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NASA NTRS2009

Evaluation of Margins of Safety in Brazed Joints

One of the essential steps in assuring reliable performance of high cost critical brazed structures is the assessment of the Margin of Safety (MS) of the brazed joints. In many cases the experimental determination of the failure loads by destructive testing of the brazed assembly is not practical and cost prohibitive. In such cases the evaluation of the MS is performed analytically by comparing the maximum design loads with the allowable ones and incorporating various safety or knock down factors imposed by the customer. Unfortunately, an industry standard methodology for the design and analysis of brazed joints has not been developed. This paper provides an example of an approach that was used to analyze an AlBeMet 162 (38%Be-62%Al) structure brazed with the AWS BAlSi-4 (Al-12%Si) filler metal. A practical and conservative interaction equation combining shear and tensile allowables was developed and validated to evaluate an acceptable (safe) combination of tensile and shear stresses acting in the brazed joint. These allowables are obtained from testing of standard tensile and lap shear brazed specimens. The proposed equation enables the assessment of the load carrying capability of complex brazed joints subjected to multi-axial loading.

Flom, Yury↗

NASA NTRS2005

Space-Based Range Safety and Future Space Range Applications

The National Aeronautics and Space Administration Space-Based Telemetry and Range Safety study is a multiphase project to demonstrate the performance, flexibility and cost savings that can be realized by using space-based assets for the Range Safety (global positioning system metric tracking data, flight termination command and range safety data relay) and Range User (telemetry) functions during vehicle launches and landings. Phase 1 included flight testing S-band Range Safety and Range User hardware in 2003 onboard a high-dynamic aircraft platform at Dryden Flight Research Center (Edwards, California) using the NASA Tracking and Data Relay Satellite System as the communications link. The current effort, Phase 2, includes hardware and packaging upgrades to the S-band Range Safety system and development of a high data rate Ku-band Range User system. The enhanced Phase 2 Range Safety Unit provided real-time video for three days during the historic GlobalFlyer (Scaled Composites, Mojave, California) flight in March, 2005. Additional Phase 2 testing will include a sounding rocket test of the Range Safety system and aircraft flight testing of both systems. Future testing will include a flight test on a launch vehicle platform. This report discusses both Range Safety and Range User developments and testing with emphasis on the Range Safety system. The operational concept of a future space-based range is also discussed.

Whiteman, Donald E.↗

NASA NTRS2008

NASA Battery Working Group - 2007-2008: Battery Task Summary Report

This presentation provides a summary of the 2007-2008 NASA Battery Working Group efforts completed in support of the NASA Engineering Safety Center (NESC). The effort covered a series of pro-active tasks that address the following: Binding Procurements -- guidelines related to requirements for the battery system that should be considered at the time of contract award Wet Life of Ni-H2 Batteries -- issues/strategies for effective storage and impact of long-term storage on performance and life Generic Guidelines for Lithium-ion Safety, Handling and Qualification -- Standardized approaches developed and risk assessments (1) Lithium-ion Performance Assessment -- survey of manufacturers and capabilities to meet mission needs. Guidelines document generated (2) Conditions Required for using Pouch Cells in Aerospace Missions -- focus on corrosion, thermal excursions and long-term performance issues. Document defining requirements to maintain performance and life (3) High Voltage Risk Assessment -- focus on safety and abuse tolerance of battery module assemblies. Recommendations of features required for safe implementation (4) Procedure for Determination of Safe Charge Rates -- evaluation of various cell chemistries and recommendation of safe operating regimes for specific cell designs

Manzo, Michelle↗

NASA NTRSDate not supplied

Capturing Multivariate Time Series Interactions to Detect High‑Risk Instability During Approach

The reduction of aviation safety metrics below target thresholds continue to drive down the number of aviation fatalities and accidents. To meet future safety demands, sustained efforts by aviation agencies promoting safety assurance processes and systems have prompted ongoing research on identifying and mitigating in-flight risks. With the projected increase in passenger load factor and rollout of more autonomous systems into the national airspace, the need to detect high-risk events in-time or ahead-of-time is becoming increasingly crucial. New anomaly detection and precursor identification algorithms will need to scale to different airframes, levels of autonomy, and system complexity. While the pervasiveness of deep learning has resulted in the development of performant anomaly detection methods, these sophisticated models currently suffer from low end-user interpretability. Building off our previous work on identifying adverse events in multivariate flight data during descent, we propose a data-driven approach for detecting in-flight adverse events caused by the complex interplay of flight variables. Our approach utilizes ordinal patterns of important aircraft stability variables (e.g., airspeed and descent rate) to capture multivariate flight dynamics that can be used to predict the onset of unstable approaches, a high-risk adverse event that can occur during approach. Through the use of ordinal patterns, we aim to create more interpretable detection models of in-flight adverse events that can be translated to future autonomous systems without difficulty. Our analysis shows the presence of distinct ordinal pattern distributions that can be used to predict unstable approaches 1 minute ahead of time with an accuracy of 0.69 and a recall of 0.73 and 30 seconds ahead with an accuracy of 0.70 and a recall of 0.86.

Risk detection↗

NASA NTRS2005

Space-Based Range Safety and Future Space Range Applications

The National Aeronautics and Space Administration (NASA) Space-Based Telemetry and Range Safety (STARS) study is a multiphase project to demonstrate the performance, flexibility and cost savings that can be realized by using space-based assets for the Range Safety [global positioning system (GPS) metric tracking data, flight termination command and range safety data relay] and Range User (telemetry) functions during vehicle launches and landings. Phase 1 included flight testing S-band Range Safety and Range User hardware in 2003 onboard a high-dynamic aircraft platform at Dryden Flight Research Center (Edwards, California, USA) using the NASA Tracking and Data Relay Satellite System (TDRSS) as the communications link. The current effort, Phase 2, includes hardware and packaging upgrades to the S-band Range Safety system and development of a high data rate Ku-band Range User system. The enhanced Phase 2 Range Safety Unit (RSU) provided real-time video for three days during the historic Global Flyer (Scaled Composites, Mojave, California, USA) flight in March, 2005. Additional Phase 2 testing will include a sounding rocket test of the Range Safety system and aircraft flight testing of both systems. Future testing will include a flight test on a launch vehicle platform. This paper discusses both Range Safety and Range User developments and testing with emphasis on the Range Safety system. The operational concept of a future space-based range is also discussed.

Whiteman, Donald E.↗

NASA NTRSDate not supplied

Early Assessments of Crew Timelines for the Lunar Surface Habitat

As NASA progresses towards sustained crewed space missions, crew timelines will become increasingly important to achieving mission goals. While it is desirable to spend as much time as possible during crewed space missions on science activities and experiments, there are a large number of activities that crew members must perform each day in order to maintain both crew and vehicle health and safety. The time available for science activities in space is highly dependent on mandatory tasks required for crew and vehicle health and safety. The different crewed activities need to be planned accordingly long before the start of a mission in order to optimize crew time for science. To begin assessing the potential crew time for available for science, an understanding of the requirements to maintain crew and vehicle health and safety is needed. These additional activities may include sleep, exercise, vehicle maintenance, logistics handling, crew personal time, as well as many other tasks. The remaining time outside of these required tasks, within a reasonable crew work schedule, can be dedicated to science operations. This paper will detail a collaborative effort to analyzing crew times for sustained spaceflight missions and how the results of that analysis are applied to the crew timeline for the proposed Lunar Surface Habitat (SH).To determine the crew time for all of these required activities, an analysis was conducted utilizing defined agency requirements and historical crewed mission data. Predicted crew activity times were integrated into a daily schedule in order to optimize the crew’s time during the mission. This methodology was utilized to produce expected crew timelines for NASA’s proposed Artemis Base Camp (ABC) missions. The current plans for the ABC contain two different sustained habitats, the Pressurized Rover (PR) and the Surface Habitat (SH). While the crew are separated between the two habitats, the timelines for each element are dependent on the other element’s operations, so the two element timelines are formed in conjunction with one another. The results described in this paper, however, will focus solely on the crew timeline in the SH. This paper will explain the methodology behind predicting the required crew time spent in the SH for each activity, and the process of incorporating these predicted crew times into a coherent schedule.

Crew Time↗

NASA NTRS1975

Evaluation of the electrochemical O2 concentrator as an O2 compressor

A program was successfully completed to analytically and experimentally evaluate the feasibility of using an electrochemical oxygen (O2) concentrator as an O2 compressor. The electrochemical O2 compressor (EOC) compresses 345 kN/sq m (50 psia) O2 generated on board the space vehicle by the water electrolysis subsystem (WES) in a single stage to 20,700 kN/sq m (3000 psia) to refill spent extravehicular equipment O2 bottles and to eliminate the need for high pressure O2 storage. The single cell EOC designed, fabricated, and used for the feasibility testing is capable of being tested at O2 pressures up to 41,400 kN/sq m (6000 psia). A ground support test facility to test the EOC cell was designed, fabricated, and used for the EOC feasibility testing. A product assurance program was established, implemented, and maintained which emphasized safety and materials compatibility associated with high pressure O2 operation. A membrane development program was conducted to develop a membrane for EOC application. Data obtained using a commercially available membrane were used to guide the development of the membranes fabricated specifically for an EOC. A total of 15 membranes were fabricated.

Marshall, R. D.↗

NASA NTRS1975

A flight simulator control system using electric torque motors

Control systems are required in flight simulators to provide representative stick and rudder pedal characteristics. A system has been developed that uses electric dc torque motors instead of the more common hydraulic actuators. The torque motor system overcomes certain disadvantages of hydraulic systems, such as high cost, high power consumption, noise, oil leaks, and safety problems. A description of the torque motor system is presented, including both electrical and mechanical design as well as performance characteristics. The system develops forces sufficiently high for most simulations, and is physically small and light enough to be used in most motion-base cockpits.

Musick, R. O.↗

NASA NTRS2008

Automated Translation of Safety Critical Application Software Specifications into PLC Ladder Logic

The numerous benefits of automatic application code generation are widely accepted within the software engineering community. A few of these benefits include raising the abstraction level of application programming, shorter product development time, lower maintenance costs, and increased code quality and consistency. Surprisingly, code generation concepts have not yet found wide acceptance and use in the field of programmable logic controller (PLC) software development. Software engineers at the NASA Kennedy Space Center (KSC) recognized the need for PLC code generation while developing their new ground checkout and launch processing system. They developed a process and a prototype software tool that automatically translates a high-level representation or specification of safety critical application software into ladder logic that executes on a PLC. This process and tool are expected to increase the reliability of the PLC code over that which is written manually, and may even lower life-cycle costs and shorten the development schedule of the new control system at KSC. This paper examines the problem domain and discusses the process and software tool that were prototyped by the KSC software engineers.

Leucht, Kurt W.↗

NASA NTRS1984

NASA's approach to flight confidence

NASA's confidence in the flight readiness of aerospace hardware and software is achieved by a thorough integration of safety activities into every program facet, from concept through the mission. This involves technical and administrative personnel, organizations that specify requirements, design, manufacturing, test and the operators. Reviews by inhouse and external specialists form an integral part of the assurance process. Examples of safety issues and their resolution for some power and propulsion functions are given (lithium cells, autoignition/fretting in high pressure oxygen environments, ignition sources from auxiliary power unit, and low thrust rocket engines). Finally, some comments on NASA's integrated safety activities and the Aerospace Safety Advisory Panel's role in the NASA review and assessment process all of which provides added confidence in achieving a high level of mission safety and success.

Roth, G. L.↗

NASA NTRS1995

Aeronautical Satellite Data Link System (SDLS) for high-density air-traffic areas

The European Space Agency has recently commissioned a study to investigate the feasibility of a low-cost aeronautical Satellite Data Link System (SDLS) to provide for the needs of Air Traffic Services, i.e. safety related communications over continental areas with high air-traffic density. This study is placed in today's context which sees the first generation of Aeronautical Mobile Satellite System (AMSS) being gradually but restrictively put into service in oceanic airspaces with low air-traffic density. This paper first discusses the case of ATS dedicated versus mixed (ATS and commercial) Comms service provision and identifies the specific ATS comms requirements context. Specific emphasis is put on the ICAO (International Civil Aviation Organization) standardization framework for both the ATN (Aeronautical Telecommunication Network) and the SSR (Secondary Surveillance Radar) Mode S specific services. An architectural system and network design for a future SDLS is then proposed, such as to meet the ATS comms requirements within the realm of existing technologies. To minimize development risk and cost, consideration is given to re-use the ESA-developed Land Mobile Communication Technology, known as MSBN (Mobile Satellite Business Network) featuring distinct subnetworks. It is particularly suited to an ATM (Air Traffic Management) decentralized architecture made of independent ATC (Air Traffic Control) Centers. Finally the study follow-on phase is introduced, which is intended to cover system design and development leading to a demonstration program, as a first step towards proposals for international standardization and acceptance.

Alain Delrieu↗

NASA NTRS2017

NASA Armstrong Flight Research Center Distributed Electric Propulsion Portfolio, and Safety and Certification Considerations

This presentation is a high level overview of ongoing electric propulsion research programs currently at AFRC.

electric propulsio↗

NASA NTRS1998

Orbital Fluid Transfer System

An automated fluid and power interface system needs to be developed for future space missions which require on orbit consumable replenishment. Current method of fluid transfer require manned vehicles and extravehicular activity. Currently the US does not have an automated capability for consumable transfer on-orbit. This technology would benefit both Space Station and long duration satellites. In order to provide this technology the Automated Fluid Interface System (AFIS) was developed. The AFIS project was an advanced development program aimed at developing a prototype satellite servicer for future space operations. This mechanism could transfer propellants, cryogens, fluids, gasses, electrical power, and communications from a tanker unit to the orbiting satellite. The development of this unit was a cooperative effort between Marshall Space Flight Center in Huntsville, Alabama, and Moog, Inc. in East Aurora, New York. An engineering model was built and underwent substantial development testing at Marshall Space Flight Center (MSFC). While the AFIS is not suitable for spaceflight, testing and evaluation of the AFIS provided significant experience which would be beneficial in building a flight unit. The lessons learned from testing the AFIS provided the foundation for the next generation fluid transfer mechanism, the Orbital Fluid Transfer System (OFTS). The OFTS project was a study contract with MSFC and Moog, Inc. The OFTS was designed for the International Space Station (ISS), but its flexible design could used for long duration satellite missions and other applications. The OFTS was designed to be used after docking. The primary function was to transfer bipropellants and high pressure gases. The other items addressed by this task included propellant storage, hardware integration, safety and control system issues. A new concept for high pressure couplings was also developed. The results of the AFIS testing provided an excellent basis for the OFTS design. The OFTS meet the servicing requirements for ISS and could also provide the automated fluid and power interface system needed for on orbit consumable resupply of spacecraft into the new century.

Johnston, A. S., (Nick)↗

NASA NTRS2007

Ground Support for the Space-Based Range Flight Demonstration 2

The primary objective of the NASA Space-Based Range Demonstration and Certification program was to develop and demonstrate space-based range capabilities. The Flight Demonstration 2 flights at NASA Dryden Flight Research Center were conducted to support Range Safety (commanding and position reporting) and high-rate (5 Mbps) Range User (video and data) requirements. Required ground support infrastructure included a flight termination system computer, the ground-data distribution network to send range safety commands and receive range safety and range user telemetry data and video, and the ground processing systems at the Dryden Mission Control Center to process range safety and range user telemetry data and video.

Burkes, Darryl A.↗

NASA NTRS1972

Survey of space flight safety systems.

Preventive and remedial conceptual approaches may be employed to enhance the safety of space flight operations. The preventive approach makes use of components of high reliability and the incorporation of redundancy in crew safety-related functions. According to the second conceptual approach the means are to be provided to cope with accidents when they arise. The remedial means include onboard systems, pre-positioned aids, and earth-launched systems. Reports or papers dealing with rescue and survival systems of various types are considered, and a summary of the results of space escape, rescue, and survivability investigations is presented.

Fleisig, R.↗

NASA NTRS2005

Advanced Vibration Analysis Tool Developed for Robust Engine Rotor Designs

Min, James B.↗

NASA NTRS1999

Control Design Strategies to Enhance Long-Term Aircraft Structural Integrity

Over the operational lifetime of both military and civil aircraft, structural components are exposed to hundreds of thousands of low-stress repetitive load cycles and less frequent but higher-stress transient loads originating from maneuvering flight and atmospheric gusts. Micro-material imperfections in the structure, such as cracks and debonded laminates, expand and grow in this environment, reducing the structural integrity and shortening the life of the airframe. Extreme costs associated with refurbishment of critical load-bearing structural components in a large fleet, or altogether reinventoring the fleet with newer models, indicate alternative solutions for life extension of the airframe structure are highly desirable. Increased levels of operational safety and reliability are also important factors influencing the desirability of such solutions. One area having significant potential for impacting crack growth/fatigue damage reduction and structural life extension is flight control. To modify the airframe response dynamics arising from command inputs and gust disturbances, feedback loops are routinely applied to vehicles. A dexterous flight control system architecture senses key vehicle motions and generates critical forces/moments at multiple points distributed throughout the airframe to elicit the desired motion characteristics. In principle, these same control loops can be utilized to influence the level of exposure to harmful loads during flight on structural components. Project objectives are to investigate and/or assess the leverage control has on reducing fatigue damage and enhancing long-term structural integrity, without degrading attitude control and trajectory guidance performance levels. In particular, efforts have focused on the effects inner loop control parameters and architectures have on fatigue damage rate. To complete this research, an actively controlled flexible aircraft model and a new state space modeling procedure for crack growth have been utilized. Analysis of the analytical state space model for crack growth revealed the critical mathematical factors, and hence the physical mechanism they represent, that influenced high rates of airframe crack growth. The crack model was then exercised with simple load inputs to uncover and expose key crack growth behavior. To characterize crack growth behavior, both "short-term" laboratory specimen test type inputs and "long-term" operational flight type inputs were considered. Harmonic loading with a single overload revealed typical exponential crack growth behavior until the overload application, after which time the crack growth was retarded for a period of time depending on the overload strength. An optimum overload strength was identified which leads to maximum retardation of crack growth. Harmonic loading with a repeated overload of varying strength and frequency again revealed an optimum overload trait for maximizing growth retardation. The optimum overload strength ratio lies near the range of 2 to 3 with dependency on frequency. Experimental data was found to correlate well with the analytical predictions.

Newman, Brett A.↗

NASA NTRS2004

Reduced-Order Blade Mistuning Analysis Techniques Developed for the Robust Design of Engine Rotors

The primary objective of this research program is to develop vibration analysis tools, design tools, and design strategies to significantly improve the safety and robustness of turbine engine rotors. Bladed disks in turbine engines always feature small, random blade-to-blade differences, or mistuning. Mistuning can lead to a dramatic increase in blade forced-response amplitudes and stresses. Ultimately, this results in high-cycle fatigue, which is a major safety and cost concern. In this research program, the necessary steps will be taken to transform a state-of-the-art vibration analysis tool, the Turbo-Reduce forced-response prediction code, into an effective design tool by enhancing and extending the underlying modeling and analysis methods. Furthermore, novel techniques will be developed to assess the safety of a given design. In particular, a procedure will be established for using eigenfrequency curve veerings to identify "danger zones" in the operating conditions--ranges of rotational speeds and engine orders in which there is a great risk that the rotor blades will suffer high stresses. This work also will aid statistical studies of the forced response by reducing the necessary number of simulations. Finally, new strategies for improving the design of rotors will be pursued. Several methods will be investigated, including the use of intentional mistuning patterns to mitigate the harmful effects of random mistuning, and the modification of disk stiffness to avoid reaching critical values of interblade coupling in the desired operating range. Recent research progress is summarized in the following paragraphs. First, significant progress was made in the development of the component mode mistuning (CMM) and static mode compensation (SMC) methods for reduced-order modeling of mistuned bladed disks (see the following figure). The CMM method has been formalized and extended to allow a general treatment of mistuning. In addition, CMM allows individual mode mistuning, which accounts for the realistic effects of local variations in blade properties that lead to different mistuning values for different mode types (e.g., mistuning of the first torsion mode versus the second flexural mode). The accuracy and efficiency of the CMM method and the corresponding Turbo-Reduce code were validated for an example finite element model of a bladed disk.

Min, James B.↗