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NASA NTRS1990

Evaluation of RSRM case hardware fretting concerns

Fretting corrosion was first noted on Shuttle flight STS-26. This flight was the first usage of the Redesigned Solid Rocket Motor (RSRM). The occurrence of fretting has since been observed on both the field and factory joints of the RSRM. Fretting is a form of corrosion that occurs at the interface between contacting, highly loaded, metal surfaces when exposed to slight relative vibratory motions. The engineering effort performed to evaluate the effect of fretting on the RSRM case hardware is summarized. Based on the results of this evaluation, several conclusions were made concerning flight safety. Also, recommendations were made concerning trending the effects of multiple generations of fretting damage.

Swauger, Thomas R.↗

NASA NTRS1992

High-speed civil transport flight- and propulsion-control technological issues

Technology advances required in the flight and propulsion control system disciplines to develop a high speed civil transport (HSCT) are identified. The mission and requirements of the transport and major flight and propulsion control technology issues are discussed. Each issue is ranked and, for each issue, a plan for technology readiness is given. Certain features are unique and dominate control system design. These features include the high temperature environment, large flexible aircraft, control-configured empennage, minimizing control margins, and high availability and excellent maintainability. The failure to resolve most high-priority issues can prevent the transport from achieving its goals. The flow-time for hardware may require stimulus, since market forces may be insufficient to ensure timely production. Flight and propulsion control technology will contribute to takeoff gross weight reduction. Similar technology advances are necessary also to ensure flight safety for the transport. The certification basis of the HSCT must be negotiated between airplane manufacturers and government regulators. Efficient, quality design of the transport will require an integrated set of design tools that support the entire engineering design team.

Ray, J. K.↗

NASA NTRS1991

Nondestructive Structural Damage Detection in Flexible Space Structures Using Vibration Characterization

Spacecraft are susceptible to structural damage over their operating life from impact, environmental loads, and fatigue. Structural damage that is not detected and not corrected may potentially cause more damage and eventually catastrophic structural failure. NASA's current fleet of reusable spacecraft, namely the Space Shuttle, has been flown on several missions. In addition, configurations of future NASA space structures, e.g. Space Station Freedom, are larger and more complex than current structures, making them more susceptible to damage as well as being more difficult to inspect. Consequently, a reliable structural damage detection capability is essential to maintain the flight safety of these structures. Visual inspections alone can not locate impending material failure (fatigue cracks, yielding); it can only observe post-failure situations. An alternative approach is to develop an inspection and monitoring system based on vibration characterization that assesses the integrity of structural and mechanical components. A methodology for detecting structural damage is presented. This methodology is based on utilizing modal test data in conjunction with a correlated analytical model of the structure to: (1) identify the structural dynamic characteristics (resonant frequencies and mode shapes) from measurements of ambient motions and/or force excitation; (2) calculate modal residual force vectors to identify the location of structural damage; and (3) conduct a weighted sensitivity analysis in order to assess the extent of mass and stiffness variations, where structural damage is characterized by stiffness reductions. The approach is unique from other existing approaches in that varying system mass and stiffness, mass center locations, the perturbation of both the natural frequencies and mode shapes, and statistical confidence factors for structural parameters and experimental instrumentation are all accounted for directly.

Ricles, James M.↗

NASA NTRS1992

Cockpit weather information needs

The primary objective is to develop an advanced pilot weather interface for the flight deck and to measure its utilization and effectiveness in pilot reroute decision processes, weather situation awareness, and weather monitoring. Identical graphical weather displays for the dispatcher, air traffic control (ATC), and pilot crew should also enhance the dialogue capabilities for reroute decisions. By utilizing a broadcast data link for surface observations, forecasts, radar summaries, lightning strikes, and weather alerts, onboard weather computing facilities construct graphical displays, historical weather displays, color textual displays, and other tools to assist the pilot crew. Since the weather data is continually being received and stored by the airborne system, the pilot crew has instantaneous access to the latest information. This information is color coded to distinguish degrees of category for surface observations, ceiling and visibilities, and ground radar summaries. Automatic weather monitoring and pilot crew alerting is accomplished by the airborne computing facilities. When a new weather information is received, the displays are instantaneously changed to reflect the new information. Also, when a new surface or special observation for the intended destination is received, the pilot crew is informed so that information can be studied at the pilot's discretion. The pilot crew is also immediately alerted when a severe weather notice, AIRMET or SIGMET, is received. The cockpit weather display shares a multicolor eight inch cathode ray tube and overlaid touch panel with a pilot crew data link interface. Touch sensitive buttons and areas are used for pilot selection of graphical and data link displays. Time critical ATC messages are presented in a small window that overlays other displays so that immediate pilot alerting and action can be taken. Predeparture and reroute clearances are displayed on the graphical weather system so pilot review of weather along the route can be accomplished prior to pilot acceptance of the clearance. An ongoing multiphase test series is planned for testing and modifying the graphical weather system. Preliminary data shows that the nine test subjects considered the graphical presentation to be much better than their current weather information source for situation awareness, flight safety, and reroute decision making.

Scanlon, Charles H.↗

NASA NTRS1969

Aeronautics and Space Report: Highlights 1968

These highlights include the end of the Surveyor Program, planetary studies, Pioneers, Orbiting Geophysical Observatory, sounding rockets, radio astronomy Explorer, Orbiting Astronomical Observatory, Nimbus, lifting bodies, X-15 Program, XB-70, V/TOL, model research, jet noise reduction, flight safety, nuclear engines, Project Apollo (testing and training), and Apollo 5, 6, 7, and 8.

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NASA NTRS1993

Development and use of computational techniques in Army Aviation research and development programs for crash resistant helicopter technology

During the 1960's over 30 full-scale aircraft crash tests were conducted by the Flight Safety Foundation under contract to the Aviation Applied Technology Directorate (AATD) of the U.S. Army Aviation Systems Command (AVSCOM). The purpose of these tests were to conduct crash injury investigations that would provide a basis for the formulation of sound crash resistance design criteria for light fixed-wing and rotary wing aircraft. This resulted in the Crash Survival Design Criteria Designer's Guide which was first published in 1967 and has been revised numerous times, the last being in 1989. Full-scale aircraft crash testing is an expensive way to investigate structural deformations of occupied spaces and to determine the decelerative loadings experienced by occupants in a crash. This gave initial impetus to the U.S. Army to develop analytical methods to predict the dynamic response of aircraft structures in a crash. It was believed that such analytical tools could be very useful in the preliminary design stage of a new helicopter system which is required to demonstrate a level of crash resistance and had to be more cost effective than full-scale crash tests or numerous component design support tests. From an economic point of view, it is more efficient to optimize for the incorporation of crash resistance features early in the design stage. However, during preliminary design it is doubtful if sufficient design details, which influence the exact plastic deformation shape of structural elements, will be available. The availability of simple procedures to predict energy absorption and load-deformation characteristics will allow the designer to initiate valuable cost, weight, and geometry tradeoff studies. The development of these procedures will require some testing of typical specimens. This testing should, as a minimum, verify the validity of proposed procedures for providing pertinent nonlinear load-deformation data. It was hoped that through the use of these analytical models, the designer could optimize aircraft design for crash resistance from both a weight and cost increment standpoint, thus enhancing the acceptance of the design criteria for crash resistance.

Burrows, Leroy T.↗

NASA NTRS1993

Aviation Weather Program (AWP)

The Aviation Weather Program (AWP) combines additional weather observations, improved forecast technology, and more efficient distribution of information to pilots, controllers, and automated systems to improve the weather information provided to the air traffic control system, pilots, and other users of aviation weather information. Specific objectives include the needs to: improve airport and en-route capacity by accurate, high resolution, timely forecasts of changing weather conditions affecting airport and en-route operations; improve analyses and forecasts of upper-level winds for efficient flight planning and traffic management; and increase flight safety through improved aviation weather hazard forecasting (e.g. icing, turbulence, severe storms, microbursts, or strong winds). The AWP would benefit from participation in a cooperative multiscale experiment by obtaining data for: evaluation of aviation weather forecast products, analysis of four dimensional data assimilation schemes, and experimental techniques for retrieving aerosol and other visibility parameters. A multiscale experiment would also be helpful to AWP by making it possible to evaluate the added benefit of enhanced data sets collected during the experiment on those forecast and analysis products. The goals of the Coperative Multiscale Experiment (CME) are an essential step in attaining the long-term AWP objective of providing two-to-four hour location-specific forecasts of significant weather. Although the possibility of a funding role for the AWP in the CME is presently unclear, modest involvement of Federal Aviation Administration (FAA)/AWP personnel could be expected.

Foote, Brant↗

NASA NTRS1994

Hot gas ingestion effects on fuel control surge recovery and AH-1 rotor drive train torque spikes

This report summarizes the work accomplished through computer simulation to understand the impact of the hydromechanical turbine assembly (TA) fuel control on rocket gas ingestion induced engine surges on the AH-1 (Cobra) helicopter. These surges excite the lightly damped torsional modes of the Cobra rotor drive train and can cause overtorqueing of the tail rotor shaft. The simulation studies show that the hydromechanical TA control has a negligible effect on drive train resonances because its response is sufficiently attenuated at the resonant frequencies. However, a digital electronic control working through the TA control's separate, emergency fuel metering system has been identified as a solution to the overtorqueing problem. State-of-the-art software within the electronic control can provide active damping of the rotor drive train to eliminate excessive torque spikes due to any disturbances including engine surges and aggressive helicopter maneuvers. Modifications to the existing TA hydromechanical control are relatively minor, and existing engine sensors can be utilized by the electronic control. Therefore, it is concluded that the combination of full authority digital electronic control (FADEC) with hydromechanical backup using the existing TA control enhances flight safety, improves helicopter performance, reduces pilot workload, and provides a substantial payback for very little investment.

Tokarski, Frank↗

NASA NTRS1994

Challenges for the aircraft structural integrity program

Thirty-six years ago the United States Air Force established the USAF Aircraft Structural Integrity Program (ASIP) because flight safety had been degraded by fatigue failures of operational aircraft. This initial program evolved, but has been stable since the issuance of MIL-STD-1530A in 1975. Today, the program faces new challenges because of a need to maintain aircraft longer in an environment of reduced funding levels. Also, there is increased pressure to reduce cost of the acquisition of new aircraft. It is the purpose of this paper to discuss the challenges for the ASIP and identify the changes in the program that will meet these challenges in the future.

Lincoln, John W.↗

NASA NTRS1995

Atmospheric environmental implications of propulsion systems

Three independent studies have been conducted for assessing the impact of rocket launches on the earth's environment. These studies have addressed issues of acid rain in the troposphere, ozone depletion in the stratosphere, toxicity of chemical rocket exhaust products, and the potential impact on global warming from carbon dioxide emissions from rocket launches. Local, regional, and global impact assessments were examined and compared with both natural sources and anthropogenic sources of known atmospheric pollutants with the following conclusions: (1) Neither solid nor liquid rocket launches have a significant impact on the earth's global environment, and there is no real significant difference between the two. (2) Regional and local atmospheric impacts are more significant than global impacts, but quickly return to normal background conditions within a few hours after launch. And (3) vastly increased space launch activities equivalent to 50 U.S. Space Shuttles or 50 Russian Energia launches per year would not significantly impact these conclusions. However, these assessments, for the most part, are based upon homogeneous gas phase chemistry analysis; heterogeneous chemistry from exhaust particulates, such as aluminum oxide, ice contrails, soot, etc., and the influence of plume temperature and afterburning of fuel-rich exhaust products, need to be further addressed. It was the consensus of these studies that computer modeling of interactive plume chemistry with the atmosphere needs to be improved and computer models need to be verified with experimental data. Rocket exhaust plume chemistry can be modified with propellant reformulation and changes in operating conditions, but, based upon the current state of knowledge, it does not appear that significant environmental improvements from propellant formulation changes can be made or are warranted. Flight safety, reliability, and cost improvements are paramount for any new rocket system, and these important aspects cannot be compromised. A detailed environmental cost-benefit-risk analysis must be conducted before any new chemistry or changes in rocket operating conditions should be seriously considered for any future space or defense applications. This paper presents a summary of the results of environmental assessments contained in these independent studies.

Mcdonald, Allan J.↗

NASA NTRS1993

Efficient decision strategies on the flight deck

Both crew productivity and flight safety depend critically on efficient crew problem solving and decision making. But what constitutes efficient problem solving and decision making behavior? Previous work has focused on crew performance in the context of a specific problem type. The present study differs from these analyses in two respects. First, we describe how aircraft crews cope with different types of problems. And second, we attempt to discern characteristics of optimal task management behavior. For this reason, we contrasted the behavior of more effective and less effective crews. Underlying this approach is the assumption that crews whom commit few operational errors also demonstrate most efficient problem solving and decision making behavior.

Fischer, Ute↗

NASA NTRS1994

The ordnance transfer interrupter: A new type of S & A device

A discussion is given in this paper of a new approach to the Safing and Arming of aerospace ordnance systems interconnected by detonation transfer lines, in which the conventional type of S&A device normally used for this purpose is replaced by a relatively simple electro-mechanical switching device, referred to as an 'Interrupter.' In this approach the Interrupter, which is interposed in the transfer line between the system initiator and output device, is completely passive in that it contains no pyrotechnic devices or materials. Being passive (therefore, non-initiating), the Interrupter is much less hazardous to handle and install, as well as being significantly less complex and costly than conventional S&A devices containing EED's and explosive leads. Details are presented relative to the design, development and qualification, by PS/EDD, of an ordnance transfer Interrupter intended for use on a commercial launch missile. This device, which is capable of simultaneously 'switching' multiple detonation transfer lines, incorporates a rod-type rotary barrier with independent transverse apertures for each transfer line. Barrier actuation is bi-modal, i.e., the barrier can be driven from safe-to-arm or from arm-to-safe positions by independent electro-mechanical actuators. The Interrupter described also features visual and remote status monitoring provisions and, in common with range-approved conventional S&A devices, a pre-flight safety locking mechanism functioned by a removable safing key.

Greenslade, John T.↗

NASA NTRS1997

Development of the Space Operations Incident Reporting Tool (SOIRT)

The space operations incident reporting tool (SOIRT) is an instrument used to record information about an anomaly occurring during flight which may have been due to insufficient and/or inappropriate application of human factors knowledge. We originally developed the SOIRT form after researching other incident reporting systems of this type. We modified the form after performing several in-house reviews and a pilot test to access usability. Finally, crew members from Space Shuttle flights participated in a usability test of the tool after their missions. Since the National Aeronautics and Space Administration (NASA) currently has no system for continuous collection of this type of information, the SOIRT was developed to report issues such as reach envelope constraints, control operation difficulties, and vision impairments. However, if the SOIRT were to become a formal NASA process, information from crew members could be collected in a database and made available to individuals responsible for improving in-flight safety and productivity. Potential benefits include documentation to justify the redesign or development of new equipment/systems, provide the mission planners with a method for identifying past incidents, justify the development of timelines and mission scenarios, and require the creation of more appropriate work/rest cycles.

Minton, Jacquie↗

NASA NTRS1997

Fatigue Reliability of Gas Turbine Engine Structures

The results of an investigation are described for fatigue reliability in engine structures. The description consists of two parts. Part 1 is for method development. Part 2 is a specific case study. In Part 1, the essential concepts and practical approaches to damage tolerance design in the gas turbine industry are summarized. These have evolved over the years in response to flight safety certification requirements. The effect of Non-Destructive Evaluation (NDE) methods on these methods is also reviewed. Assessment methods based on probabilistic fracture mechanics, with regard to both crack initiation and crack growth, are outlined. Limit state modeling techniques from structural reliability theory are shown to be appropriate for application to this problem, for both individual failure mode and system-level assessment. In Part 2, the results of a case study for the high pressure turbine of a turboprop engine are described. The response surface approach is used to construct a fatigue performance function. This performance function is used with the First Order Reliability Method (FORM) to determine the probability of failure and the sensitivity of the fatigue life to the engine parameters for the first stage disk rim of the two stage turbine. A hybrid combination of regression and Monte Carlo simulation is to use incorporate time dependent random variables. System reliability is used to determine the system probability of failure, and the sensitivity of the system fatigue life to the engine parameters of the high pressure turbine. 'ne variation in the primary hot gas and secondary cooling air, the uncertainty of the complex mission loading, and the scatter in the material data are considered.

Cruse, Thomas A.↗

NASA NTRS1999

Propellant Feed System Leak Detection: Lessons Learned From the Linear Aerospike SR-71 Experiment (LASRE)

This paper presents pertinent results and assessment of propellant feed system leak detection as applied to the Linear Aerospike SR-71 Experiment (LASRE) program flown at the NASA Dryden Flight Research Center, Edwards, California. The LASRE was a flight test of an aerospike rocket engine using liquid oxygen and high-pressure gaseous hydrogen as propellants. The flight safety of the crew and the experiment demanded proven technologies and techniques that could detect leaks and assess the integrity of hazardous propellant feed systems. Point source detection and systematic detection were used. Point source detection was adequate for catching gross leakage from components of the propellant feed systems, but insufficient for clearing LASRE to levels of acceptability. Systematic detection, which used high-resolution instrumentation to evaluate the health of the system within a closed volume, provided a better means for assessing leak hazards. Oxygen sensors detected a leak rate of approximately 0.04 cubic inches per second of liquid oxygen. Pressure sensor data revealed speculated cryogenic boiloff through the fittings of the oxygen system, but location of the source(s) was indeterminable. Ultimately, LASRE was cancelled because leak detection techniques were unable to verify that oxygen levels could be maintained below flammability limits.

Hass, Neal↗

NASA NTRS2000

Development and Implementation of Real-Time Information Delivery Systems for Emergency Management

The disaster management community has an on-going need for real-time data and information, especially during catastrophic events. Currently, twin engine or jet aircraft with limited altitude and duration capabilities collect much of the data. Flight safety is also an issue. Clearly, much of the needed data could be delivered via over-the-horizon transfer through a uninhabited aerial vehicles (UAV) platform to mission managers at various locations on the ground. In fact, because of the ability to stay aloft for long periods of time, and to fly above dangerous situations, UAV's are ideally suited for disaster missions. There are numerous situations that can be considered disastrous for the human population. Some, such as fire or flood, can continue over a period of days. Disaster management officials rely on data from the site to respond in an optimum way with warnings, evacuations, rescue, relief, and to the extent possible, damage control. Although different types of disasters call for different types of response, most situations can be improved by having visual images and other remotely sensed data available. "Disaster Management" is actually made up of a number of activities, including: - Disaster Prevention and Mitigation - Emergency Response Planning - Disaster Management (real-time deployment of resources, during an event) - Disaster / Risk Modeling All of these activities could benefit from real-time information, but a major focus for UAV-based technology is in real-time deployment of resources (i.e., emergency response teams), based on changing conditions at the location of the event. With all these potential benefits, it is desirable to demonstrate to user agencies the ability to perform disaster management missions as described. The following demonstration project is the first in a program designed to prove the feasibility of supporting disaster missions with UAV technology and suitable communications packages on-board. A several-year program is envisioned, in which a broad range of disaster-related activities are demonstrated to the appropriate user communities.

Wegener, Steve↗

NASA NTRS2001

Survey of Advanced Booster Options for Potential Shuttle Derivative Vehicles

A never-ending major goal for the Space Shuttle program is to continually improve flight safety, as long as this launch system remains in operational service. One of the options to improve system safety and to enhance vehicle performance as well, that has been seriously studied over the past several decades, is to replace the existing strap-on four segment solid rocket boosters (SRB's) with more capable units. A number of booster upgrade options have been studied in some detail, ranging from five segment solids through hybrids and a wide variety of liquid strap-ons (both pressure and pump fed with various propellants); all the way to a completely reusable liquid fly back booster (complete with air breathing engines for controlled landing and return). All of these possibilities appear to offer improvements in varying degrees; and each has their strengths and weaknesses from both programmatic and technical points of view. The most beneficial booster upgrade/design, if the shuttle program were to continue long enough to justify the required investment, would be an approach that greatly increased both vehicle and crew safety. This would be accomplished by increasing the minimum range/minimum altitude envelope that would readily allow abort to orbit (ATO), possibly even to zero/zero, and possibly reduce or eliminate the Return to Launch Site (RTLS) and even the Trans Atlantic Landing (TAL) abort mode requirements. This paper will briefly survey and discuss all of the various booster'upgrade options studied previously, and compare their relative attributes. The survey will explicitly discuss, in summary comparative form, options that include: five segment solids; several hybrid possibilities; pressure and/or pump-fed liquids using either LO2/kerosene, H2O/kerosene and LO2/J2, any of which could be either fully expendable, partly or fully reusable; and finally a fully reusable liquid fly back booster system, with a number of propellant and propulsion system options. Performance and configuration comparison illustrations and tables will be included to provide a comprehensive survey for the paper.

Sackheim, Robert L.↗

NASA NTRS2002

Thermal Barrier/Seal for Extreme Temperature Applications

Large solid rocket motors, as found on the Space Shuttle, are fabricated in segments for manufacturing considerations, bolted together, and sealed using conventional Viton O-ring seals. Similarly the nine large solid rocket motor nozzles are assembled from several different segments, bolted together, and sealed at six joint locations using conventional O-ring seals. The 5500 F combustion gases are generally kept a safe distance away from the seals by thick layers of phenolic or rubber insulation. Joint-fill compounds, including RTV (room temperature vulcanized compound) and polysulfide filler, are used to fill the joints in the insulation to prevent a direct flow-path to the O-rings. Normally these two stages of protection are enough to prevent a direct flow-path of the 900-psi hot gases from reaching the temperature-sensitive O-ring seals. However, in the current design 1 out of 15 Space Shuttle solid rocket motors experience hot gas effects on the Joint 6 wiper (sacrificial) O-rings. Also worrisome is the fact that joints have experienced heat effects on materials between the RTV and the O-rings, and in two cases O-rings have experienced heat effects. These conditions lead to extensive reviews of the post-flight conditions as part of the effort to monitor flight safety. We have developed a braided carbon fiber thermal barrier to replace the joint fill compounds in the Space Shuttle solid rocket motor nozzles to reduce the incoming 5500 F combustion gas temperature and permit only cool (approximately 100 F) gas to reach the temperature-sensitive O-ring seals. Implementation of this thermal barrier provides more robust, consistent operation with shorter turn around times between Shuttle launches.

Steinetz, Bruce M.↗