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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Two Phase Technology Development Initiatives

Three promising thermal technology development initiatives, vapor compression thermal control system, electronics cooling, and electrohydrodynamics applications are outlined herein. These technologies will provide thermal engineers with additional tools to meet the thermal challenges presented by increased power densities and reduced architectural options that will be available in future spacecraft. Goddard Space Flight Center and the University of Maryland are fabricating and testing a 'proto- flight' vapor compression based thermal control system for the Ultra Long Duration Balloon (ULDB) Program. The vapor compression system will be capable of transporting approximately 400 W of heat while providing a temperature lift of 60C. The system is constructed of 'commercial off-the-shelf' hardware that is modified to meet the unique environmental requirements of the ULDB. A demonstration flight is planned for 1999 or early 2000. Goddard Space Flight Center has embarked upon a multi-discipline effort to address a number of design issues regarding spacecraft electronics. The program addressed the high priority design issues concerning the total mass of standard spacecraft electronics enclosures and the impact of design changes on thermal performance. This presentation reviews the pertinent results of the Lightweight Electronics Enclosure Program. Electronics cooling is a growing challenge to thermal engineers due to increasing power densities and spacecraft architecture. The space-flight qualification program and preliminary results of thermal performance tests of copper-water heat pipes are presented. Electrohydrodynamics (EHD) is an emerging technology that uses the secondary forces that result from the application of an electric field to a flowing fluid to enhance heat transfer and manage fluid flow. A brief review of current EHD capabilities regarding heat transfer enhancement of commercial heat exchangers and capillary pumped loops is presented. Goddard Space Flight Center research efforts applying this technique to fluid management and fluid pumping are discussed.

Didion, Jeffrey R.↗
NASA NTRS2008

A Flexible Evolvable Architecture for Constellation Mission Systems User Applications

While simulating a complex set of repair tasks to be performed by EVA crewmembers on an upcoming mission, flight controllers and astronauts determine that the repair will take much longer than originally anticipated. All equipment in the vicinity of the worksite must be powered off to maintain a safe environment for the astronauts. Because heater power will be unavailable, several critical components will now be at risk of freezing and permanent damage. If an impending thermal violation is detected, Mission Control will have very limited time to react. Therefore, flight controllers must not only modify their procedures to account for these risks, they must also incorporate into their displays outputs from thermal models, alternate temperature measurements, new alarm limits, and emergency power-on commands to enable the detection and response to freezing conditions. Current software for mission control systems makes scenarios like this difficult to address. Given the time frame for modifying software, operations teams are left with labor-intensive operational workarounds as their only options. NASA Ames Research Center (ARC) and NASA Johnson Space Center (JSC) are collaborating on the development of a flexible software system for mission operations that will enable greater user flexibility than has been available to date. Using composable software, end users in the scenario described above could recompose procedures and command and control displays to allow flight controllers to monitor temperature measurements, identify time-critical conditions, and execute the procedures required to respond to these conditions before flight hardware is permanently damaged.

Trimble, Jay P.↗
NASA NTRS2014

Launch Control System Message Reduction

System Monitoring and Control (SMC) message browsers receive many messages daily that operators do not need to see. My job is to reduce the number of messages so that warning and emergency messages can be seen easily and therefore, responded to promptly. There are two methods to reduce messages: duplicate and state-based message correlations. With duplicate message correlation, SMC display the message the first time it shows up. The next times it occurs, a duplicate number will count the number of times the message appears. State-based message correlation is a process in which more informative messages acknowledge less useful ones and send them to history. I also work on correcting the severity level and text formats of messages. I follow two SMC message filtering tenets as I'm working on this project. Firstly, before filtering an offending message, a non-conformance (NC) must be created in order to attempt fixing that message through hardware or software. Only after the NC assessment states that it cannot fix an offending message, it can be filtered by SMC. Secondly, per Launch Control System (LCS) Coding Standards, SMC does not send information messages to the active message browser unless it's a response to an operator action.

correlation↗
NASA NTRS2011

Design, Development and Test Challenges: Separation Mechanisms for the Orion Pad Abort-1 Flight Test

On May 6, 2010, NASA launched the first successful integrated flight test, Pad Abort-1, of the Orion Project from the White Sands Missile Range in Las Cruces, New Mexico. This test demonstrated the ability to perform an emergency pad abort of a full-scale 4.8 m diameter, 8200 kg crew capsule. During development of the critical separation mechanisms for this flight test, various challenges were overcome related to environments definition, installation complications, separation joint retraction speed, thruster ordnance development issues, load path validation and significant design loads increases. The Launch Abort System retention and release (LAS R&R) mechanism consisted of 6 discrete structural connections between the LAS and the crew module (CM) simulator, each of which had a preloaded tension tie, Superbolt torque-nut and frangible nut. During the flight test, the frangible nuts were pyrotechnically split, permitting the CM to separate from the LAS. The LAS separation event was the driving case in the shock environment for many co-located hardware items. During development testing, it was necessary to measure the source shock during the separation event so the predicted shock environment could be validated and used for certification testing of multiple hardware items. The Lockheed Martin test team measured the source separation shock due to the LAS R&R function, which dramatically decreased the predicted environment by 90% at 100 Hz. During development testing a hydraulic tensioner was used to preload the joint; however, the joint relaxation with the tensioner proved unsatisfactory so the design was modified to include a Superbolt torque-nut. The observed preload creep during lab testing was 4% after 30 days, with 2.5% occurring in the first 24 hours. The conversion of strain energy (preload) to kinetic energy (retraction) was measured to be 50-75%. Design features and careful monitoring of multiple strain gauges on each tension tie allowed a pure tensile load to be applied after stacking at the launch pad. Following installation, preload in each joint was monitored for 24 hours. Due to unforeseen complications and the influence of temperature on the portable data acquisition system, the team encountered difficulty in tracking the joint relaxation. In some cases, bond-line failure of the strain gauges occurred.

Dinsel, Alison↗
NASA NTRS2018

High Performance Space Computing with System-on-Chip Instrument Avionics for Space-based Next Generation Imaging Spectrometers (NGIS).

The emergent technology of system-on-chip (SoC) devices promises lighter, smaller, cheaper, and more capable and reliable space electronic systems that could help to unveil some of the most treasured secrets in our universe. This technology is an improvement over the technology that is currently used in space applications, which lags behind stateof-the-art commercial-off-the-shelf (COTS) equipment by several generations. SoC technology integrates all computational power required by next-generation space exploration science instruments onto a single chip. This presentation will describe a Xilinx Zynq-based data acquisition, cloud-screening and compression computing system that has been developed at the Jet Propulsion Laboratory (JPL) for JPL’s Next Generation Imaging Spectrometers (NGIS). The Xilinx Zynq-based Alpha Data hardware assembly fits into a 120mm by 190m by 40mm assembly and uses 9 watts at peak performance. The computing element is a Xilinx Zynq Z7045Q which includes a Kintex-7 FPGA (equivalent to 3 RAD Virtex5 FPGAs in terms of logic cell resources) and dual-core ARM Cortex-A9 Processors (equivalent to 10 RAD750 Power PCs in term of processing capability).

Smith, Adam↗
NASA NTRS2018

High Performance Space Computing with System-on-Chip Instrument Avionics for Space-based Next Generation Imaging Spectrometers (NGIS).

The emergent technology of system-on-chip (SoC) devices promises lighter, smaller, cheaper, and more capable and reliable space electronic systems that could help to unveil some of the most treasured secrets in our universe. This technology is an improvement over the technology that is currently used in space applications, which lags behind state-of-the-art commercial-off-the-shelf (COTS) equipment by several generations. SoC technology integrates all computational power required by next-generation space exploration science instruments onto a single chip. This presentation will describe a Xilinx Zynq-based data acquisition, cloud-screening and compression computing system that has been developed at the Jet Propulsion Laboratory (JPL) for JPL’s Next Generation Imaging Spectrometers (NGIS). The Xilinx Zynq-based Alpha Data hardware assembly fits into a 120mm by 190m by 40mm assembly and uses 9 watts at peak performance. The computing element is a Xilinx Zynq Z7045Q which includes a Kintex-7 FPGA (equivalent to 3 RAD Virtex5 FPGAs in terms of logic cell resources) and dual-core ARM Cortex-A9 Processors (equivalent to 10 RAD750 Power PCs in term of processing capability).

Dolinar, Sam↗
NASA NTRS2019

High performance space computing with system-on-chip instrument avionics for space-based Next Generation Imaging Spectrometers (NGIS)

The emergent technology of system-on-chip (SoC) devices promises lighter, smaller, cheaper, and more capable and reliable space electronic systems that could help to unveil some of the most treasured secrets in our universe. This technology is an improvement over the technology that is currently used in space applications, which lags behind state-of-the-art commercial-off-the-shelf (COTS) equipment by several generations. SoC technology integrates all computational power required by next-generation space exploration science instruments onto a single chip. This presentation will describe a Xilinx Zynq-based data acquisition, cloud-screening and compression computing system that has been developed at the Jet Propulsion Laboratory (JPL) for JPL’s Next Generation Imaging Spectrometers (NGIS). The Xilinx Zynq-based Alpha Data hardware assembly fits into a 120mm by 190m by 40mm assembly and uses 9 watts at peak performance. The computing element is a Xilinx Zynq Z7045Q which includes a Kintex-7 FPGA (equivalent to 3 RAD Virtex5 FPGAs in terms of logic cell resources) and dual-core ARM Cortex-A9 Processors (equivalent to 10 RAD750 Power PCs in term of processing capability).

Dolinar, Sam↗
NASA NTRSDate not supplied

Development of ASCENT Propellant Thrusters and Propulsion Systems

Since the 1960s, hydrazine technology has dominated the market of propulsion technology by providing reliable performance on a wide variety of spacecraft. Efforts to replace hydrazine with a higher-performance and safer alternative have engaged numerous emerging technologies in the industry to mature. ASCENT propellant, also known as AF-M315E, is an example of one such green propellant. Initially developed to provide a safer handling environment than hydrazine, ASCENT offers higher overall performance than a hydrazine equivalent by creating more heat during ignition. The next generation of propulsion technology, based on ASCENT propellant, produces a higher impulse and energy density, expanding the realm of applicable missions from LEO to GEO and beyond. Building on a strong background in small satellite technology and expertise in thermal and oxidation resistant materials, Plasma Processes began several thruster programs for variety of small satellite applications using ASCENT-based technology. Plasma Processes’ background expertise in thermal and oxidation resistant materials provides the necessary foundation to create ASCENT-based technology hardware.

Green Propellant↗
NASA NTRS2018

Thermal Modeling of an Advanced Geared Turbofan for Distributed Engine Control Application

Reliability and life-expectancy of gas turbine engine components is very much correlated to the temperature environment in which they operate. This is no different for control system components, especially those with electronic parts. In recent years, the concept of Distributed Engine Control (DEC) has emerged to address the limitations of the current centralized control implementation. This new approach involves relocating control system components from a relatively benign environment to the harsher thermal environment of the engine casing and its surrounding structures and cavities. In this paper, an approach to modeling the gas turbine thermal environment is described. The modeling approach is applied to a 3rd generation geared turbofan design with a focus on the engine locations where control instrumentation and actuation could be installed. The analysis was conducted with an eye toward component reliability and service life as it relates to the thermal environment. The results were found to be reasonable. Furthermore, the model is shown to execute in real-time within a multi-model simulation environment that demonstrates the capability to interact with hardware to drive test equipment.

Kratz, Jonathan↗
NASA NTRS2015

NASA Near Earth Network (NEN), Deep Space Network (DSN) and Space Network (SN) Support of CubeSat Communications

There has been a historical trend to increase capability and drive down the Size, Weight and Power (SWAP) of satellites and that trend continues today. Small satellites, including systems conforming to the CubeSat specification, because of their low launch and development costs, are enabling new concepts and capabilities for science investigations across multiple fields of interest to NASA. NASA scientists and engineers across many of NASAs Mission Directorates and Centers are developing exciting CubeSat concepts and welcome potential partnerships for CubeSat endeavors. From a communications and tracking point of view, small satellites including CubeSats are a challenge to coordinate because of existing small spacecraft constraints, such as limited SWAP and attitude control, low power, and the potential for high numbers of operational spacecraft. The NASA Space Communications and Navigation (SCaN) Programs Near Earth Network (NEN), Deep Space Network (DSN) and the Space Network (SN) are customer driven organizations that provide comprehensive communications services for space assets including data transport between a missions orbiting satellite and its Mission Operations Center (MOC). The NASA NEN consists of multiple ground antennas. The SN consists of a constellation of geosynchronous (Earth orbiting) relay satellites, named the Tracking and Data Relay Satellite System (TDRSS). The DSN currently makes available 13 antennas at its three tracking stations located around the world for interplanetary communication. The presentation will analyze how well these space communication networks are positioned to support the emerging small satellite and CubeSat market. Recognizing the potential support, the presentation will review the basic capabilities of the NEN, DSN and SN in the context of small satellites and will present information about NEN, DSN and SN-compatible flight radios and antenna development activities at the Goddard Space Flight Center (GSFC) and across industry. The presentation will review concepts on how the SN multiple access capability could help locate CubeSats and provide a low-latency early warning system. The presentation will also present how the DSN is evolving to maximize use of its assets for interplanetary CubeSats. The critical spectrum-related topics of available and appropriate frequency bands, licensing, and coordination will be reviewed. Other key considerations, such as standardization of radio frequency interfaces and flight and ground communications hardware systems, will be addressed as such standardization may reduce the amount of time and cost required to obtain frequency authorization and perform compatibility and end-to-end testing. Examples of standardization that exist today are the NASA NEN, DSN and SN systems which have published users guides and defined frequency bands for high data rate communication, as well as conformance to CCSDS standards. The workshop session will also seek input from the workshop participants to better understand the needs of small satellite systems and to identify key development activities and operational approaches necessary to enhance communication and navigation support using NASA's NEN, DSN and SN.

Telecommunication↗
NASA NTRS1992

Advanced Technology Blade testing on the XV-15 Tilt Rotor Research Aircraft

The XV-15 Tilt Rotor Research Aircraft has just completed the first series of flight tests with the Advanced Technology Blade (ATB) rotor system. The ATB are designed specifically for flight research and provide the ability to alter blade sweep and tip shape. A number of problems were encountered from first installation through envelope expansion to airplane mode flight that required innovative solutions to establish a suitable flight envelope. Prior to operation, the blade retention hardware had to be requalified to a higher rated centrifugal load, because the blade weight was higher than expected. Early flights in the helicopter mode revealed unacceptably high vibratory control system loads which required a temporary modification of the rotor controls to achieve higher speed flight and conversion to airplane mode. The airspeed in airplane mode was limited, however, because of large static control loads. Furthermore, analyses based on refined ATB blade mass and inertia properties indicated a previously unknown high-speed blade mode instability, also requiring airplane-mode maximum airspeed to be restricted. Most recently, a structural failure of an ATB cuff (root fairing) assembly retention structure required a redesign of the assembly. All problems have been addressed and satisfactory solutions have been found to allow continued productive flight research of the emerging tilt rotor concept.

Wellman, Brent↗
NASA NTRSDate not supplied

Predicting the Microgravity Performance of Terrestrial Portable Fire Extinguishers

Portable fire extinguishers (PFEs) are a key component of spacecraft emergency response systems. The International Space Station uses custom PFEs to meet the unique microgravity and enclosed space requirements of the vehicle. For future crewed missions to Low Earth Orbit and Deep Space destinations, terrestrial commercial off-the-shelf (COTS) PFEs may offer more economical solutions for the destination as well as the visiting vehicle. However, depending on the design of both the spacecraft and the PFE, the reduced gravity environment is likely to impact PFE performance, especially when multiphase microgravity liquid transport processes are present. Additionally, many terrestrial PFEs now use halocarbons as the suppressant. While studies show these are effective in certain terrestrial fires, some data suggest that low concentrations may actually exacerbate a fire, a phenomenon that would prove particularly concerning in spacecraft. To better characterize the potential of employing COTS hardware, two terrestrial PFEs, one charged with HFC-227ea and Nitrogen pressurant and one charged with carbon dioxide, were modeled to predict performance in both 1-g and microgravity environments. Testing was conducted in 1-g to validate the model. Testing was also conducted to evaluate the effect of sub-extinguishment HFC-227ea concentrations on burn rate in controlled samples. Here we provide a detailed description of the model, report the methods and results of PFE testing, discuss the predicted effects of microgravity on PFE performance, and report the results of material burn rates at sub-extinguishment levels of HFC-227ea.

Morgan B Abney↗
NASA NTRS2005

Structural Analysis Made 'NESSUSary'

Everywhere you look, chances are something that was designed and tested by a computer will be in plain view. Computers are now utilized to design and test just about everything imaginable, from automobiles and airplanes to bridges and boats, and elevators and escalators to streets and skyscrapers. Computer-design engineering first emerged in the 1970s, in the automobile and aerospace industries. Since computers were in their infancy, however, architects and engineers during the time were limited to producing only designs similar to hand-drafted drawings. (At the end of 1970s, a typical computer-aided design system was a 16-bit minicomputer with a price tag of $125,000.) Eventually, computers became more affordable and related software became more sophisticated, offering designers the "bells and whistles" to go beyond the limits of basic drafting and rendering, and venture into more skillful applications. One of the major advancements was the ability to test the objects being designed for the probability of failure. This advancement was especially important for the aerospace industry, where complicated and expensive structures are designed. The ability to perform reliability and risk assessment without using extensive hardware testing is critical to design and certification. In 1984, NASA initiated the Probabilistic Structural Analysis Methods (PSAM) project at Glenn Research Center to develop analysis methods and computer programs for the probabilistic structural analysis of select engine components for current Space Shuttle and future space propulsion systems. NASA envisioned that these methods and computational tools would play a critical role in establishing increased system performance and durability, and assist in structural system qualification and certification. Not only was the PSAM project beneficial to aerospace, it paved the way for a commercial risk- probability tool that is evaluating risks in diverse, down- to-Earth application

Source record↗
NASA NTRS2016

An Efficient Approach for Mars Sample Return Using Emerging Commercial Capabilities

Mars Sample Return is the highest priority science mission for the next decade as recommended by the 2011 Decadal Survey of Planetary Science. This article presents the results of a feasibility study for a Mars Sample Return mission that efficiently uses emerging commercial capabilities expected to be available in the near future. The motivation of our study was the recognition that emerging commercial capabilities might be used to perform Mars Sample Return with an Earth-direct architecture, and that this may offer a desirable simpler and lower cost approach. The objective of the study was to determine whether these capabilities can be used to optimize the number of mission systems and launches required to return the samples, with the goal of achieving the desired simplicity. All of the major element required for the Mars Sample Return mission are described. Mission system elements were analyzed with either direct techniques or by using parametric mass estimating relationships. The analysis shows the feasibility of a complete and closed Mars Sample Return mission design based on the following scenario: A SpaceX Falcon Heavy launch vehicle places a modified version of a SpaceX Dragon capsule, referred to as "Red Dragon", onto a Trans Mars Injection trajectory. The capsule carries all the hardware needed to return to Earth Orbit samples collected by a prior mission, such as the planned NASA Mars 2020 sample collection rover. The payload includes a fully fueled Mars Ascent Vehicle; a fueled Earth Return Vehicle, support equipment, and a mechanism to transfer samples from the sample cache system onboard the rover to the Earth Return Vehicle. The Red Dragon descends to land on the surface of Mars using Supersonic Retropropulsion. After collected samples are transferred to the Earth Return Vehicle, the single-stage Mars Ascent Vehicle launches the Earth Return Vehicle from the surface of Mars to a Mars phasing orbit. After a brief phasing period, the Earth Return Vehicle performs a Trans Earth Injection burn. Once near Earth, the Earth Return Vehicle performs Earth and lunar swing-bys and is placed into a Lunar Trailing Orbit - an Earth orbit, at lunar distance. A retrieval mission then performs a rendezvous with the Earth Return Vehicle, retrieves the sample container, and breaks the chain of contact with Mars by transferring the sample into a sterile and secure container. With the sample contained, the retrieving spacecraft makes a controlled Earth re-entry preventing any unintended release of Martian materials into the Earth's biosphere. The mission can start in any one of three Earth to Mars launch opportunities, beginning in 2022.

Commercial↗
NASA NTRS2016

Ka-band Technologies for Small Spacecraft Communications via Relays and Direct Data Downlink

As the scientific capabilities and number of small spacecraft missions in the near Earth region increase, standard yet configurable user spacecraft terminals operating in Ka-band are needed to lower mission cost and risk and enable significantly higher data return than current UHF or S-band terminals. These compact Ka-band terminals are intended to operate with both the current and next generation of Ka-band relay satellites and via direct data communications with near Earth tracking terminals. This presentation provides an overview of emerging NASA-sponsored and commercially provided technologies in software defined radios (SDRs), transceivers, and electronically steered antennas that will enable data rates from hundreds of kbps to over 1 Gbps and operate in multiple frequency bands (such as S- and X-bands) and expand the use of NASA's common Ka-bands frequencies: 22.55-23.15 GHz for forward data or uplink; and 25.5-27.0 GHz for return data or downlink. Reductions in mass, power and volume come from integration of multiple radio functions, operations in Ka-band, high efficiency amplifiers and receivers, and compact, flat and vibration free electronically steered narrow beam antennas for up to + 60 degrees field of regard. The software defined near Earth space transceiver (SD-NEST) described in the presentation is intended to be compliant with NASA's space telecommunications radio system (STRS) standard for communications waveforms and hardware interoperability.

Extremely High Frequency↗
NASA NTRS2019

Thermal, Avionics, and Power Considerations for Designing a Nuclear Thermal Propulsion Flight Demonstrator

As part of the Appropriations Bill passed by the US Congress in February 2019, NASA was instructed to develop a nuclear thermal propulsion (NTP) flight demonstrator by 2024. [4] In response to this directive, the Advanced Concepts Office (ACO) at Marshall Space Flight Center (MSFC) was tasked with beginning concept studies for the flight demonstration (FD) mission. During the NTP study formulation, two philoso- phies emerged with regards to FD concept design. The first, Flight Demo 1 (FD1), strictly observes the 2024 schedule requirement at the expense of lower engine performance than expected of theoretical NTP engines. The second concept, Flight Demo 2 (FD2), relaxes the schedule requirement to allow for higher engine performance and more traceability to future operational systems. Both the FD1 and FD2 concepts present considerable challenges for subsystem design, specifically in the areas of thermal control, avionics, and power. To guard against undesired graveyard orbits, a requirement to keep the NTP engine and the reaction control system (RCS) separate was put in place. As a result of this requirement, the avionics subsystem must provide separate command and data handling (CDH) and instrumentation for each propulsion system. In-space instrumentation and monitoring of a NTP system has never been done before, necessitating the development of novel strategies and unique hardware. The heating rates produced by the NTP engine are extremely high, leading to difficulties with thermal control. The FD1 concept utilizes high-pressure gaseous hydrogen (GH2), which is largely insensitive to temperature fluctuations. The FD2 concept, however, utilizes cryogenic liquid hydrogen (LH2) which must be kept stable near 20 Kelvin. A high-performance thermal control system (TCS) will be required to ensure all components and subsystems are maintained within their operational temperature ranges. This paper will highlight the thermal, avionics, and power solutions required for the full scope of challenges for a NTP flight demonstrator.

Johnson, W. E.↗
NASA NTRS1999

Deep Space Control Challenges of the New Millennium

The exploration of deep space presents a variety of significant control challenges. Long communication delays coupled with challenging new science objectives require high levels of system autonomy and increasingly demanding pointing and control capabilities. Historically, missions based on the use of a large single spacecraft have been successful and popular since the early days of NASA. However, these large spacecraft missions are currently being displaced by more frequent and more focused missions based on the use of smaller and less expensive spacecraft designs. This trend drives the need to design smart software and good algorithms which together with the miniaturization of control components will improve performance while replacing the heavier and more expensive hardware used in the past. NASA's future space exploration will also include mission types that have never been attempted before, posing significant challenges to the underlying control system. This includes controlled landing on small bodies (e.g., asteroids and comets), sample return missions (where samples are brought back from other planets), robotic exploration of planetary surfaces (e.g., intelligent rovers), high precision formation flying, and deep space optical interferometry, While the control of planetary spacecraft for traditional flyby and orbiter missions are based on well-understood methodologies, control approaches for many future missions will be fundamentally different. This paradigm shift will require completely new control system development approaches, system architectures, and much greater levels of system autonomy to meet expected performance in the presence of significant environmental disturbances, and plant uncertainties. This paper will trace the motivation for these changes and will layout the approach taken to meet the new challenges. Emerging missions will be used to explain and illustrate the need for these changes.

Bayard, David S.↗
NASA NTRS2012

Overview of C/C-SiC Composite Development for the Orion Launch Abort System

Past and present efforts by the authors to further understanding of the ceramic matrix composite (CMC) material used in the valve components of the Orion Launch Abort System (LAS) Attitude Control Motor (ACM) will be presented. The LAS is designed to quickly lift the Orion Crew Exploration Vehicle (CEV) away from its launch vehicle in emergency abort scenarios. The ACM is a solid rocket motor which utilizes eight throttleable nozzles to maintain proper orientation of the CEV during abort operations. Launch abort systems have not been available for use by NASA on manned launches since the last Apollo ]Saturn launch in 1975. The CMC material, carbon-carbon/silicon-carbide (C/C-SiC), is manufactured by Fiber Materials, Inc. and consists of a rigid 4-directional carbon-fiber tow weave reinforced with a mixed carbon plus SiC matrix. Several valve and full system (8-valve) static motor tests have been conducted by the motor vendor. The culmination of these tests was the successful flight test of the Orion LAS Pad Abort One (PA ]1) vehicle on May 6, 2010. Due to the fast pace of the LAS development program, NASA Marshall Space Flight Center assisted the LAS community by performing a series of material and component evaluations using fired hardware from valve and full ]system development motor tests, and from the PA-1 flight ACM motor. Information will be presented on the structure of the C/C-SiC material, as well as the efficacy of various non ]destructive evaluation (NDE) techniques, including but not limited to: radiography, computed tomography, nanofocus computed tomography, and X-ray transmission microscopy. Examinations of the microstructure of the material via scanning electron microscopy and energy dispersive spectroscopy will also be discussed. The findings resulting from the subject effort are assisting the LAS Project in risk assessments and in possible modifications to the final ACM operational design.

Allen, Lee R.↗