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At least 253 records · Page 14

Vertical Motion Simulator -- A Unique Facility for Piloted GNC Research

This material is for presentation at the annual meeting of the NASA Engineering and Safety Center (NESC) Guidance, Navigation, and Control (GNC) Technical Discipline Team (TDT), on 22 July 2020. The briefing is entitled “Vertical Motion Simulator – A Unique Facility for Piloted GNC Research.” It provides a technical description of key VMS features and a high-level overview of some large bodies of work conducted in the VMS over the past 40 years.

Vertical Motion Simulator↗

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric surface imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method models. Data collection methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps on how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the pre-processing methods and results from Py_TIGIRS are provided and compared for Composite Test Article (CTA) 8.2B. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future development of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Sandwich structures↗

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method (FEM) models. Geometry measurement methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps of how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the preprocessing methods and results from Py_TIGIRS are provided and compared for Composite Test Articles (CTA) 8.2, 8.2B, and 8.3. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future developments of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Geometric imperfections↗

Implementing Geometric Surface Imperfections into Sandwich Composite Cylinder Finite Element Method Models

The buckling responses of certain cylindrical shell structures are extremely sensitive to geometric imperfections. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) is conducting research to develop analysis-based buckling design recommendations. Experiments are used to verify the analysis-based factors, but the sensitivity of the test articles to geometric imperfections requires implementing as-manufactured imperfections into high-fidelity finite element method (FEM) models. Geometry measurement methods such as structured light scanning are used for all geometric surface data used in this work. Common preprocessing and visualization steps used in SBKF are discussed, and steps of how surface scans are prepared for implementation into a finite element model is described. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS), written specifically for the use with SBKF, is briefly described and uses eight functions to extract, modify, and write geometric imperfections into Abaqus input files. Results of the preprocessing methods and results from Py_TIGIRS are provided and compared for Composite Test Articles (CTA) 8.2, 8.2B, and 8.3. Excellent agreement between the visualized scan data and the FEM-extracted geometry is demonstrated. A brief example of why geometric surface imperfections are significant in nonlinear numerical analyses for thin cylinders in axial compression is provided as motivation to use tools such as Py_TIGIRS. Future developments of Py_TIGIRS including expansion to structures of arbitrary geometry is planned.

Geometric imperfections↗

Application of Micro-Thruster Technology for Space Observatory Pointing Stability

This assessment was requested by the NASA Engineering and Safety Center (NESC) Guidance, Navigation, and Control (GN&C) Technical Discipline Team (TDT), which identified the topic as an unrecognized critical need for the Agency’s future space science observatory-class space platforms. An initial low-fidelity feasibility study of the use of cold-gas micro-thrusters as a replacement for reaction wheels was performed in 2017 as a GN&C TDT discretionary activity. The assessment documented in this final report was initiated in 2018 as a follow-on high-fidelity study.

Guidance↗

The Effects of Arcing Ejecta on Space Suit Materials from ISS RPCM Hot Mate/Demate During EVA

Onboard ISS, taking systems off-line when powering down to perform servicing on Remote Power Control Modules (RPCMs) introduces operational risk. An investigation lead by the NASA Engineering and Safety Center (NESC) was performed by a multi-center team to assess the safety of performing on-orbit replacement of RPCMs without powering down. This investigation revealed the potential for molten metal particulate generation in the event of an arcing occurrence. As RPCM replacement can be performed outside ISS during an Extra Vehicular Activity (EVA), it is necessary to assess the effects of this molten metal ejecta contact with the Extravehicular Mobility Unit (EMU) Space Suit Assembly (SSA) during an arcing event. A test was devised to mimic arcing ejecta contact with samples representing various SSA cross-sections. Four areas of the SSA were chosen for test to represent the majority of the SSA cross-sections. Testing was conducted by the University of California, Riverside that generated the molten metal particles, included varying composition, size and temperature, and dropped them onto the surface of the various SSA cross-sections. Exposed SSA materials were then evaluated for degree of damage, penetration, and thermal conductance through the cross-section by ILC Dover. Results showed that the SSA Glove is most susceptible to damage from arcing events. This data will be used to make risk management decisions for future RPCM servicing operations. This testing also demonstrated the durability of the SSA design and materials to exposure to extreme environments

Linda S Hewes↗

NASA Engineering and Safety Center Technical Bulletin No. 21-02: Genesis Flight Mechanics Simulation

Genesis Flight Mechanics Simulation The NASA Engineering and Safety Center (NESC) consolidated and modernized a suite of legacy flight mechanics simulations, including the Flight Analysis and Simulation Tool (FAST), resulting in Genesis, a generic, multi-vehicle, variable-degree-of-freedom flight mechanics simulation for ascent, aerocapture, entry, descent, and landing (A2EDL) trajectory design. Genesis is more flexible, capable, and performant than FAST. It enables trajectory optimization and interactive trajectory generation. Its interoperability with Copernicus, an exo-atmospheric and interplanetary trajectory design tool, facilitates end-to-end trajectory optimization across all mission phases. Genesis is implemented in Julia, a new language for technical computing that combines the ease of use of scripting languages with the run-time performance of compiled languages.

EDL↗

The Effects of Arcing Ejecta on Space Suit Materials from ISS RPCM Hot Mate/Demate During EVA

Onboard ISS, taking systems off-line when powering down to perform servicing on Remote Power Control Modules (RPCMs) introduces operational risk. An investigation lead by the NASA Engineering and Safety Center (NESC) was performed by a multi-center team to assess the safety of performing on-orbit replacement of RPCMs without powering down. This investigation revealed the potential for molten metal particulate generation in the event of an arcing occurrence. As RPCM replacement can be performed outside ISS during an Extra Vehicular Activity (EVA), it is necessary to assess the effects of this molten metal ejecta contact with the Extravehicular Mobility Unit (EMU) Space Suit Assembly (SSA) during an arcing event. A test was devised to mimic arcing ejecta contact with samples representing various SSA cross-sections. Four areas of the SSA were chosen for test to represent the majority of the SSA cross-sections. Testing was conducted by the University of California, Riverside that generated the molten metal particles, included varying composition, size and temperature, and dropped them onto the surface of the various SSA cross-sections. Exposed SSA materials were then evaluated for degree of damage, penetration, and thermal conductance through the cross-section by ILC Dover. Results showed that the SSA Glove is most susceptible to damage from arcing events. This data will be used to make risk management decisions for future RPCM servicing operations. This testing also demonstrated the durability of the SSA design and materials to exposure to extreme environments.

Linda S. Hewes↗

Temperature and Frequency Dependent Electrical Properties of AVCOAT and Shuttle Tile Material

This technical memorandum presents the data and results from a series of tests performed on AVCOAT, charred AVCOAT, and different Shuttle Thermal Protection System (TPS) tile coatings to determine their electrical properties as a function of temperature and frequency. Initially, the samples were assumed to be insulators and the complex permittivities were measured from data collected by sandwiching each sample between two conductors to form a sandwich. However, the AVCOAT sample data showed that the material becomes conductive as it begins to char. To get an accurate conductivity reading on these charred samples, a four-point resistance probe was used to collect data. Overall, this testing showed that the virgin AVCOAT starts out as a material that is a good insulator but transitions to one with a conductivity on the order of 1860 S/m as it chars. The deeper layers of AVCOAT (un-charred) all exhibited a temperature and frequency dependence that is possibly indicative of a dielectric relaxation in the material. As the sample temperatures were increased, a knee appears in the real permittivity data sets below 1 kHz. Both the real permittivity and resistivity drop up to several orders of magnitude yet show that the material remains an insulator. The Shuttle High Temperature Reusable Surface Insulation (HRSI) tile coatings studied included Reac- tion Cured Glass (RCG), Aluminum Enhanced Thermal Barrier (AETB), and Toughened Unipiece Fibrous Insulation (TUFI). The purely glass fiber parts of the tile were removed leaving only the outer layers con- taining just the coating. The data collected shows that the RCG, AETB, and outermost layer of the TUFI have similar electrical properties. The real permittivity plots show that there appears to be a relaxation that shows up at frequencies below 1 kHz. The relaxation frequency increases with increasing temperature. Also, the real permittivity increases up to about a factor of four between room temperature and 650K. Likewise, the resistivity (related to the imaginary permittivity) decreases up to five orders of magnitude over the same temperature interval, but still remains an insulator. This data was collected to support a NASA Engineering and Safety Center (NESC) assessment team investigating the source of thermocouple anomalies in both Shuttle TPS material and AVCOAT used for on the Orion spacecraft for Exploration Flight Test 1 (EFT-1). The details of their findings will be documented in a separate report with this document serving as a reference.

Mark A Nurge↗

Buckling Test and Analysis of the 8-Foot-Diameter Sandwich Composite Cylinder Test Article CTA8.2 as Part of the Shell Buckling Knockdown Factor Project: Test Dates 5-7 December 2017

It is well known that the buckling response of thin shell structures can be sensitive to small imperfections in the geometry and loading. The NASA Engineering and Safety Center (NESC) Shell Buckling Knockdown Factor Project (SBKF) has the goal of developing buckling design recommendations for select classes of metallic and composite shells. Part of completed SBKF work is described in this report. In particular, the test and analysis results from the second SBKF composite test article, CTA8.2, are described. This test was the second in a series of tests on sandwich composite cylinders that can be used to experimentally validate analysis methods, which in turn can be used to develop analysis-based shell buckling design guidelines for sandwich composite launch-vehicle cylindrical structures. CTA8.2 was an 8-foot diameter honeycomb-core sandwich cylinder that was fabricated and tested at the Marshall Space Flight Center (MSFC). The primary objectives of this test were to interrogate the structural capability of the composite test article, and to verify the test-article design and analysis approach for cylinders subjected to axial compression loads. This report contains the descriptions of the test-article design, fabrication, and test. The pre-test modeling and analysis methods, and corresponding results used in support of the test-article design and test planning, are also described. Additional post-test modeling and analysis efforts and results follow. Selected test results are compared to pre-test predictions and post-test analyses.

Adam Przekop↗

Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems

In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.

Kurt A Polzin↗

Case Study of Meteoroid Fluence on a Mars Sample Return Mission

The Mars Sample Return Campaign must satisfy a Back Planetary Protection requirement that limits the risk of biological contamination of the Earth by Martian microbes. The Earth Re-turn Orbiter (ERO), being developed by the European Space Agency (ESA), will carry a Capture, Containment and Return System (CCRS), which is being developed by NASA to retrieve orbiting samples (OS) from Mars orbit, surround them with two containment layers to create a Contained OS (COS), and transfer the COS to the Earth Entry System (EES), which will be re-leased by ERO to carry the samples through entry, descent and landing at the Utah Test and Training Range. Micrometeoroid impact damage to the Thermal Protection System (TPS) of the EES, which may occur at any time in the ERO mission, is recognized as a potential risk driver for loss of sample containment that needs to be rigorously assessed. A Micrometeoroid Protection System (MMPS) will be implemented to limit that risk. The MMPS consists of a shield covering the TPS called the Micrometeoroid Garage (MMG) and a system of cameras to inspect the TPS. An extensive study was performed by the CCRS Project in collaboration with the NASA Engineering and Safety Center (NESC)to assess the probability of damage to the MMG and TPS by meteoroids over the entire ERO mission. This included the computation of the meteoroid fluence on the MMG and directly on the TPS after EES separation, and assessment of damage to the MMG and TPS via hypervelocity impact tests, hydrocode simulations, and empirical damage prediction and ballistic limit equations (BLEs). The focus of this paper is the meteoroid fluence on the MMG.

Micrometeoroid↗

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

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

single-piece↗

Phasing in COTS EEE parts in NASA

A number of activities within NASA and the space community, as well as growing technology needs and supply chain changes have accelerated the need to expand the use of COTS parts within NASA. While the use of COTS has been formally institutionalized and deemed acceptable for Class D space missions and those with greater tolerance for risk, there is still a lack of understanding of how to most effectively use COTS in such high risk-tolerance missions, and no apparent path towards broad use in missions with much less tolerance for risk. However, the reality is that the fundamental limitations of technology associated with the military specification system combined with the need to fly newer technologies in upcoming flagship robotic missions and human space flight missions will ultimately demand a more expansive use of COTS. The infinite nature of COTS gives rise to numerous challenges in the selection, acceptance, testing, and usage of COTS when reliable operation is essential. This presentation will highlight some of the current artifacts of a NASA Engineering and Safety Center (NESC) study on the use of COTS parts, as well as many of the historical through current facts about parts assurance within Agency to provide a path forward for reliable use of COTS for a range of space applications and risk postures.

EEE parts↗

Independent Reliability Assessment of the NASA GSFC Laser Transmitter for the LISA Program

The Laser Interferometer Space Antenna (LISA) is a partnership between the European Space Agency (ESA) and NASA to build a Gravitational Wave (GW) observatory. The observatory, which consists of a three-spacecraft constellation with a nominal separation of 2.5 million km between each spacecraft, provides a tool for scientists to directly detect gravitational waves generated from various astronomical phenomena in a waveband that is not accessible from Earth. NASA is developing laser transmitters as one of the potential US contributions to LISA. The NASA laser design leverages lessons learned from previous flight missions and included the latest technologies in photonics packaging and reliability engineering to ensure a laser lifetime of >16 years covering integration and test through a possible extended mission phase. As part of the laser development process, NASA’s Goddard Space Flight Center (GSFC) requested support from the NASA Engineering and Safety Center (NESC) to independently assess the Technology Readiness Level (TRL) of the LISA Laser System (LS). The independent assessment included the following tasks: (a) assess the design for weaknesses and suggest improvements to mitigate risks, (b) assess the laser reliability plan for weaknesses and suggest improvements to mitigate risks and improve effectiveness, and (c) assess the current redundancy plan on laser subsystems for weaknesses and suggest improvements to mitigate risks and improve effectiveness. The NESC team comprised of a team of subject matter experts (SMEs) and performed a 12-month review of every aspect of the laser design. We present the assessment findings and the current development progress of the LISA laser to meet the mission requirements with a delivery of a form, fit, and functional TRL6 laser to the LSIA mission by late 2023.

LISA↗

Case Study of Meteoroid Fluence on a Mars Sample Return Mission

The Mars Sample Return Campaign must satisfy a Back Planetary Protection requirement that limits the risk of biological contamination of the Earth by Martian microbes. The Earth Re-turn Orbiter (ERO), being developed by the European Space Agency (ESA), will carry a Capture, Containment and Return System (CCRS), which is being developed by NASA to retrieve orbiting samples (OS) from Mars orbit, surround them with two containment layers to create a Contained OS (COS), and transfer the COS to the Earth Entry System (EES), which will be re-leased by ERO to carry the samples through entry, descent and landing at the Utah Test and Training Range. Micrometeoroid impact damage to the Thermal Protection System (TPS) of the EES, which may occur at any time in the ERO mission, is recognized as a potential risk driver for loss of sample containment that needs to be rigorously assessed. A Micrometeoroid Protection System (MMPS) will be implemented to limit that risk. The MMPS consists of a shield covering the TPS called the Micrometeoroid Garage (MMG) and a system of cameras to inspect the TPS. An extensive study was performed by the CCRS Project in collaboration with the NASA Engineering and Safety Center (NESC)to assess the probability of damage to the MMG and TPS by meteoroids over the entire ERO mission. This included the computation of the meteoroid fluence on the MMG and directly on the TPS after EES separation, and assessment of damage to the MMG and TPS via hypervelocity impact tests, hydrocode simulations, and empirical damage prediction and ballistic limit equations (BLEs). The focus of this paper is the meteoroid fluence on the MMG.

micrometeoroid↗

Utilizing 3D-DIC on Mars 2020 Rover Wheel Assembly: Test-Analysis Correlation

Following the successful implementation of full-field photogrammetry, more specifically three-dimensional Digital Image Correlation (3D-DIC), on the Mars 2020 Heat Shield Structural Failure Review assessment, 3D-DIC was selected as one of the primary measurement techniques for the Mars 2020 Rover wheel assembly qualification test at the NASA Jet Propulsion Laboratory (JPL). To validate the Rover wheel landing loads simulations, it was extremely important to have high confidence in the wheel models. Due to the large deformations and strains that the wheel would be subject to during landing, traditional instrumentation such as linear variable displacement transducers (LVDTs), electrical-resistance strain gages and string potentiometers, would not be sufficient on their own to provide all the necessary validation data. Therefore, the NASA Engineering and Safety Center (NESC) provided the 3D-DIC expertise and support to measure the high deformation and strain in the wheel flexures and qualify the overall structural response of the Mars 2020 rover wheel assembly. There were two key objectives for the photogrammetry technique: (1) monitor the wheel response in real-time, guarding against anomalous behavior and failure, and (2) provide test data for test-analysis correlation to validate and/or improve the high-fidelity computational model. The contents of this paper will focus on the challenges of applying 3D-DIC to the Mars 2020 Rover wheel assembly and how these challenges were overcome. Examples of test-analysis correlation during the stiffness characterization and structural qualification will be presented and discussed in detail. Experimental results were compared with the analysis and showed excellent agreement between the predicted behavior and helped validate the high-fidelity models.

Mars 2020 Rover Wheel↗