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NASA NTRS2009

Operational Considerations and Comparisons of the Saturn, Space Shuttle and Ares Launch Vehicles

The United States (U.S.) space exploration policy has directed the National Aeronautics and Space Administration (NASA) to retire the Space Shuttle and to replace it with a new generation of space transportation systems for crew and cargo travel to the International Space Station, the Moon, Mars, and beyond. As part of the Constellation Program, engineers at NASA's Marshall Space Flight Center in Huntsville, Alabama are working to design and build the Ares I, the first of two large launch vehicles to return humans to the Moon. A deliberate effort is being made to ensure a high level of operability in order to significantly increase safety and availability as well as reduce recurring costs of this new launch vehicle. It is the Ares Project's goal to instill operability as part of the requirements development, design and operations of the vehicle. This paper will identify important factors in launch vehicle design that affect the operability and availability of the system. Similarities and differences in operational constraints will also be compared between the Saturn V, Space Shuttle and current Ares I design. Finally, potential improvements in operations and operability for large launch vehicles will be addressed. From the examples presented, the paper will discuss potential improvements for operability for future launch vehicles.

Cruzen, Craig↗

NASA NTRS2007

The First Year in Review: NASA's Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle

The U.S. Vision for Space Exploration guides NASA's challenging missions of scientific discovery.' Developing safe, reliable, and affordable space transportation systems for the human and robotic exploration of space is a key component of fulfilling the strategic goals outlined in the Vision, as well as in the U.S. Space Policy. In October 2005, the Exploration Systems Mission Directorate and its Constellation Program chartered the Exploration Launch Projects Office, located at the Marshall Space Flight Center, to design, develop, test, and field a new generation of launch vehicles that would fulfill customer and stakeholder requirements for trips to the Moon, Mars, and beyond. The Ares I crew launch vehicle is slated to loft the Orion crew exploration vehicle to orbit by 2014, while the heavy-lift Ares V cargo launch vehicle will deliver the lunar lander to orbit by 2020 (Fig. 1). These systems are being designed to empower America's return to the Moon to prepare for the first astronaut on Mars. The new launch vehicle designs now under study reflect almost 50 years of hard-won experience gained from the Saturn's missions to the Moon in the late 1960s and early 1970s, and from the venerable Space Shuttle, which is due to be retired by 2010.

Dumbacher, Daniel L.↗

NASA NTRS2009

NASA #837 Tribute The Jet with a Thousand Faces

This slide presentation reviews the TF-1 (later designated as an F-15B) aircraft, which was delivered as an F-15 trainer. The aircraft was used as a test aircraft for various programs. The aircraft was later renamed to NASA 837 in 2001. Prior to its retirement it was used to test various features and concepts. Some of these tests were: (1) Canopy Off Testing, (2) STOL and Maneuvering Technology Demonstrator (S/MTD), (3) 2D Nozzles (4) Autonomous landing guidance, (5) Advanced Control Technology for Integrated Vehicles (ACTIVE), (6) Intelligent Flight Control System (IFCS), (7) Structural Loads Model Validation (SLMV), (8) Enhanced Communication and Navigation System (ECANS), (9) QuietSpike Probing, and (10) Lift and Nozzle Effects on Tail Shocks (LaNCETS)

Rhoades, Carrie M.↗

NASA NTRS2009

The 50 Constellation Priority Sites

The Constellation program (CxP) has developed a list of 50 sites of interest on the Moon which will be targeted by the LRO narrow angle camera. The list has also been provided to the M~ team to supplement their targeting list. This list does not represent a "site selection" process; rather the goal was to find "representative" sites and terrains to understand the range of possible surface conditions for human lunar exploration to aid engineering design and operational planning. The list compilers leveraged heavily on past site selection work (e.g. Geoscience and a Lunar Base Workshop - 1988, Site Selection Strategy for a Lunar Outpost - 1990, Exploration Systems Architecture Study (ESAS) - 2005). Considerations included scientific, resource utilization, and operational merits, and a desire to span lunar terrain types. The targets have been organized into two "tiers" of 25 sites each to provide a relative priority ranking in the event of mutual interference. A LEAG SAT (special action team) was established to validate and recommend modifications to the list. This SAT was chaired by Dr. Paul Lucey. They provided their final results to CxP in May. Dr. Wendell Mendell will organize an on-going analysis of the data as they come down to ensure data quality and determine if and when a site has sufficient data to be retired from the list. The list was compiled using the best available data, however, it is understood that with the flood of new lunar data, minor modifications or adjustments may be required.

Noble, S.↗

NASA NTRS2009

Methods Reduce Cost, Enhance Quality of Nanotubes

For all the challenges posed by the microgravity conditions of space, weight is actually one of the more significant problems NASA faces in the development of the next generation of U.S. space vehicles. For the Agency s Constellation Program, engineers at NASA centers are designing and testing new vessels as safe, practical, and cost-effective means of space travel following the eventual retirement of the space shuttle. Program components like the Orion Crew Exploration Vehicle, intended to carry astronauts to the International Space Station and the Moon, must be designed to specific weight requirements to manage fuel consumption and match launch rocket capabilities; Orion s gross liftoff weight target is about 63,789 pounds. Future space vehicles will require even greater attention to lightweight construction to help conserve fuel for long-range missions to Mars and beyond. In order to reduce spacecraft weight without sacrificing structural integrity, NASA is pursuing the development of materials that promise to revolutionize not only spacecraft construction, but also a host of potential applications on Earth. Single-walled carbon nanotubes are one material of particular interest. These tubular, single-layer carbon molecules - 100,000 of them braided together would be no thicker than a human hair - display a range of remarkable characteristics. Possessing greater tensile strength than steel at a fraction of the weight, the nanotubes are efficient heat conductors with metallic or semiconductor electrical properties depending on their diameter and chirality (the pattern of each nanotube s hexagonal lattice structure). All of these properties make the nanotubes an appealing material for spacecraft construction, with the potential for nanotube composites to reduce spacecraft weight by 50 percent or more. The nanotubes may also feature in a number of other space exploration applications, including life support, energy storage, and sensor technologies. NASA s various efforts with carbon nanotubes have made it a global leader in this field. Among the many examples are Johnson Space Center s Carbon Nanotube Project, which focuses on bulk nanotube production, purification, and application, and Goddard Space Flight Center s improved arc discharge method of nanotube production, developed under the direction of Jeannette Benavides (featured in Spinoff 2007 and 2008). While the Agency continues its own research, it partners with private companies to advance this unique technology for use on Earth as well as among the stars.

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NASA NTRS2009

Ares V Overview and Status

As part of NASA s Constellation Program to resume exploration beyond low Earth orbit (LEO), the Ares V heavy-lift cargo launch vehicle as currently conceived will be able to send more crew and cargo to more places on the Moon than the Apollo Program Saturn V. (Figure 1) It also has unprecedented cargo mass and volume capabilities that will be a national asset for science, commerce, and national defense applications. Compared to current systems, it will offer approximately five times the mass and volume to most orbits and locations. The Columbia space shuttle accident, the resulting investigation, the Vision for Space Exploration, and the Exploration Systems Architecture Study (ESAS) broadly shaped the Constellation architecture. Out of those events and initiatives emerged an architecture intended to replace the space shuttle, complete the International Space Station (ISS), resume a much more ambitious plan to explore the moon as a stepping stone to other destinations in the solar system. The Ares I was NASA s main priority because of the goal to retire the Shuttle. Ares V remains in a concept development phase, evolving through hundreds of configurations. The current reference design was approved during the Lunar Capabilities Concept Review/Ares V Mission Concept Review (LCCR/MCR) in June 2008. This reference concept serves as a starting point for a renewed set of design trades and detailed analysis into its interaction with the other components of the Constellation architecture and existing launch infrastructure. In 2009, the Ares V team was heavily involved in supporting the Review of U.S. Human Space Flight Plans Committee. Several alternative designs for Ares V have been supplied to the committee. This paper will discuss the origins of the Ares V design, the evolution to the current reference configuration, and the options provided to the review committee.

Creech, Steve↗

NASA NTRS2010

Overview of the Orion Thermal Protection System

The Orion spacecraft is being developed as part of the Constellation Exploration Program and will serve as the United States crewed transportation system to the International Space Station after the retirement of the Space Shuttle in 2010 and as the eventual means to return U.S. astronauts to the Moon. Therefore, Orion is being designed for reentry missions from both low Earth orbit and from Lunar-return trajectories. This presentation will provide an overview of the development of the Orion TPS, a critical component in the development of the spacecraft. The thermal protection system (TPS) that protects the crew module from the extreme environments associated with Earth atmospheric reentry consists of a forward heatshield and an aft backshell. The requirements that drive the design of the TPS will be discussed, including several key requirements that establish a precedent for U.S. human-rated spacecraft. For the first time in U.S. human spaceflight, a vehicle s TPS is being designed with a specific, derived requirement for reliability. Also, due to the increased presence of spacecraft in Earth s orbit in recent decades, requirements for micro-meteoroid/orbital debris damage tolerance are also a driving requirement that has affected the selection of portions of the TPS. The efforts to select materials and to define a preliminary design for both the heatshield and the backshell will be described. This will include a discussion of the design challenges presented by the numerous penetrations on both the backshell and the heatshield. Finally, the verification and validation plan which is currently under development to certify the TPS for human-rated missions will be outlined. To support the execution of this plan, a ground test campaign for both thermal and structural performance is being designed. This test campaign will directly support thermal and thermal/structural analyses that also are fundamental to the certification effort.

Kowal, T. John↗

NASA NTRS2010

Risk Mitigation Approach to Commercial Resupply to the International Space Station

In August 2006, NASA awarded Space Act Agreements (SAAs) for Commercial Orbital Transportation Services (COTS) under the Commercial Crew and Cargo Project Office at Johnson Space Center. One of the goals of the SAAs is to facilitate U.S. private industry demonstration of cargo transportation capabilities, ultimately achieving reliable, cost effective access to low-Earth orbit (LEO). Each COTS provider is required to complete International Space Stations (ISS) Integration activities, which includes meeting the physical and functional interfaces and interface requirements between the ISS and COTS vehicles. These requirements focus on the areas of risk to the ISS during rendezvous and proximity operations, as well as the integration operations while the COTS vehicle is berthed to the ISS. On December 23, 2008, NASA awarded Commercial Resupply Service (CRS) contracts to provide resupply services to the ISS, following the Shuttle retirement. In addition to performing any ISS Integration activities, NASA will be performing independent assessments of the launch vehicle and orbital vehicle to evaluate the readiness of the contractor to deliver NASA cargo safely to the ISS. This paper will address the activities NASA Centers, both JSC and KSC, in the oversight and insight function over commercial visiting vehicles to the ISS.

Koons, Diane S.↗

NASA NTRS2010

Estimating the Reliability of a Soyuz Spacecraft Mission

Once the US Space Shuttle retires in 2010, the Russian Soyuz Launcher and Soyuz Spacecraft will comprise the only means for crew transportation to and from the International Space Station (ISS). The U.S. Government and NASA have contracted for crew transportation services to the ISS with Russia. The resulting implications for the US space program including issues such as astronaut safety must be carefully considered. Are the astronauts and cosmonauts safer on the Soyuz than the Space Shuttle system? Is the Soyuz launch system more robust than the Space Shuttle? Is it safer to continue to fly the 30 year old Shuttle fleet for crew transportation and cargo resupply than the Soyuz? Should we extend the life of the Shuttle Program? How does the development of the Orion/Ares crew transportation system affect these decisions? The Soyuz launcher has been in operation for over 40 years. There have been only two loss of life incidents and two loss of mission incidents. Given that the most recent incident took place in 1983, how do we determine current reliability of the system? Do failures of unmanned Soyuz rockets impact the reliability of the currently operational man-rated launcher? Does the Soyuz exhibit characteristics that demonstrate reliability growth and how would that be reflected in future estimates of success? NASA s next manned rocket and spacecraft development project is currently underway. Though the projects ultimate goal is to return to the Moon and then to Mars, the launch vehicle and spacecraft s first mission will be for crew transportation to and from the ISS. The reliability targets are currently several times higher than the Shuttle and possibly even the Soyuz. Can these targets be compared to the reliability of the Soyuz to determine whether they are realistic and achievable? To help answer these questions this paper will explore how to estimate the reliability of the Soyuz Launcher/Spacecraft system, compare it to the Space Shuttle, and its potential impacts for the future of manned spaceflight. Specifically it will look at estimating the Loss of Mission (LOM) probability using historical data, reliability growth, and Probabilistic Risk Assessment techniques

Lutomski, Michael G.↗

NASA NTRS2010

Development of Weld Inspection of the Ares I Crew Launch Vehicle Upper Stage

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges in inspection. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Russell, Sam↗

NASA NTRS2010

Using SCOR as a Supply Chain Management Framework for Government Agency Contract Requirements

Enterprise Supply Chain Management consists of: Specifying suppliers to support inter-program and inter-agency efforts. Optimizing inventory levels and locations throughout the supply chain. Executing corrective actions to improve quality and lead time issues throughout the supply chain. Processing reported data to calculate and make visible supply chain performance (provide information for decisions and actions). Ensuring the right hardware and information is provided at the right time and in the right place. Monitoring the industrial base while developing, producing, operating and retiring a system. Seeing performance deep in the supply chain that could indicate issues affecting system availability and readiness.

Paxton, Joe↗

NASA NTRS2010

Heavy-Lift for a New Paradigm in Space Operations

NASA is developing an unprecedented heavy-lift capability to enable human exploration beyond low Earth orbit (LEO). This capability could also significantly enhance numerous other missions of scientific, national security, and commercial importance. That capability is currently configured as the Ares V cargo launch vehicle. This capability will eclipse the capability the United States lost with the retirement of the Saturn V. It is capable of launching roughly 53 percent more payload mass to trans lunar injection (TLI) and 30 percent more payload mass to LEO than its Apollo Program predecessor. Ares V is a major element of NASA's Constellation Program, which also includes the Ares I crew launch vehicle (CLV), Orion crew exploration vehicle (CEV), and a lunar lander for crew and cargo. As currently configured, Ares V will be capable of launching 413,800 pounds (187.7 mT) to LEO, 138,500 pounds (63 mT) direct to the Moon or 156,700 pounds (71.1 mT) in its dual-launch architecture role with Ares I. Its 33-foot (10 m) shroud provides unprecedented payload volume. Assessment of astronomy and planetary science payload requirements since spring 2008 has indicated that a Saturn V-class heavy-lift vehicle has the potential to support a range of payloads and missions. This vehicle configuration enables some missions previously considered difficult or impossible and enhances many others. Collaborative design/architecture inputs, exchanges, and analyses have already begun between scientists and payload developers. This early dialogue between NASA engineers and payload designers allows both communities to shape their designs and operational concepts to be mutually supportive to the extent possible with the least financial impact. This paper provides an overview of the capabilities of a heavy-lift vehicle to launch payloads with increased mass and/or volume and reduce technical and cost risk in both design and operations.

Morris, Bruce↗

NASA NTRS2010

Ares I First Stage Propulsion System Status

With the retirement of the Space Shuttle inevitable, the US is faced with the need to loft a reliable cost-effective, technologically viable solution to bring the nation s fleet of spacecraft back up to industry standard. It must not only support the International Space Station (ISS), it must also be capable of supporting human exploration beyond low Earth orbit (LEO). NASA created the Constellation Program to develop a new fleet including the launch vehicles, the spacecraft, and the mission architecture to meet those objectives. The Ares First Stage Team is tasked with developing a propulsion system capable of safely, dependably and repeatedly lofting that new fleet. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle were used as a starting point in the design and production of a new first stage element. While the first stage will provide the foundation, the structural backbone, power, and control for launch, the new propulsive element will also provide a greater total impulse to loft a safer, more powerful, fleet of space flight vehicles. Substantial design and system upgrades were required to meet the mass and trajectory requisites of the new fleet. Noteworthy innovations and design features include new forward structures, new propellant grain geometry, a new internal insulation system, and a state-of-the art avionics system. Additional advances were in materials and composite structures development, case bond liners, and thermal protection systems. Significant progress has been made in the design, development and testing of the propulsion and avionics systems for the new first stage element. Challenges, such as those anticipated with thrust oscillation, have been better characterized, and are being effectively mitigated. The test firing of the first development motor (DM-1) was a success that validated much of the engineering development to date. Substantive data has been collected and analyzed, allowing the Ares First Stage team to move forward, fine-tune the design, and advance to production of the second development motor (DM-2), which is now in fabrication. This paper will provide an overview of the design, development, challenges, and progress on the production of the new Ares First Stage propulsion system

Priskos, Alex S.↗

NASA NTRS2010

EA Shuttle Document Retention Effort

This slide presentation reviews the effort of code EA at Johnson Space Center (JSC) to identify and acquire databases and documents from the space shuttle program that are adjudged important for retention after the retirement of the space shuttle.

Wagner, Howard A.↗

NASA NTRS2009

Advanced Development Program for a 625 lbf thrust engine for Ares First Stage Roll Control System

NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;

Dawson, Matt↗

NASA NTRS2010

Converting an MPLM to a PMM

The Multi-Purpose Logistics Module (MPLM) are pressurized modules for transporting equipment, supplies and experimental devices to and from the International Space Station (ISS). An MPLM is carried in the cargo bay of a Shuttle and attached to the Unity or Harmony modules on the ISS for the duration of a mission, usually about 10 days. From there, supplies are offloaded, and finished experiments and waste are reloaded. The MPLM is then returned to the Space Shuttle payload bay for return to Earth. Three modules were built, Leonardo, Raffaello and Donatello. The modules were provided to NASA under contract by the Italian Space Agency. Each MPLM was built to be on-orbit a maximum of one month at a time. The MPLM Leonardo is being modified to turn it into the Pressurized Multipurpose Module (PMM), which will remain permanently attached to the ISS following the STS- 133 mission. The Space Shuttle is the only vehicle or rocket that has the capacity to carry the MPLM to the ISS. With the planned retirement of the Space Shuttle in 2011, NASA has found another use for the MPLM. With the modifications of the MPLM into a PMM the ISS will have another permanent module as part of the ISS that will be used as a storage module

Perez, Hector P.↗

NASA NTRS2010

The J-2X Upper Stage Engine: From Design to Hardware

NASA is well on its way toward developing a new generation of launch vehicles to support of national space policy to retire the Space Shuttle fleet, complete the International Space Station, and return to the Moon as the first step in resuming this nation s exploration of deep space. The Constellation Program is developing the launch vehicles, spacecraft, surface systems, and ground systems to support those plans. Two launch vehicles will support those ambitious plans the Ares I and Ares V. (Figure 1) The J-2X Upper Stage Engine is a critical element of both of these new launchers. This paper will provide an overview of the J-2X design background, progress to date in design, testing, and manufacturing. The Ares I crew launch vehicle will lift the Orion crew exploration vehicle and up to four astronauts into low Earth orbit (LEO) to rendezvous with the space station or the first leg of mission to the Moon. The Ares V cargo launch vehicle is designed to lift a lunar lander into Earth orbit where it will be docked with the Orion spacecraft, and provide the thrust for the trans-lunar journey. While these vehicles bear some visual resemblance to the 1960s-era Saturn vehicles that carried astronauts to the Moon, the Ares vehicles are designed to carry more crew and more cargo to more places to carry out more ambitious tasks than the vehicles they succeed. The government/industry team designing the Ares rockets is mining a rich history of technology and expertise from the Shuttle, Saturn and other programs and seeking commonality where feasible between the Ares crew and cargo rockets as a way to minimize risk, shorten development times, and live within the budget constraints of its original guidance.

Byrd, Thomas↗

NASA NTRS2010

Space Flight Resource Management for ISS Operations

Although the astronaut training flow for the International Space Station (ISS) spans 2 years, each astronaut or cosmonaut often spends most of their training alone. Rarely is it operationally feasible for all six ISS crewmembers to train together, even more unlikely that crewmembers can practice living together before launch. Likewise, ISS Flight Controller training spans 18 months of learning to manage incredibly complex systems remotely in plug-and-play ground teams that have little to no exposure to crewmembers before a mission. How then do all of these people quickly become a team - a team that must respond flexibly yet decisively to a variety of situations? The answer implemented at NASA is Space Flight Resource Management (SFRM), the so-called "soft skills" or team performance skills. Based on Crew Resource Management, SFRM was developed first for shuttle astronauts and focused on managing human errors during time-critical events (Rogers, et al. 2002). Given the nature of life on ISS, the scope of SFRM for ISS broadened to include teamwork during prolonged and routine operations (O'Keefe, 2008). The ISS SFRM model resembles a star with one competency for each point: Communication, Cross-Culture, Teamwork, Decision Making, Team Care, Leadership/Followership, Conflict Management, and Situation Awareness. These eight competencies were developed with international participation by the Human Behavior and Performance Training Working Group. Over the last two years, these competencies have been used to build a multi-modal SFRM training flow for astronaut candidates and flight controllers that integrates team performance skills into the practice of technical skills. Preliminary results show trainee skill increases as the flow progresses; and participants find the training invaluable to performing well and staying healthy during ISS operations. Future development of SFRM training will aim to help support indirect handovers as ISS operations evolve further with the retirement of the Space Shuttle Program.

Schmidt, Lacey L.↗