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NASA NTRS2011

Readiness for First Crewed Flight

The NASA Engineering and Safety Center (NESC) was requested to develop a generic framework for evaluating whether any given program has sufficiently complete and balanced plans in place to allow crewmembers to fly safely on a human spaceflight system for the first time (i.e., first crewed flight). The NESC assembled a small team which included experts with experience developing robotic and human spaceflight and aviation systems through first crewed test flight and into operational capability. The NESC team conducted a historical review of the steps leading up to the first crewed flights of Mercury through the Space Shuttle. Benchmarking was also conducted with the United States (U.S.) Air Force and U.S. Navy. This report contains documentation of that review.

Schaible, Dawn M.↗

NASA NTRS2011

Autonomous Aerobraking: A Design, Development, and Feasibility Study

Aerobraking has been used four times to decrease the apoapsis of a spacecraft in a captured orbit around a planetary body with a significant atmosphere utilizing atmospheric drag to decelerate the spacecraft. While aerobraking requires minimum fuel, the long time required for aerobraking requires both a large operations staff, and large Deep Space Network resources. A study to automate aerobraking has been sponsored by the NASA Engineering and Safety Center to determine initial feasibility of equipping a spacecraft with the onboard capability for autonomous aerobraking, thus saving millions of dollars incurred by a large aerobraking operations workforce and continuous DSN coverage. This paper describes the need for autonomous aerobraking, the development of the Autonomous Aerobraking Development Software that includes an ephemeris estimator, an atmospheric density estimator, and maneuver calculation, and the plan forward for continuation of this study.

Prince, Jill L. H.↗

NASA NTRS2011

Implementation and Simulation Results using Autonomous Aerobraking Development Software

An Autonomous Aerobraking software system is currently under development with support from the NASA Engineering and Safety Center (NESC) that would move typically ground-based operations functions to onboard an aerobraking spacecraft, reducing mission risk and mission cost. The suite of software that will enable autonomous aerobraking is the Autonomous Aerobraking Development Software (AADS) and consists of an ephemeris model, onboard atmosphere estimator, temperature and loads prediction, and a maneuver calculation. The software calculates the maneuver time, magnitude and direction commands to maintain the spacecraft periapsis parameters within design structural load and/or thermal constraints. The AADS is currently tested in simulations at Mars, with plans to also evaluate feasibility and performance at Venus and Titan.

Maddock, Robert W.↗

NASA NTRS2011

MLAS and LAS: Project Comparison of Lessons Learned

The development of new and safer manned space vehicles is a top priority at NASA. Recently two different approaches of how to accomplish this mission of keeping astronauts safe was successfully demonstrated. With work already underway on an Apollo-like launch abort system for the Orion Crew Exploration Vehicle (CEV), an alternative design concept named the Max Launch Abort System, or MLAS, was developed as a parallel effort. The Orion system, managed by the Constellation office, is based on the design of a single solid launch abort motor in a tower positioned above the capsule. The MLAS design takes a different approach placing the solid launch abort motor underneath the capsule. This effort was led by the NASA Engineering and Safety Center (NESC). Both escape systems were designed with the Ares I Rocket as the launch vehicle and had the same primary requirement to safely propel a crew module away from any emergency event either on the launch pad or during accent. Beyond these two parameters, there was little else in common between the two projects, except that they both concluded in successful launches that will further promote the development of crew launch abort systems. This presentation will compare both projects from the standpoint of technical requirements; program management and flight test objectives and highlight the synergistic lessons learned by two engineers who worked on each program.

Dittemore, Gary↗

NASA NTRS2011

Comparison of Two Recent Launch Abort Platforms

The development of new and safer manned space vehicles is a top priority at NASA. Recently two different approaches of how to accomplish this mission of keeping astronauts safe was successfully demonstrated. With work already underway on an Apollo-like launch abort system for the Orion Crew Exploration Vehicle (CEV), an alternative design concept named the Max Launch Abort System, or MLAS, was developed as a parallel effort. The Orion system, managed by the Constellation office, is based on the design of a single solid launch abort motor in a tower positioned above the capsule. The MLAS design takes a different approach placing the solid launch abort motor underneath the capsule. This effort was led by the NASA Engineering and Safety Center (NESC). Both escape systems were designed with the Ares I Rocket as the launch vehicle and had the same primary requirement to safely propel a crew module away from any emergency event either on the launch pad or during accent. Beyond these two parameters, there was little else in common between the two projects, except that they both concluded in successful launches that will further promote the development of crew launch abort systems. A comparison of these projects from the standpoint of technical requirements; program management and flight test objectives will be done to highlight the synergistic lessons learned by two engineers who worked on each program. This comparison will demonstrate how the scope of the project architecture and management involvement in innovation should be tailored to meet the specific needs of the system under development.

Dittemore, Gary D.↗

NASA NTRS2011

Space Transportation System (STS)-133/External Tank (ET)-137 Intertank (IT) Stringer Cracking Issue and Repair Assessment: Proximate Cause Determination and Material Characterization Study

Several cracks were detected in stringers located beneath the foam on the External Tank (ET) following the launch scrub of Space Transportation System (STS)-133 on November 5, 2010. The stringer material was aluminum-lithium (AL-Li) 2090-T83 fabricated from sheets that were nominally 0.064 inches thick. The mechanical properties of the stringer material were known to vary between different material lots, with the stringers from ET-137 (predominately lots 620853 and 620854) having the highest yield and ultimate stresses. Subsequent testing determined that these same lots also had the lowest fracture toughness properties. The NASA Engineering and Safety Center (NESC) supported the Space Shuttle Program (SSP)-led investigation. The objective of this investigation was to develop a database of test results to provide validation for structural analysis models, independently confirm test results obtained from other investigators, and determine the proximate cause of the anomalous low fracture toughness observed in stringer lots 620853 and 620854. This document contains the outcome of the investigation.

Piascik, Robert S.↗

NASA NTRS2012

Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement. Variables Acceptance Sampling Calculators: Derivations and Verification of Plans

The NASA Engineering and Safety Center was requested to improve on the Best Practices document produced for the NESC assessment, Verification of Probabilistic Requirements for the Constellation Program, by giving a recommended procedure for using acceptance sampling by variables techniques. This recommended procedure would be used as an alternative to the potentially resource-intensive acceptance sampling by attributes method given in the document. This document contains the outcome of the assessment.

Johnson, Kenneth L.↗

NASA NTRS2012

Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement. Variables Acceptance Sampling Calculators: Empirical Testing

The NASA Engineering and Safety Center was requested to improve on the Best Practices document produced for the NESC assessment, Verification of Probabilistic Requirements for the Constellation Program, by giving a recommended procedure for using acceptance sampling by variables techniques as an alternative to the potentially resource-intensive acceptance sampling by attributes method given in the document. In this paper, the results of empirical tests intended to assess the accuracy of acceptance sampling plan calculators implemented for six variable distributions are presented.

Johnson, Kenneth L.↗

NASA NTRS2012

Composite Structures Damage Tolerance Analysis Methodologies

This report presents the results of a literature review as part of the development of composite hardware fracture control guidelines funded by NASA Engineering and Safety Center (NESC) under contract NNL04AA09B. The objectives of the overall development tasks are to provide a broad information and database to the designers, analysts, and testing personnel who are engaged in space flight hardware production.

Chang, James B.↗

NASA NTRS2012

Voluntary Consensus Organization Standards for Nondestructive Evaluation of Thin-Walled Metallic Liners and Composite Overwraps in Composite Overwrapped Pressure Vessels

NASA fracture control requirements outlined in NASA-STD-5009 and NASA-STD-5014 are predicated on the availability and use of sensitive nondestructive evaluation (NDE) methods that can detect and monitor defects, thereby providing data that can be used to predict failure or reduce the risk of failure in fracture critical components. However, in the case of composite materials and components, including composite overwrapped pressure vessels (COPVs), the effect of defects is poorly understood, the NDE methods used to evaluate locate and size defects are typically at lower technical readiness level than analogous NDE methods used for metals, and demonstration studies to verify the probability of detection (POD) are generally lacking or unavailable. These factors together make failure prediction of fracture critical composite materials and components based on size, quantity, or orientation of defects nearly impossible. Also, when inspecting metal liners in as-manufactured COPVs, sensitivity is lost and only the inner surface of the liner is accessible. Also, NDE of COPVs as applied during manufacturing varies significantly from manufacturer to manufacturer and has not yet been standardized. Although requirements exist to perform NDE immediately after manufacturing to establish initial integrity of the parts, procedural detail for NDE of composites is still nonexistent or under development. For example, in practice, only a visual inspection of COPVs is performed during manufacturing and service, leaving in question whether defects of concern, for example, bridging, overwrap winding anomalies, impact damage below visible threshold, out-of-family strain growth, and liner buckling have been adequately detected and monitored. To address these shortcomings, in 2005 the NASA Nondestructive Evaluation Working Group (NNWG) began funding work to develop and adopt standards for nondestructive evaluation of aerospace composites in collaboration with the American Society for Testing and Materials (ASTM) Committee E07 on Nondestructive Testing. Similarly, in 2006 the NASA Engineering and Safety Center (NESC) recommended that nondestructive evaluation methods that can predict composite failure in COPVs should be developed and verified, and integrated into the damage control plan for these vessels

Waller, Jess↗

NASA NTRS2012

Assessment of Microphone Phased Array for Measuring Launch Vehicle Lift-off Acoustics

The specific purpose of the present work was to demonstrate the suitability of a microphone phased array for launch acoustics applications via participation in selected firings of the Ares I Scale Model Acoustics Test. The Ares I Scale Model Acoustics Test is a part of the discontinued Constellation Program Ares I Project, but the basic understanding gained from this test is expected to help development of the Space Launch System vehicles. Correct identification of sources not only improves the predictive ability, but provides guidance for a quieter design of the launch pad and optimization of the water suppression system. This document contains the results of the NASA Engineering and Safety Center assessment.

Garcia, Roberto↗

NASA NTRS2012

Model Calibration Efforts for the International Space Station's Solar Array Mast

The International Space Station (ISS) relies on sixteen solar-voltaic blankets to provide electrical power to the station. Each pair of blankets is supported by a deployable boom called the Folding Articulated Square Truss Mast (FAST Mast). At certain ISS attitudes, the solar arrays can be positioned in such a way that shadowing of either one or three longerons causes an unexpected asymmetric thermal loading that if unchecked can exceed the operational stability limits of the mast. Work in this paper documents part of an independent NASA Engineering and Safety Center effort to assess the existing operational limits. Because of the complexity of the system, the problem is being worked using a building-block progression from components (longerons), to units (single or multiple bays), to assembly (full mast). The paper presents results from efforts to calibrate the longeron components. The work includes experimental testing of two types of longerons (straight and tapered), development of Finite Element (FE) models, development of parameter uncertainty models, and the establishment of a calibration and validation process to demonstrate adequacy of the models. Models in the context of this paper refer to both FE model and probabilistic parameter models. Results from model calibration of the straight longerons show that the model is capable of predicting the mean load, axial strain, and bending strain. For validation, parameter values obtained from calibration of straight longerons are used to validate experimental results for the tapered longerons.

Elliott, Kenny B.↗

NASA NTRS2012

Reacting Multi-Species Gas Capability for USM3D Flow Solver

The USM3D Navier-Stokes flow solver contributed heavily to the NASA Constellation Project (CxP) as a highly productive computational tool for generating the aerodynamic databases for the Ares I and V launch vehicles and Orion launch abort vehicle (LAV). USM3D is currently limited to ideal-gas flows, which are not adequate for modeling the chemistry or temperature effects of hot-gas jet flows. This task was initiated to create an efficient implementation of multi-species gas and equilibrium chemistry into the USM3D code to improve its predictive capabilities for hot jet impingement effects. The goal of this NASA Engineering and Safety Center (NESC) assessment was to implement and validate a simulation capability to handle real-gas effects in the USM3D code. This document contains the outcome of the NESC assessment.

Frink, Neal T.↗

NASA NTRS2013

Composite Crew Module (CCM) Permeability Characterization

In January 2007, the NASA Administrator chartered the NASA Engineering and Safety Center (NESC) to form an Agency team to design and build a composite crew module in 18 months in order to gain hands-on experience in anticipation that future exploration systems may be made of composite materials. One of the conclusions from this Composite Crew Module Primary Structure assessment was that there was a lack of understanding regarding the ability for composite pressure shells to contain consumable gases, which posed a technical risk relative to the use of a metallic design. After the completion of the Composite Crew Module test program, the test article was used in a new program to assess the overall leakage/permeability and identify specific features associated with high leak rates. This document contains the outcome of the leakage assessment.

Kirsch, Michael T.↗

NASA NTRS2013

Thermal Performance Data Services (TPDS)

Initiated as a NASA Engineering and Safety Center (NESC) assessment in 2009, the Thermal Performance Database (TPDB) was a response to the need for a centralized thermal performance data archive. The assessment was renamed Thermal Performance Data Services (TPDS) in 2012; the undertaking has had two fronts of activity: the development of a repository software application and the collection of historical thermal performance data sets from dispersed sources within the thermal performance community. This assessment has delivered a foundational tool on which additional features should be built to increase efficiency, expand the protection of critical Agency investments, and provide new discipline-advancing work opportunities. This report contains the information from the assessment.

French, Richard T.↗

NASA NTRS2013

Independent Assessment of Instrumentation for ISS On-Orbit NDE

International Space Station (ISS) Structural and Mechanical Systems Manager, requested that the NASA Engineering and Safety Center (NESC) provide a quantitative assessment of commercially available nondestructive evaluation (NDE) instruments for potential application to the ISS. This work supports risk mitigation as outlined in the ISS Integrated Risk Management Application (IRMA) Watch Item #4669, which addresses the requirement for structural integrity after an ISS pressure wall leak in the event of a penetration due to micrometeoroid or debris (MMOD) impact. This document contains the outcome of the NESC assessment.

Madaras, Eric I↗

NASA NTRS2013

Probing Aircraft Flight Test Hazard Mitigation for the Alternative Fuel Effects on Contrails & Cruise Emissions (ACCESS) Research Team

The Alternative Fuel Effects on Contrails & Cruise Emissions (ACCESS) Project Integration Manager requested in July 2012 that the NASA Engineering and Safety Center (NESC) form a team to independently assess aircraft structural failure hazards associated with the ACCESS experiment and to identify potential flight test hazard mitigations to ensure flight safety. The ACCESS Project Integration Manager subsequently requested that the assessment scope be focused predominantly on structural failure risks to the aircraft empennage raft empennage.

Kelly, Michael J.↗

NASA NTRS2013

Probing Aircraft Flight Test Hazard Mitigation for the Alternative Fuel Effects on Contrails and Cruise Emissions (ACCESS) Research Team : Appendices - Volume 2

The Alternative Fuel Effects on Contrails and Cruise Emissions (ACCESS) Project Integration Manager requested in July 2012 that the NASA Engineering and Safety Center (NESC) form a team to independently assess aircraft structural failure hazards associated with the ACCESS experiment and to identify potential flight test hazard mitigations to ensure flight safety. The ACCESS Project Integration Manager subsequently requested that the assessment scope be focused predominantly on structural failure risks to the aircraft empennage (horizontal and vertical tail). This report contains the Appendices to Volume I.

Kelly, Michael J.↗