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NASA NTRS2006

MSL EDL Entry Guidance using the Entry Terminal Point Controller

The Mars Science Laboratory will be the first Mars mission to attempt a guided entry with the objective of safely delivering the entry vehicle to a survivable parachute deploy state within 10 km of the pre-designated landing site. The Entry Terminal Point Controller guidance algorithm is derived from the final phase Apollo Command Module guidance and, like Apollo, modulates the bank angle to control range based on deviations in range, altitude rate, and drag acceleration from a reference trajectory. For application to Mars landers which must make use of the tenuous Martian atmosphere, it is critical to balance the lift of the vehicle to minimize the range while still ensuring a safe deploy altitude. An overview of the process to generate optimized guidance settings is presented, discussing improvements made over the last four years. Performance tradeoffs between ellipse size and deploy altitude will be presented, along with imposed constraints of entry acceleration and heating. Performance sensitivities to the bank reversal deadbands, heading alignment, attitude initialization error, and atmospheric delivery errors are presented. Guidance settings for contingency operations, such as those appropriate for severe dust storm scenarios, are evaluated.

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NASA NTRS2006

Blunt Body Aerodynamics for Hypersonic Low Density Flows

Numerical simulations are performed for the Apollo capsule from the hypersonic rarefied to the continuum regimes. The focus is on flow conditions similar to those experienced by the Apollo 6 Command Module during the high altitude portion of its reentry. The present focus is to highlight some of the current activities that serve as a precursor for computational tool assessments that will be used to support the development of aerodynamic data bases for future capsule flight environments, particularly those for the Crew Exploration Vehicle (CEV). Results for aerodynamic forces and moments are presented that demonstrate their sensitivity to rarefaction; that is, free molecular to continuum conditions. Also, aerodynamic data are presented that shows their sensitivity to a range of reentry velocities, encompassing conditions that include reentry from low Earth orbit, lunar return, and Mars return velocities (7.7 to 15 km/s). The rarefied results obtained with direct simulation Monte Carlo (DSMC) codes are anchored in the continuum regime with data from Navier-Stokes simulations.

Moss, James N.↗

NASA NTRS2006

Solid Modeling of Crew Exploration Vehicle Structure Concepts for Mass Optimization

Parametric solid and surface models of the crew exploration vehicle (CEV) command module (CM) structure concepts are developed for rapid finite element analyses, structural sizing and estimation of optimal structural mass. The effects of the structural configuration and critical design parameters on the stress distribution are visualized, examined to arrive at an efficient design. The CM structural components consisted of the outer heat shield, inner pressurized crew cabin, ring bulkhead and spars. For this study only the internal cabin pressure load case is considered. Component stress, deflection, margins of safety and mass are used as design goodness criteria. The design scenario is explored by changing the component thickness parameters and materials until an acceptable design is achieved. Aluminum alloy, titanium alloy and an advanced composite material properties are considered for the stress analysis and the results are compared as a part of lessons learned and to build up a structural component sizing knowledge base for the future CEV technology support. This independent structural analysis and the design scenario based optimization process may also facilitate better CM structural definition and rapid prototyping.

Mukhopadhyay, Vivek↗

NASA NTRS2006

Apollo Seals: A Basis for the Crew Exploration Vehicle Seals

The National Aeronautics and Space Administration is currently designing the Crew Exploration Vehicle (CEV) as a replacement for the Space Shuttle for manned missions to the International Space Station, as a command module for returning astronauts to the moon, and as an earth reentry vehicle for the final leg of manned missions to the moon and Mars. The CEV resembles a scaled-up version of the heritage Apollo vehicle; however, the CEV seal requirements are different than those from Apollo because of its different mission requirements. A review is presented of some of the seals used on the Apollo spacecraft for the gap between the heat shield and backshell and for penetrations through the heat shield, docking hatches, windows, and the capsule pressure hull.

Finkbeiner, Joshua R.↗

NASA NTRS2007

Organics in APOLLO Lunar Samples

One of many unknowns prior to the Apollo landings concerned the possibility of life, its remains, or its organic precursors on the surface of the Moon. While the existence of lunar organisms was considered highly unlikely, a program of biological quarantine and testing for the astronauts, the Apollo Command Modules, and the lunar rock and soil samples, was instituted in the Lunar Receiving Laboratory (LRL). No conclusive evidence of lunar organisms, was detected and the quarantine program was ended after Apollo 14. Analyses for organic compounds were also con-ducted. Considerable effort was expended, during lunar surface operations and in the LRL, to minimize and quantify organic contamination. Post-Apollo curatorial operations and cleaning minimize contamination from particulates, oxygen, and water but no longer specifically address organic contamination. The organic compounds measured in Apollo samples are generally consistent with known sources of contamination.

Allen, C. C.↗

NASA NTRS2000

The Mission Transcript Collection: U.S. Human Spaceflight Missions from Mercury Redstone 3 to Apollo 17

Aboard every U.S. piloted spacecraft, from Mercury through Apollo, NASA installed tape recorders that captured nearly every word spoken by the astronauts during their history-making flights into space. For the first time ever, NASA has digitally scanned all of the transcripts made from both the onboard tapes and those tape recordings made on the ground from the air-to-ground transmissions and placed them on this two CD-ROM set. Gathered in this special collection are 80 transcripts totaling nearly 45,000 pages of text that cover every US human spaceflight from the first human Mercury mission through the last lunar landing flight of Apollo 17. Users of this CD will note that the quantity and type of transcripts made for each mission vary. For example, the Mercury flights each had one transcript whereas the Gemini missions produced several. Starting with the Gemini flights, NASA produced a Public Affairs Office (PAO) commentary version, as well as at least one "technical" air-to-ground transcript version, per mission. Most of the Apollo missions produced four transcripts per flight. These included the onboard voice data recorder transcripts made from the Data Storage Equipment (DSE) on the Command Module (CM), and the Data Storage Electronics Assembly (DSEA) onboard the Lunar Module (LM), in addition to the PAO commentary and air-to-ground technical transcripts. The CD set includes an index listing each transcript file by name. Some of the transcripts include a detailed explanation of their contents and how they were made. Also included in this collection is a listing of all the original air-to-ground audiotapes housed in NASA's archives from which many of these transcripts were made. We hope you find this collection of transcripts interesting and useful.

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NASA NTRS2005

Nanostructured Thermal Protection Systems for Space Exploration Missions

Strong research and development programs in nanotechnology and Thermal Protection Systems (TPS) exist at NASA Ames. Conceptual studies have been undertaken to determine if new, nanostructured materials (composites of existing TPS materials and nanostructured composite fibers) could improve the performance of TPS. To this end, we have studied various candidate heatshields, some composed of existing TPS materials (with known material properties), to provide a baseline for comparison with others that are admixtures of such materials and a nanostructured material. In the latter case, some assumptions were made about the thermal conductivity and strength of the admixture, relative to the baseline TPS material. For the purposes of this study, we have made the conservative assumption that only a small fraction of the remarkable properties of carbon nanotubes (for example) will be realized in the material properties of the admixtures employing them. The heatshields studied included those for Sharp leading edges (appropriate to out-of-orbit entry and aero-maneuvering), probes, an out-of-orbit Apollo Command Module (as a surrogate for NASA's new Crew Exploration Vehicle [CEV]), a Mars Sample Return Vehicle and a large heat shield for Mars aerocapture missions. We report on these conceptual studies, which show that in some cases (not all), significant improvements in the TPS can be achieved through the use of nanostructured materials.

Arnold, J. O.↗

NASA NTRS2007

Apollo Seals: A Basis for the Crew Exploration Vehicle Seals

Finkbeiner, Joshua R.↗

NASA NTRS1965

Landing Characteristics of the Apollo Spacecraft with Deployed Heat Shield Impact Attenuation Systems

An experimental investigation was made to determine the landing characteristics of a 1/4-scale dynamic model of the Apollo spacecraft command module using two different active (heat shield deployed prior to landing) landing systems for impact attenuation. One landing system (configuration 1) consisted of six hydraulic struts and eight crushable honeycomb struts. The other landing system (configuration 2), consisted of four hydraulic struts and six strain straps. Tests made on water and the hard clay-gravel composite landing surfaces simulated parachute letdown (vertical) velocities of 23 ft/sec (7.0 m/s) (full scale). Landings made on the sand landing surface simulated vertical velocities of 30 ft/sec (9.1 m/s). Horizontal velocities of from 0 to 50 ft/sec (15 m/s) were simulated. Landing attitudes ranged from -30'degrees to 20 degrees, and the roll attitudes were O degrees, 90 degrees, and 180 degrees. For configuration 1, maximum normal accelerations at the vehicle center of gravity for landings on water, sand, and the hard clay-gravel composite surface were 9g, 20g, and 18g, respectively. The maximum normal center-of-gravity acceleration for configuration 2 which was landed only on the hard clay-gravel landing surface was approximately 19g. Accelerations for configuration 2 were generally equal to or lower than accelerations for configuration 1 and normal.

EXPERIMENTS↗

NASA NTRS1967

Dynamic Model Investigation of Water Pressures and Accelerations Encountered During Landings of the Apollo Spacecraft

An experimental investigation was made to determine impact water pressures, accelerations, and landing dynamics of a 1/4-scale dynamic model of the command module of the Apollo spacecraft. A scaled-stiffness aft heat shield was used on the model to simulate the structural deflections of the full-scale heat shield. Tests were made on water to obtain impact pressure data at a simulated parachute letdown (vertical) velocity component of approximately 30 ft/sec (9.1 m/sec) full scale. Additional tests were made on water, sand, and hard clay-gravel landing surfaces at simulated vertical velocity components of 23 ft/sec (7.0 m/sec) full scale. Horizontal velocity components investigated ranged from 0 to 50 ft/sec (15 m/sec) full scale and the pitch attitudes ranged from -40 degrees to 29 degrees. Roll attitudes were O degrees, 90 degrees, and 180 degrees, and the yaw attitude was 0 degrees.

Tests↗

NASA NTRS2007

2006 NASA Seal/Secondary Air System Workshop; Volume 1

The 2006 NASA Seal/Secondary Air System workshop covered the following topics: (i) Overview of NASA s new Exploration Initiative program aimed at exploring the Moon, Mars, and beyond; (ii) Overview of NASA s new fundamental aeronautics technology project; (iii) Overview of NASA Glenn Research Center s seal project aimed at developing advanced seals for NASA s turbomachinery, space, and reentry vehicle needs; (iv) Reviews of NASA prime contractor, vendor, and university advanced sealing concepts including tip clearance control, test results, experimental facilities, and numerical predictions; and (v) Reviews of material development programs relevant to advanced seals development. Turbine engine studies have shown that reducing seal leakages as well as high-pressure turbine (HPT) blade tip clearances will reduce fuel burn, lower emissions, retain exhaust gas temperature margin, and increase range. Several organizations presented development efforts aimed at developing faster clearance control systems and associated technology to meet future engine needs. The workshop also covered several programs NASA is funding to develop technologies for the Exploration Initiative and advanced reusable space vehicle technologies. NASA plans on developing an advanced docking and berthing system that would permit any vehicle to dock to any on-orbit station or vehicle. Seal technical challenges (including space environments, temperature variation, and seal-on-seal operation) as well as plans to develop the necessary "androgynous" seal technologies were reviewed. Researchers also reviewed seal technologies employed by the Apollo command module that serve as an excellent basis for seals for NASA s new Crew Exploration Vehicle (CEV).

Steinetz, Bruce, M.↗

NASA NTRS2008

Visualization of Flowfield Modification by RCS Jets on a Capsule Entry Vehicle

Nitric oxide planar laser-induced fluorescence (NO PLIF) has been used to visualize the flow on the aft-body of an entry capsule having an activated RCS jet in NASA Langley Research Center's 31-Inch Mach 10 wind tunnel facility. A capsule shape representative of the Apollo command module was tested. These tests were performed to demonstrate the ability of the PLIF method to visualize RCS jet flow while providing some preliminary input to NASA's Orion Vehicle design team. Two different RCS nozzle designs - conical and contoured - were tested. The conical and contoured nozzles had area ratios of 13.4 and 22.5 respectively. The conical nozzle had a half-angle of 10 . Low- and high-Reynolds number cases were investigated by changing the tunnel stagnation pressure from 350 psi to 1300 psi, resulting in freestream Reynolds numbers of 0.56 and 1.8 million per foot respectively. For both of these cases, three different jet plenum pressures were tested (nominally 56, 250 and 500 psi). A single angle-of-attack was investigated (24 degrees). NO PLIF uses an ultraviolet laser sheet to interrogate a slice in the flow containing seeded NO; this UV light excites fluorescence from the NO molecules which is detected by a high-speed digital camera. The system has spatial resolution of about 200 microns (2 pixel blurring) and has flow-stopping time resolution (approximately 1 microsecond). NO was seeded into the flow two different ways. First, the RCS jet fluid was seeded with approximately 1-5% NO, with the balance N2. This allowed observation of the shape, structure and trajectory of the RCS jets. Visualizations of both laminar and turbulent flow jet features were obtained. Visualizations were obtained with the tunnel operating at Mach 10 and also with the test section held at a constant pressure similar to the aftbody static pressure (0.04 psi) obtained during tunnel runs. These two conditions are called "tunnel on" and "tunnel off" respectively. Second, the forebody flow was seeded with a very low flowrate (<100 standard cubic centimeters per minute) of pure NO. This trace gas was entrained into and allowed visualization of the shear layer forming between the expansion fan on the shoulder of the model and the recirculating separated flow in the wake of the model. This shear layer was observed to be laminar in the absence of the RCS jet operation and turbulent above a certain RCS jet flowrate. Furthermore, the operation of the RCS jet is seen to push the shear layer out away from the model, with a higher jet pressures resulting in larger deflections. Figures show some data from this test, partially processed. In the final paper, these images will be processed and rendered on a three dimensional visualization of the test hardware for clearer visualization and interpretation of the flowfields.

Danehy, P. M.↗

NASA NTRS2006

Trajectory and Aeroheating Environment Development and Sensitivity Analysis for Capsule-shaped Vehicles

Recently, NASA's Exploration Systems Research and Technology Project funded several tasks that endeavored to develop and evaluate various thermal protection systems and high temperature material concepts for potential use on the crew exploration vehicle. In support of these tasks, NASA Langley's Vehicle Analysis Branch generated trajectory information and associated aeroheating environments for more than 60 unique entry cases. Using the Apollo Command Module as the baseline entry system because of its relevance to the favored crew exploration vehicle design, trajectories for a range of lunar and Mars return, direct and aerocapture Earth-entry scenarios were developed. For direct entry, a matrix of cases was created that reflects reasonably expected minimum and maximum values of vehicle ballistic coefficient, inertial velocity at entry interface, and inertial flight path angle at entry interface. For aerocapture, trajectories were generated for a range of values of initial velocity and ballistic coefficient that, when combined with proper initial flight path angles, resulted in achieving a low Earth orbit either by employing a full lift vector up or full lift vector down attitude. For each trajectory generated, aeroheating environments were generated which were intended to bound the thermal protection system requirements for likely crew exploration vehicle concepts. The trades examined clearly pointed to a range of missions / concepts that will require ablative systems as well as a range for which reusable systems may be feasible. In addition, the results clearly indicated those entry conditions and modes suitable for manned flight, considering vehicle deceleration levels experienced during entry. This paper presents an overview of the analysis performed, including the assumptions, methods, and general approach used, as well as a summary of the trajectory and aerothermal environment information that was generated.

Robinson, Jeffrey S.↗

NASA NTRS2006

Utilization of Porous Media for Condensing Heat Exchangers

The use of porous media as a mean of separating liquid condensate from the air stream in condensing heat exchangers has been explored in the past inside small plant growth chambers and in the Apollo Command Module. Both applications used a cooled porous media made of sintered stainless steel to cool and separate condensation from the air stream. However, the main issues with the utilization of porous media in the past have been the deterioration of the porous media over long duration, such as clogging and changes in surface wetting characteristics. In addition, for long duration usage, biofilm growth from microorganisms on the porous medial would also be an issue. In developing Porous Media Condensing Heat Exchangers (PMCHX) for future space applications, different porous materials and microbial growth control methods will need to be explored. This paper explores the work performed at JSC and GRC to evaluate different porous materials and microbial control methods to support the development of a Porous Media Condensing Heat Exchanger. It outlines the basic principles for designing a PMCHX and issues that were encountered and ways to resolve those issues. The PMCHX has potential of mass, volume, and power savings over current CHX and water separator technology and would be beneficial for long duration space missions.

Tuan, George C.↗

NASA NTRS2008

Assessment of the LC-2 Prelaunch Fatigue Spectra of the CM-to-SM Flange Weld

The pad stay and rollout components of the Ares I-X life cycle can generate cyclic stress oscillations to the vehicle that could initiate and grow fatigue cracks from weld defects. The Ares I-X Project requested that a study be performed to determine if stabilization of the vehicle is required to reduce the stresses that could initiate and grow fatigue cracks at the flange-to-skin weld of the Command Module (CM) and Service Module (SM) interface. A fatigue crack growth analysis was conducted that used loads (LC-2) and stress analyses developed by the Ares I-X Project and utilized material data and analysis methods developed by a critical initial flaw size (CIFS) analysis conducted by NASA Engineering and Safety Center (NESC) for the Upper Stage Simulator (USS) of the Ares I-X vehicle. A full CIFS analysis for the CM-to-SM flange-to-skin weld was not performed because the full flight spectrum was not provided and was not necessary to answer the question posed by the Ares I-X Project. Instead, an approach was developed to determine if the crack growth due to the pad stay and rollout components of the flight spectrum would adversely influence the CIFS. The approach taken used a number of conservative assumptions that eliminated the need for high-fidelity analyses and additional material testing, but still provided a bounding solution for the uncertainties of the problem. The results from this analysis indicate that the LC-2 pad stay and rollout spectrum components would not produce significant fatigue crack growth on the CM-to-SM flange-to-skin weld. Thus, from a fatigue crack growth standpoint, no stabilization is required to reduce the LC-2 pad stay and rollout cyclic stresses on the CM-to-SM flange-to-skin weld.

Dawicke, David S.↗

NASA NTRS2009

Cluster Development Test 2: An Assessment of a Failed Test

On 31 July 2008 the National Aeronautics and Space Administration Crew Exploration Vehicle Parachute Assembly System team conducted the final planned cluster test of the first generation parachute recovery system design. The two primary test objectives were to demonstrate the operation of the complete parachute system deployed from a full scale capsule simulator and to demonstrate the test technique of separating the capsule simulator from the Low Velocity Air Drop pallet used to extract the test article from a United States Air Force C-17 aircraft. The capsule simulator was the Parachute Test Vehicle with an accurate heat shield outer mold line and forward bay compartment of the Crew Exploration Vehicle Command Module. The Parachute Test Vehicle separated cleanly from the pallet following extraction, but failed to reach test conditions resulting in the failure of the test and the loss of the test assets. No personnel were injured. This paper will discuss the design of the test and the findings of the team that investigated the test, including a discussion of what were determined to be the root causes of the failure.

Machin, Ricardo A.↗

NASA NTRS2008

Lunar Dust Effects on Spacesuit Systems: Insights from the Apollo Spacesuits

Systems and components of selected Apollo A7L/A7LB flight-article spacesuits that were worn on the lunar surface have been studied to determine the degree to which they suffered contamination, abrasion and wear or loss of function due to effects from lunar soil particles. Filter materials from the lithium hydroxide (LiOH) canisters from the Apollo Command Module were also studied to determine the amount and type of any lunar dust particles they may have captured from the spacecraft atmosphere. The specific spacesuit study materials include the outermost soft fabric layers on Apollo 12 and 17 integrated thermal micrometeorite garment assemblies and outermost fabrics on Apollo 17 extravehicular pressure gloves. In addition, the degree of surface wear in the sealed wrist rotation bearing from Apollo 16 extravehicular and intravehicular pressure gloves was evaluated and compared. Scanning electron microscope examination of the Apollo 12 T-164 woven TeflonO fabric confirms the presence of lunar soil particles and the ability of these particles to cause separation and fraying of the Teflon fibers. Optical imaging, chemical analysis and particle sampling applied to the outer fabric of the Apollo 17 spacesuit has identified Ti as a potentially useful chemical marker for comparing the amount of lunar soil retained on different areas of the spacesuit outer fabric. High-yield particle sampling from the Apollo 17 fabric surfaces using adhesive tape found 80% of particles on the fabric are lunar soil particles averaging 10.5 m in diameter, with the rest being intrinsic fabric materials or environmental contaminants. Analysis of the mineralogical composition of the lunar particles found that on a grain-count basis the particle population is dominated by plagioclase feldspar and various types of glassy particles derived mostly from soil agglutinates, with a subordinate amount of pyroxene. On a grain size basis, however, the pyroxene grains are generally a factor of 2 larger than glass and plagioclase, so conversion of the data to a modal (volume %) basis results in pyroxene becoming the modally dominant particle type with glass and plagioclase significantly less abundant. When comparisons are made to the modal composition of lunar soil at the Apollo 17 landing site, the results suggest that pyroxene particles have overall better retention on the spacesuit outer fabric compared to plagioclase and especially glass. Scanning electron microscopy revealed no measureable difference in the amount of wear and abrasion in the wrist rotation bearing of an Apollo 16 pressure glove worn only in the spacecraft and one worn only for extravehicular activity on the lunar surface. The results suggest either that the bearing prevented entry of lunar dust, or that dust was not sufficiently abrasive to damage the bearing, or both.

Christoffersen, Roy↗

NASA NTRS2010

A Comparison Between Orion Automated and Space Shuttle Rendezvous Techniques

The Orion spacecraft will replace the space shuttle and will be the first human spacecraft since the Apollo program to leave low earth orbit. This vehicle will serve as the cornerstone of a complete space transportation system with a myriad of mission requirements necessitating rendezvous to multiple vehicles in earth orbit, around the moon and eventually beyond . These goals will require a complex and robust vehicle that is, significantly different from both the space shuttle and the command module of the Apollo program. Historically, orbit operations have been accomplished with heavy reliance on ground support and manual crew reconfiguration and monitoring. One major difference with Orion is that automation will be incorporated as a key element of the man-vehicle system. The automated system will consist of software devoted to transitioning between events based on a master timeline. This effectively adds a layer of high level sequencing that moves control of the vehicle from one phase to the next. This type of automated control is not entirely new to spacecraft since the shuttle uses a version of this during ascent and entry operations. During shuttle orbit operations however many of the software modes and hardware switches must be manually configured through the use of printed procedures and instructions voiced from the ground. The goal of the automation scheme on Orion is to extend high level automation to all flight phases. The move towards automation represents a large shift from current space shuttle operations, and so these new systems will be adopted gradually via various safeguards. These include features such as authority-to-proceed, manual down modes, and functional inhibits. This paper describes the contrast between the manual and ground approach of the space shuttle and the proposed automation of the Orion vehicle. I will introduce typical orbit operations that are common to all rendezvous missions and go on to describe the current Orion automation architecture and contrast it with shuttle rendezvous techniques and circumstances. The shuttle rendezvous profile is timed to take approximately 3 days from orbit insertion to docking at the International Space Station (ISS). This process can be divided into 3 phases: far-field, mid-field and proximity operations. The far-field stage is characterized as the most quiescent phase. The spacecraft is usually too far to navigate using relative sensors and uses the Inertial Measurement Units (IMU s) to numerically solve for its position. The maneuvers are infrequent, roughly twice per day, and are larger than other burns in the profile. The shuttle uses this opportunity to take extensive ground based radar updates and keep high fidelity orbit states on the ground. This state is then periodically uplinked to the shuttle computers. The targeting solutions for burn maneuvers are also computed on the ground and uplinked. During the burn the crew is responsible for setting the shuttle attitude and configuring the propulsion system for ignition. Again this entire process is manually driven by both crew and ground activity. The only automatic processes that occur are associated with the real-time execution of the burn. The Orion automated functionality will seek to relieve the workload of both the crew and ground during this phase

Ruiz, Jose O,↗