined as including all necessary optics, detectors, and related electronics) that will ultimately lead to cheaper missions by reducing (2), improving (3), and, through work with spacecraft designers, reducing (4). Despite this logical approach, there is no guarantee that smaller sensors are necessarily either better or cheaper. We have previously advocated applying analytical 'quality factors' to plasma sensors (and spacecraft) and have begun to develop miniaturized particle optical systems by applying quantitative optimization criteria. We are currently designing a Miniaturized Optimized Smart Sensor (MOSS) in which miniaturized electronics (e.g., employing new power supply topology and extensive us of gate arrays and hybrid circuits) are fully integrated with newly developed particle optics to give significant savings in volume and mass. The goal of the SwRI MOSS program is development of a fully self-contained and functional plasma sensor weighing 1 lb and requiring 1 W. MOSS will require only a typical spacecraft DC power source (e.g., 30 V) and command/data interfaces in order to be fully functional, and will provide measurement capabilities comparable in most ways to current sensors.
The National Aeronautics and Space Administration (NASA) is pursuing using ceramic matrix composites (CMC) as primary structural components for advanced rocket engines. This endeavor is due to the requirement of increasing safety by two orders of magnitude and reducing costs from $10,000/lb to $1,000/lb both within ten years. Out year goals are even more aggressive. Safety gains, through using CMCS, will be realized by increasing temperature margins, tolerance for extreme thermal transients, and damping capability of components and systems, by using components with lower weight and thermal conductivity, etc. Gains in cost reduction, through using CMCS, are anticipated by enabling higher performance systems, using lighter weight components and systems, enabling 100 mission reusability without system refurbishment, greatly reducing cooling requirements and erosion rates, selecting safe fabrication processes that are ideally cost competitive with metal processes at low volume production, etc. This philosophy contrasts the previous philosophy of rocket engine development focused largely on achieving the highest performance with metals and ablatives -- cost and safety were not the focal point of the initial design. Rocket engine components currently being pursued, largely C/SiC and SiC/SiC, include blisks or rotors, 10 foot by 8 foot nozzle ramps, gas generators, thrust chambers, and upperstage nozzles. The Simplex Turbopump CMC blisk effort has just successfully completed a 4.5 year development and test program. The other components mentioned are in the design or fabrication stage. Although the temperature limits of the CMC materials are not quantified in a realistic environment yet, CMC materials are projected to be the only way to achieve significant safety risks mitigation and cost reductions simultaneously. We, the end-users, material fabricators, technology facilitators, and government organizations are charged with developing and demonstrating a much safer and a lot less costly Earth-to-Orbit full-scale propulsion system by 2005.
NASA's has established long term goals for access-to-space. The third generation launch systems are to be fully reusable and operational around 2025. The goals for the third generation launch system are to significantly reduce cost and improve safety over current systems. The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville, AL has the agency lead to develop space transportation technologies. Within ASTP, under the Spaceliner Investment Area, third generation technologies are being pursued. The Spaceliner Investment Area's primary objective is to mature vehicle technologies to enable substantial increases in the design and operating margins of third generation RLVs (current Space Shuttle is considered the first generation RLV) by incorporating advanced propulsion systems, materials, structures, thermal protection systems, power, and avionics technologies. Advancements in design tools and better characterization of the operational environment will result in reduced design and operational variabilities leading to improvements in margins. Improvements in operational efficiencies will be obtained through the introduction of integrated vehicle health management, operations and range technologies. Investments in these technologies will enable the reduction in the high operational costs associated with today's vehicles by allowing components to operate well below their design points resulting in improved component operating life, reliability, and safety which in turn reduces both maintenance and refurbishment costs. The introduction of advanced technologies may enable horizontal takeoff by significantly reducing the takeoff weight and allowing use of existing infrastructure. This would be a major step toward the goal of airline-like operation. These factors in conjunction with increased flight rates, resulting from reductions in transportation costs, will result in significant improvements of future vehicles. The real-world problem is that resources are limited and technologies need to be prioritized to assure the resources are spent on technologies that provide the highest system level benefits. Toward that end, a systems approach is being taken to determine the benefits of technologies for the Spaceliner Investment Area. Technologies identified to be enabling will be funded. However, the other technologies will be funded based on their system's benefits. Since the final launch system concept will not be decided for many years, several vehicle concepts are being evaluated to determine technology benefits. Not only performance, but also cost and operability are being assessed. This will become an annual process to assess these technologies against their goals and the benefits to various launch systems concepts. The paper describes the system process, tools and concepts used to determine the technology benefits. Preliminary results will be presented along with the current technology investments that are being made by ASTP's Spaceliner Investment Area.
Mariner Mark II is a program of missions, now under study at JPL, which will maximize scientific return at substantially reduced cost. There will be 3 to 5 missions in the program investigating comets, asteroids, the outer planets and their satellites, and Mars in the 1990s. Mission opportunities for these targets in this time period are described in terms of launch vehicle, propulsion, and flight time requirements, as well as other mission constraints such as margin and launch period objectives. Example encounter designs as well as mission launch scenarios are also described.
The use of existing earth-orbiting satellite technology represents a potential way of fulfilling important planetary exploration goals at greatly reduced cost, at least within the region between Venus and the inner asteroid belt. The present paper reports three studies of options for such missions to near-earth asteroids, the moon and Mars. The asteroid mission projected would be that of a rendezvous with either Anteros or Eros for purposes of resource determination, using an adaptation of the Tiros-N weather satellite. Two parallel studies were done on geoscience orbiters intended to provide detailed composition mapping from low polar orbit of the moon and Mars based on the modification of the same spacecraft design: the FLTSATCOM spacecraft, and the Atmospheric Explorer/Dynamics Explorer (later changed to Tiros for combined moon-Mars missions). Studies have shown the major modifications required to involve the telecommunications, data handling, power, propulsion and attitude control subsystems, and have demonstrated concept feasibility.
The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.
A 28V 32 Ah cell Li/MnO2 and a 28V NiMH battery systems for the Deorbit Propulsion Stage (DPS) and the X-38 Crew Return Vehicle (CRV) are developed in Friwo-Silforkraft, Germany with the following objectives and approach: Provide safe battery designs for lowest volume and cost, and within schedule; Take advantage of less complex requests for V201 vs OPS CRV to simplify design and reduce cost; Use only existing commercial cell designs as building blocks for larger battery; Derive battery designs from the ASTRO-SPAS design which is the largest lithium battery design with Shuttle flight experience; Place maximum amount of battery energy on DPS; DPS battery is non rechargeable; and CRV batteries are rechargeable. This paper contains the following sections: a brief introduction on CRV requirements, CRV advantages over Soyuz, and X-38 programs; Battery objectives and approach; Battery requirements and groundrules (performance, on-orbit operation, etc); Design trades, solutions, redundancy plan, and margins; Envelope, size, and mass; Interfaces (structural, electrical & thermal); and Deviation from OPS CRV.
Today's launch systems have major shortcomings that will increase in significance in the future, and thus are principal drivers for seeking major improvements in space transportation. They are too costly; insufficiently reliable, safe, and operable; and increasingly losing market share to international competition. For the United States to continue its leadership in the human exploration and wide ranging utilization of space, the first order of business must be to achieve low cost, reliable transportatin to Earth orbit. NASA's Access to Space Study, in 1993, recommended the development of a fully reusable single-stage-to-orbit (SSTO) rocket vehicle as an Agency goal. The goal of the Reusable Launch Vehicle (RLV) technology program is to mature the technologies essential for a next-generation reusable launch system capable of reliably serving National space transportation needs at substantially reduced costs. The primary objectives of the RLV technology program are to (1) mature the technologies required for the next-generation system, (2) demonstrate the capability to achieve low development and operational cost, and rapid launch turnaround times and (3) reduce business and technical risks to encourage significant private investment in the commercial development and operation of the next-generation system. Developing and demonstrating the technologies required for a Single Stage to Orbit (SSTO) rocket is a focus of the program becuase past studies indicate that it has the best potential for achieving the lowest space access cost while acting as an RLV technology driver (since it also encompasses the technology requirements of reusable rocket vehicles in general).
The costs regarding solar power systems are considered, giving attention to the total system cost index for the power system as a function of solar array area, and the recurring cost per square foot for the solar array versus the total area flight arrays built for each project. It is found that the costs decrease as production volume increases. Design standardization together with improvements in solar cell and array technology show promise of reducing costs. A long range program has been started to improve substantially the efficiency of silicon cells. Efficiencies approaching 20% are theoretically possible. One obstacle to cost reduction is that the volume of production required to satisfy the space program is not enough to justify a high degree of mechanization or automation.
Automatic fault diagnostic schemes rely on various types of sensors (e.g., temperature, pressure, vibration, etc) to measure the system parameters. Efficacy of a diagnostic scheme is largely dependent on the amount and quality of information available from these sensors. The reliability of sensors, as well as the weight, volume, power, and cost constraints, often makes it impractical to monitor a large number of system parameters. An optimized sensor allocation that maximizes the fault diagnosibility, subject to specified weight, volume, power, and cost constraints is required. Use of optimal sensor allocation strategies during the design phase can ensure better diagnostics at a reduced cost for a system incorporating a high degree of built-in testing. In this paper, we propose an approach that employs multiple fault diagnosis (MFD) and optimization techniques for optimal sensor placement for fault detection and isolation (FDI) in complex systems. Keywords: sensor allocation, multiple fault diagnosis, Lagrangian relaxation, approximate belief revision, multidimensional knapsack problem.
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.
The purpose of health monitoring systems is to detect failures or defects for increased safety and performance and to provide on-condition maintenance with reduced costs. The problems associated with health monitoring systems include high rates of false alarms and missed failures, which make monitoring an unreliable and costly task. The reason for this is that unaccounted variations invalidate signal modeling assumptions. Our approach was to focus on vibration monitoring of rotating components. We analyzed baseline signals to determine statistical variations, identify and model factors that influence vibrations (pre-production vs. post-production variations), determine hit and false alarm rates with baseline flight data, model and predict effects of defects and variations on vibrations, and develop algorithms and metrics for failure and anomaly detection in the presence of variations.
The paper discusses launch operations from a program perspective. Launch operations cost is a significant part of program cost. New approaches to launch operations, integrated with lessons learned, have the potential to increase safety and reliability as well as reduce cost. Operational efficiency must be an initial program goal. Design technology and management philosophy must be implemented early to ensure operational cost goals. Manufacturing cost and launch cost are related to operational efficiency. True program savings can be realized through implementation of launch operations cost saving approaches which do not correspondingly increase cost in other program areas such as manufacturing and software development and maintenance. Launch rate is a key factor in the cost/flight analysis and the determination of launch operations efficiency goals.