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NASA NTRS2017

NASA's Space Launch System: Progress Toward the Proving Ground

With significant and substantial progress being accomplished toward readying the Space Launch System (SLS) rocket for its first test flight, work is already also underway on preparations for the second flight - using an upgraded version of the vehicle - and beyond. SLS is the most powerful human-rated launch vehicle the United States has ever undertaken, and together with the Orion spacecraft will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. This paper will provide a description of the SLS vehicle, and an overview of the vehicle's capabilities and utilization potential.

Jackman, Angie↗
NASA NTRS2012

NASA's Space Launch System Advanced Booster Engineering Demonstration and/or Risk Reduction Efforts

The National Aeronautics and Space Administration (NASA) formally initiated the Space Launch System (SLS) development in September 2011, with the approval of the program s acquisition plan, which engages the current workforce and infrastructure to deliver an initial 70 metric ton (t) SLS capability in 2017, while using planned block upgrades to evolve to a full 130 t capability after 2021. A key component of the acquisition plan is a three-phased approach for the first stage boosters. The first phase is to complete the development of the Ares and Space Shuttle heritage 5-segment solid rocket boosters (SRBs) for initial exploration missions in 2017 and 2021. The second phase in the booster acquisition plan is the Advanced Booster Risk Reduction and/or Engineering Demonstration NASA Research Announcement (NRA), which was recently awarded after a full and open competition. The NRA was released to industry on February 9, 2012, with a stated intent to reduce risks leading to an affordable advanced booster and to enable competition. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the advanced boosters. There are no existing boosters that can meet the performance requirements for the 130 t class SLS. The expected thrust class of the advanced boosters is potentially double the current 5-segment solid rocket booster capability. These new boosters will enable the flexible path approach to space exploration beyond Earth orbit (BEO), opening up vast opportunities including near-Earth asteroids, Lagrange Points, and Mars. This evolved capability offers large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements. NASA developed the Advanced Booster Engineering Demonstration and/or Risk Reduction NRA to seek industry participation in reducing risks leading to an affordable advanced booster that meets the SLS performance requirements. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an advanced booster. This paper will discuss, for the first time publicly, the contract awards and how NASA intends to use the data from these efforts to prepare for the planned advanced booster DDT&E acquisition as the SLS Program moves forward with competitively procured affordable performance enhancements.

Crumbly, Christopher M.↗
NASA NTRS2012

NASA's Space Launch System Advanced Booster Engineering Demonstration and Risk Reduction Efforts

The National Aeronautics and Space Administration (NASA) formally initiated the Space Launch System (SLS) development in September 2011, with the approval of the program s acquisition plan, which engages the current workforce and infrastructure to deliver an initial 70 metric ton (t) SLS capability in 2017, while using planned block upgrades to evolve to a full 130 t capability after 2021. A key component of the acquisition plan is a three-phased approach for the first stage boosters. The first phase is to complete the development of the Ares and Space Shuttle heritage 5-segment solid rocket boosters for initial exploration missions in 2017 and 2021. The second phase in the booster acquisition plan is the Advanced Booster Risk Reduction and/or Engineering Demonstration NASA Research Announcement (NRA), which was recently awarded after a full and open competition. The NRA was released to industry on February 9, 2012, and its stated intent was to reduce risks leading to an affordable Advanced Booster and to enable competition. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the Advanced Boosters. There are no existing boosters that can meet the performance requirements for the 130 t class SLS. The expected thrust class of the Advanced Boosters is potentially double the current 5-segment solid rocket booster capability. These new boosters will enable the flexible path approach to space exploration beyond Earth orbit, opening up vast opportunities including near-Earth asteroids, Lagrange Points, and Mars. This evolved capability offers large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements. NASA developed the Advanced Booster Engineering Demonstration and/or Risk Reduction NRA to seek industry participation in reducing risks leading to an affordable Advanced Booster that meets the SLS performance requirements. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an Advanced Booster. This paper will discuss, for the first time publicly, the contract awards and how NASA intends to use the data from these efforts to prepare for the planned Advanced Booster DDT&E acquisition as the SLS Program moves forward with competitively procured affordable performance enhancements.

Crumbly, Christopher M.↗
NASA NTRSDate not supplied

NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch

The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.

Steve Creech↗
NASA NTRS2014

Space Launch System Base Heating Test: Sub-Scale Rocket Engine/Motor Design, Development and Performance Analysis

The Space Launch System (SLS) base heating test is broken down into two test programs: (1) Pathfinder and (2) Main Test. The Pathfinder Test Program focuses on the design, development, hot-fire test and performance analyses of the 2% sub-scale SLS core-stage and booster element propulsion systems. The core-stage propulsion system is composed of four gaseous oxygen/hydrogen RS-25D model engines and the booster element is composed of two aluminum-based model solid rocket motors (SRMs). The first section of the paper discusses the motivation and test facility specifications for the test program. The second section briefly investigates the internal flow path of the design. The third section briefly shows the performance of the model RS-25D engines and SRMs for the conducted short duration hot-fire tests. Good agreement is observed based on design prediction analysis and test data. This program is a challenging research and development effort that has not been attempted in 40+ years for a NASA vehicle.

Mehta, Manish↗
NASA NTRS2016

Quantification of the Uncertainties for the Space Launch System Liftoff/Transition and Ascent Databases

A detailed description of the uncertainty quantification process for the Space Launch System Block 1 vehicle configuration liftoff/transition and ascent 6-Degree-of-Freedom (DOF) aerodynamic databases is presented. These databases were constructed from wind tunnel test data acquired in the NASA Langley Research Center 14- by 22-Foot Subsonic Wind Tunnel and the Boeing Polysonic Wind Tunnel in St. Louis, MO, respectively. The major sources of error for these databases were experimental error and database modeling errors.

Favaregh, Amber L.↗
NASA NTRS2017

Time Domain Stability Margin Assessment of the NS Space Launch System GN&C Design for Exploration Mission One

The baseline stability margins for NASA's Space Launch System (SLS) launch vehicle were generated via the classical approach of linearizing the system equations of motion and determining the gain and phase margins from the resulting frequency domain model. To improve the fidelity of the classical methods, the linear frequency domain approach can be extended by replacing static, memoryless nonlinearities with describing functions. This technique, however, does not address the time varying nature of the dynamics of a launch vehicle in flight. An alternative technique for the evaluation of the stability of the nonlinear launch vehicle dynamics along its trajectory is to incrementally adjust the gain and/or time delay in the time domain simulation until the system exhibits unstable behavior. This technique has the added benefit of providing a direct comparison between the time domain and frequency domain tools in support of simulation validation.

Clements, Keith↗
NASA NTRS2017

Time Domain Stability Margin Assessment of the NASA Space Launch System GN&C Design for Exploration Mission One

The baseline stability margins for NASA's Space Launch System (SLS) launch vehicle were generated via the classical approach of linearizing the system equations of motion and determining the gain and phase margins from the resulting frequency domain model. To improve the fidelity of the classical methods, the linear frequency domain approach can be extended by replacing static, memoryless nonlinearities with describing functions. This technique, however, does not address the time varying nature of the dynamics of a launch vehicle in flight. An alternative technique for the evaluation of the stability of the nonlinear launch vehicle dynamics along its trajectory is to incrementally adjust the gain and/or time delay in the time domain simulation until the system exhibits unstable behavior. This technique has the added benefit of providing a direct comparison between the time domain and frequency domain tools in support of simulation validation.

Clements, Keith↗
NASA NTRSDate not supplied

Guidance Modifications and Enhancements for Space Launch System Block-1 in Support of Artemis I and Beyond

NASA is currently building the Space Launch System (SLS) Block-1 launch vehicle for the Artemis I test flight. Design of the Artemis II mission, which will use theBlock-1 vehicle to take astronauts around the moon for the first time in decades, is also underway. The Guidance, Navigation, and Controls (GN&C) algorithms will be largely similar for the two missions. However, the extensive simulation and testing campaign for Artemis I has revealed opportunities for improvements in the GN&C algorithms, allowing more effective use of the capabilities of the SLS vehicle, and enhancing safety for the astronauts aboard. This paper will de-scribe several planned algorithm updates for the Artemis II mission. The updates enhance the Powered Explicit Guidance (PEG) algorithm and auxiliary guidance algorithms.

Matt Hawkins↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the NASA Space Launch System (SLS) program. Testing was needed because SLS ascent loads are 35% higher than Space Shuttle loads. Objectives of testing were to determine margins of safety, demonstrate reliability, and validate analytical models. Testing combined with analysis was able to show heritage forward skirts were acceptable to use on the SLS program.

Lohrer, J. D.↗
NASA NTRSDate not supplied

NASA Space Launch System Artemis I & II Post Flight Ascent Aerothermal Environments Overview

Since 2011 the Aerosciences Branch/EV33 at NASA Marshall Space Flight Center has been involved with the development of ascent external aerothermal environments for the NASA Space Launch System (SLS) Block 1 launch vehicle for the purposes of supporting thermal analysis and the design of thermal protection systems. The SLS Block 1 Artemis I and II launch vehicles successfully launched from Pad39B at NASA Kennedy Space Center on November 16th, 2022 and April 1st, 2026, respectively. Over 70 aerothermal islands, consisting of over 265 operational instruments captured aerodynamic heating and plume induced environments throughout the launch vehicles. Gauges consisted of calorimeters, radiometers, gas temperature probes, pressure transducers, bi-directional pressure probes and thermocouples. Prior to launch, aerothermal design environment models were generated to predict ascent aerodynamic heating and plume induced environments over a design space that covered a range of vehicle trajectories that varied atmospheric, vehicle performance, and off-nominal, engine-out conditions. Post flight reconstruction models were developed for each flight island using the Day-of-Launch (DOL) Best Equivalent Trajectory (BET) that provided freestream conditions and propulsion system boundary conditions. This paper discusses a summary of the ascent aerothermal environments observed during the flights and the respective modelling approaches and the performance of them through comparisons of flight data and predictions.

aerothermodynamics↗
NASA NTRSDate not supplied

NASA’s Space Launch System: Comprehensive Test Program Leads to Mission Success during Artemis I Flight Test

NASA’s SLS (Space Launch System) rocket had a successful first launch on Nov. 16, 2022, sending an uncrewed Orion spacecraft to the Moon on the agency’s Artemis I mission. Ten 6U CubeSats were also deployed from SLS during the mission. Orbital insertion parameters, including insertion velocity and altitude, were within hundredths and tenths of a percent from predicted values, corroborating data collected from the individual elements that showed similar performance accuracy. While launch remains the main test – and Artemis I was a true test flight – to collect data, confirm and refine computer models, and validate hardware test data, multiple test programs led up to the first flight and enabled the historic launch. Additionally, SLS was designed from the beginning to be a crew-rated launch vehicle, and teams put the astronauts who will fly on it at the forefront of the development process. This paper and presentation will cover the SLS design and development programs that led to the successful Artemis I mission, and which have set the stage to send the first astronauts back to cislunar space since the Apollo 17 crew in 1972.

John Honeycutt↗
NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.

Michael W Lee↗
NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.

Michael Lee↗
NASA NTRSDate not supplied

Space Launch System (SLS) Human Factors Engineering Modeling & Analysis

The Human Systems Integration & Engineering (HSI&E) team at NASA’s Marshall Space Flight Center (MSFC) strives to advocate for the humans in the loop of Space Launch System’s (SLS) ground operations. Using assessment methods like human simulation, virtual reality, and physical mockups, both flight hardware and ground support equipment (GSE) are evaluated for human integration. Those ranging from 5th percentile female (approximately 5’2” tall) to 95th percentile male (approximately 6’2” tall) should be able to perform all SLS stacking operations. Operations include element physical mates, element electrical mates, and testing activities. The primary human simulation software used is Process Simulate Human (PSH) made by Siemens. This software supplies highly accurate human manikins that can interact with CAD models. PSH was used to evaluate the Transportation and Integration Platform’s (TIP) side opening that was designed for access to the Payload Adapter (PLA) cables. Technicians will need to access these cables for testing purposes before element stacking at Kennedy Space Center (KSC). After performing an analysis in PSH using the TIP side opening, it was found that neither a 5th percentile female or a 95th percentile male could perform the task as the designers had intended. There is a C-beam that blocks access to the cables (both physically and visually). An alternative analysis was performed using PSH to look at another access point to the PLA cables. Although this method would disrupt already established procedures and produce more work, the designers confirmed it was an option. Instead of technicians accessing the cables through the side opening in the TIP, a human simulation was performed for going through a panel opening in the bottom of the TIP. This method requires removal of a TIP panel and a stepladder of at least 36 inches for a 5th percentile female to access the cables.

human factors↗
NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗
NASA NTRS2017

Next-Generation RS-25 Engines for the NASA Space Launch System

The utilization of heritage RS-25 engines, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over 1 million seconds total accumulated hot-fire time. In addition, there were also 16 flight engines and 2 development engines remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway to improve system affordability and eliminate obsolescence concerns. These key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.

Ballard, Richard O.↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗