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NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for Discovery

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human spaceflight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Making its first uncrewed test flight in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, capable of supporting human missions into deep space and to Mars. This paper will summarize the planned capabilities of the vehicle, the progress the SLS Program has made in the years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130 t lift capability. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and recordbreaking engine testing, to life-cycle milestones such as the vehicle's Preliminary Design Review in the summer of 2013. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. In addition, this paper will demonstrate how the Space Launch System is being designed to enable or enhance not only human exploration missions, but robotic scientific missions as well. Because of its unique launch capabilities, SLS will support simplifying spacecraft complexity, provide improved mass margins and radiation mitigation, and reduce mission durations. These capabilities offer attractive advantages for ambitious science missions by reducing infrastructure requirements, cost, and schedule. A traditional baseline approach for a mission to investigate the Jovian system would require a complicated trajectory with several gravity-assist planetary fly-bys to achieve the necessary outbound velocity. The SLS rocket, offering significantly higher C3 energies, can more quickly and effectively take the mission directly to its destination, providing scientific results sooner and at lower operational cost. The SLS rocket will launch payloads of unprecedented mass and volume, such as "monolithic" telescopes and in-space infrastructure, and will revolutionize science mission planning and design for years to come. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

Creech, Stephen D.↗

NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for Discovery

Creech, Stephen D.↗

NASA NTRS1977

Space Shuttle Program Progress Report

A status report is presented on progress in the design, manufacturing and testing of components of the space transportation system (STS), and primarily the Space Shuttle vehicles. Project landmarks from 1969 to 1981 are indicated, fabrication of the Shuttle Orbiter and rollout of the first prototype are described, fabrication and assembly of some Orbiter parts are sketched, and some of the subsystems (thermal protection, avionics, maneuvering aids, reaction control, remote manipulator) are described. Also discussed are: Orbiter carrier aircraft, Shuttle main engine and tests, external fuel tank, solid rocket booster, launch and landing facilities. A separate section is devoted to ground tests (vibration, propulsion, electronics, avionics integration), trainers and simulators, and flight tests (captive flight, free flight, landing and approach, orbital flight).

Thompson, R. F.↗

NASA NTRS2003

Effect of Sizings on the Durability of High Temperature Polymer Composites

To increase performance and durability of high-temperature composite for potential rocket engine components, it is necessary to optimize wetting and interfacial bonding between high modulus carbon fibers and high-temperature polyimide resins. Sizing commercially supplied on most carbon fiber are not compatible with polyimides. In this study, the chemistry of sizing on two high modulus carbon fiber (M40J and M60J, Tiray) was characterized. A continuous desizling system that uses an environmentally friendly chemical-mechanical process was developed for tow level fiber. Composites were fabricated with fibers containing the manufacturer's sizing, desized, and further treated with a reactive finish. Results of room-temperature tests after thermal aging show that the reactive finish produces a higher strength and more durable interface compared to the manufacturer's sizing. When exposed to moisture blistering tests, however, the butter bonded composite displayed a tendency to delaminate, presumably due to trapping of volatiles.

Allred, Ronald E.↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

NASA NTRS2005

GRCop-84: A High Temperature Copper-based Alloy For High Heat Flux Applications

While designed for rocket engine main combustion chamber liners, GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) offers potential for high heat flux applications in industrial applications requiring a temperature capability up to approximately 700 C (1292 F). GRCop-84 is a copper-based alloy with excellent elevated temperature strength, good creep resistance, long LCF lives and enhanced oxidation resistance. It also has a lower thermal expansion than copper and many other low alloy copper-based alloys. GRCop-84 can be manufactured into a variety of shapes such as tubing, bar, plate and sheet using standard production techniques and requires no special production techniques. GRCop-84 forms well, so conventional fabrication methods including stamping and bending can be used. GRCop-84 has demonstrated an ability to be friction stir welded, brazed, inertia welded, diffusion bonded and electron beam welded for joining to itself and other materials. Potential applications include plastic injection molds, resistance welding electrodes and holders, permanent metal casting molds, vacuum plasma spray nozzles and high temperature heat exchanger applications.

Ellis, David L.↗

NASA NTRS2005

Return to Flight Resource Reel 2 of 2

A continuation of the tests performed on the Space Shuttle Discovery in preparation for its return to flight is presented. The tests include: 1) Shuttle Robot Arm Recertification; 2) Michael Hiltz Systems Group Leader; 3) Orbiter Boom Fabrication; 4) Orbiter Boom Final Development; 5) Gary Searle Manager of Orbiter Boom Sensor System (OBSS) Manufacturing and Assembly; 6) Orbiter Boom Qualification Unit; 7) STS-114 Crew Inspects Orbiter Boom at Kennedy Space Center; 8) Orbiter Boom Inspection of Thermal Protection System Animation; 9) External Tank Bipod Redesign; 10) External Tank Flange Redesign; 11) External Tank Bellows Redesign; 12) Shuttle Main Engine Testing and Delivery to Kennedy Space Center; 13) Ronnie Rigney Project Manager Space Shuttle Main Engine Program Office; 14) Gene Goldmman NASA Project Manager Space Shuttle Main Engine Project; 15) Mike Cosgrove Boeing-Rocketdyne Flow Manager; 16) Shuttle Rocket Booster Build-Up; 17) Ascent Imagery Improvements; and 18) STS-114 Flight Control Team and Mission Management Team.

Source record↗

NASA NTRS2019

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗

NASA NTRS2019

NASA’s Space Launch System: First Mission Hardware Nears Completion

The Space Launch System (SLS) Program (Fig. 1) completed several significant production milestones in 2018 for its first mission and is poised for greater accomplishments in 2019. With manufacturing and hardware installation complete, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success and scientific discovery. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗

NASA NTRS2004

Supersonic Rocket Thruster Flow Predicted by Numerical Simulation

Despite efforts in the search for alternative means of energy, combustion still remains the key source. Most propulsion systems primarily use combustion for their needed thrust. Associated with these propulsion systems are the high-velocity hot exhaust gases produced as the byproducts of combustion. These exhaust products often apply uneven high temperature and pressure over the surfaces of the appended structures exposed to them. If the applied pressure and temperature exceed the design criteria of the surfaces of these structures, they will not be able to protect the underlying structures, resulting in the failure of the vehicle mission. An understanding of the flow field associated with hot exhaust jets and the interactions of these jets with the structures in their path is critical not only from the design point of view but for the validation of the materials and manufacturing processes involved in constructing the materials from which the structures in the path of these jets are made. The hot exhaust gases often flow at supersonic speeds, and as a result, various incident and reflected shock features are present. These shock structures induce abrupt changes in the pressure and temperature distribution that need to be considered. In addition, the jet flow creates a gaseous plume that can easily be traced from large distances. To study the flow field associated with the supersonic gases induced by a rocket engine, its interaction with the surrounding surfaces, and its effects on the strength and durability of the materials exposed to it, NASA Glenn Research Center s Combustion Branch teamed with the Ceramics Branch to provide testing and analytical support. The experimental work included the full range of heat flux environments that the rocket engine can produce over a flat specimen. Chamber pressures were varied from 130 to 500 psia and oxidizer-to-fuel ratios (o/f) were varied from 1.3 to 7.5.

Davoudzadeh, Farhad↗

NASA NTRS2011

Space Shuttle Main Engine - The Relentless Pursuit of Improvement

The Space Shuttle Main Engine (SSME) is the only reusable large liquid rocket engine ever developed. The specific impulse delivered by the staged combustion cycle, substantially higher than previous rocket engines, minimized volume and weight for the integrated vehicle. The dual pre-burner configuration permitted precise mixture ratio and thrust control while the fully redundant controller and avionics provided a very high degree of system reliability and health diagnosis. The main engine controller design was the first rocket engine application to incorporate digital processing. The engine was required to operate at a high chamber pressure to minimize engine volume and weight. Power level throttling was required to minimize structural loads on the vehicle early in flight and acceleration levels on the crew late in ascent. Fatigue capability, strength, ease of assembly and disassembly, inspectability, and materials compatibility were all major considerations in achieving a fully reusable design. During the multi-decade program the design evolved substantially using a series of block upgrades. A number of materials and manufacturing challenges were encountered throughout SSME s history. Significant development was required for the final configuration of the high pressure turbopumps. Fracture control was implemented to assess life limits of critical materials and components. Survival in the hydrogen environment required assessment of hydrogen embrittlement. Instrumentation systems were a challenge due to the harsh thermal and dynamic environments within the engine. Extensive inspection procedures were developed to assess the engine components between flights. The Space Shuttle Main Engine achieved a remarkable flight performance record. All flights were successful with only one mission requiring an ascent abort condition, which still resulted in an acceptable orbit and mission. This was achieved in large part via extensive ground testing to fully characterize performance and to establish acceptable life limits. During the program over a million seconds of accumulated test and flight time was achieved. Post flight inspection and assessment was a key part of assuring proper performance of the flight hardware. By the end of the program the predicted reliability had improved by a factor of four. These unique challenges, evolution of the design, and the resulting reliability will be discussed in this paper.

VanHooser, Katherine P.↗

NASA NTRS2000

Separation and Conditioning of Mars Atmospheric Gases via TSA

Space and planetary exploration almost always presents interesting and unusual engineering challenges. Separations engineering for chemical processes that are critical to humans working in space is no exception. The challenges are becoming clearer as we make the transition from concepts and planning to hardware development, and as we understand better the constraints and environments in which the processes must perform. The coming decade will see a robotic Mars exploration program that has recovered from recent setbacks and is building a knowledge and technology base for human exploration. One of the missions will carry a small chemical pilot plant for demonstrating the manufacture of rocket propellants and life support consumables from the low-pressure (0.01 atm) Martian atmosphere. By manufacturing and storing the fuel and consumables needed for human-return missions in situ, launch mass and landed mass are reduced by tons and missions become far less expensive. The front-end to the pilot plant is a solid-state atmosphere acquisition and separation unit based on temperature-swing adsorption (TSA). The unit produces purified and pressurized (to 1.0 atm) carbon dioxide to downstream reactors that will make methane and oxygen. The unit also produces a nitrogen-argon mixture as a valuable by-product for life support, inflatable structures, and propellant pressurization. With nighttime temperatures falling to -100 degrees C, power availability restricted to a few watts, and flawless operation critical to success, the dusty Martian surface is a difficult place to operate a remote plant. This talk will focus on how this TSA separation process is designed and implemented for this application, and how it might be used in the more distant future for human exploration.

Finn, John E.↗

NASA NTRS1998

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗

NASA NTRS2005

The Spaceflight Revolution Revisited

This essay will first consider whether technological breakthroughs in space technology and the rational motives of ordinary institutions have the capacity to break out of this relatively static situation. Then we will survey the roles that social movements of various kinds might play and conclude with an examination of one particular nascent movement that might possibly build the foundation for a spacefaring civilization. A third of a century ago, practical nuclear fission rockets were under development, but this approach now seems environmentally unacceptable. It is hard to devise a more environmentally benign propellant than the hydrogen and oxygen used by the main engines of the Space Shuttle. There is some hope that nanotechnology will save the day with materials based on carbon nanotubes that are vastly stronger yet lighter than metals.6 However, the X-33 failure shows that it is not easy to work with radically new structural materials in demanding aerospace applications, and we may be many decades away from being able to manufacture propellant tanks, wings, and other large structures from carbon nanotubes. Satellites in low-Earth and synchronous orbit are of great importance in the collection and distribution of information, thus essential to the information economy. The wide range of civilian applications includes telephone, data transmission, television, navigation, weather observation, agriculture monitoring, and prospecting for natural resources.8 The technology is largely perfected, and incremental progress can be achieved by improvement in information systems and simply by investing in more relatively small satellites of the kinds we already have.

Bainbridge, William Sims↗

NASA NTRS2009

Propelling Exploration to the Moon and Beyond

As the Constellation Program enters its fourth year, the Ares Projects have made substantial progress toward sending human explorers beyond Earth orbit. The Ares I crew launch vehicle, which will take six astronauts or cargo to the International Space Station or four astronauts to rendezvous with Ares V for missions to the Moon, is the first human-rated vehicle NASA has developed in over 30 years. Since the Exploration Systems Architecture Study in 2005, the Ares Projects have completed a successful system requirements review, system definition review, and preliminary design review for the Ares I crew launch vehicle. The Ares I elements are well into development, beginning with the Shuttle-derived, five-segment solid rocket motor that will provide first-stage propulsion. The first stage team has poured its first production simulation article motor and will be pouring and firing the first five-segment development motor in 2009. Large-scale tooling has been installed and tested to produce propellant tanks for the liquid-fuel upper stage at Marshall Space Flight Center (MSFC) in Alabama. The initial upper stage units and main propulsion test article will be manufactured and tested at MSFC before transferring to Michoud Assembly Facility in Louisiana. The upper stage engine team has completed powerpack testing using Apollo J-2 heritage hardware and begun construction of a new altitude test stand at Stennis Space Center in Mississippi. The flight and integrated testing group has designed and built hardware for the Ares I-X test flight scheduled for 2009, as well as begun refurbishing existing infrastructure to support ground testing. Additionally, a base configuration has been selected for the Ares V cargo launch vehicle, which will send the Altair lunar lander and Orion to the Moon. Today, the Ares Projects are well on the way to building America s next generation of exploration-capable launch vehicles.

Cook, Stephen A.↗

NASA NTRS2016

NASA's SPACE LAUNCH SYSTEM: Development and Progress

NASA is embarked on a new era of space exploration that will lead to new capabilities, new destinations, and new discoveries by both human and robotic explorers. Today, the International Space Station (ISS) and robotic probes are yielding knowledge that will help make this exploration possible. NASA is developing both the Orion crew vehicle and the Space Launch System (SLS) (Figure 1), that will carry out a series of increasingly challenging missions leading to human exploration of Mars. This paper will discuss the development and progress on the SLS. The SLS architecture was designed to be safe, affordable, and sustainable. The current configuration is the result of literally thousands of trade studies involving cost, performance, mission requirements, and other metrics. The initial configuration of SLS, designated Block 1, will launch a minimum of 70 metric tons (mT) (154,324 pounds) into low Earth orbit - significantly greater capability than any current launch vehicle. It is designed to evolve to a capability of 130 mT (286,601 pounds) through the use of upgraded main engines, advanced boosters, and a new upper stage. With more payload mass and volume capability than any existing rocket, SLS offers mission planners larger payloads, faster trip times, simpler design, shorter design cycles, and greater opportunity for mission success. Since the program was officially created in fall 2011, it has made significant progress toward launch readiness in 2018. Every major element of SLS continued to make significant progress in 2015. Engineers fired Qualification Motor 1 (QM-1) in March 2015 to test the 5-segment motor, including new insulation, joint, and propellant grain designs. More than 70 major components of test article and flight hardware for the Core Stage have been manufactured. Seven test firings have been completed with an RS-25 engine under SLS operating conditions. The test article for the Interim Cryogenic Propulsion Stage (ICPS) has also been completed. Major work continues in 2016 as the program continues both flight and development RS-25 engine testing, begins welding test article and flight core stage tanks, completes stage adapter manufacturing, and test fires the second booster qualification motor. This paper will discuss the program's key accomplishments to date and the challenging work ahead for what will be the world's most capable launch vehicle.

Honeycutt, John↗

NASA NTRS1985

Small centrifugal pumps for low thrust rockets

This paper presents the results of a combined analytical and experimental investigation of low specific speed pumps for potential use as components of propellant feed systems for low thrust rocket engines. Shrouded impellers and open face impellers were tested in volute type and vaned diffuser type pumps. Full- and partial-emission diffusers and full- and partial-admission impellers were tested. Axial and radial loads, head and efficiency versus flow, and cavitation tests were conducted. Predicted performance of two pumps are compared when pumping water and liquid hydrogen. Detailed pressure loss and parasitic power values are presented for two pump configurations. Partial-emission diffusers were found to permit use of larger impeller and diffuser passages with a minimal performance penalty. Normal manufacturing tolerances were found to result in substantial power requirement variation with only a small pressure rise change. Impeller wear ring leakage was found to reduce pump pressure rise to an increasing degree as the pump flowrate was decreased.

Gulbrandsen, N. C.↗