Large launch vehicles - Present and future
Saturn launch vehicle systems in terms of design, operating characteristics and potential applications, showing need for reusable space shuttle systems
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Saturn launch vehicle systems in terms of design, operating characteristics and potential applications, showing need for reusable space shuttle systems
Saturn 5 launch vehicle navigation system design, discussing configurations, implementation schemes, system tradeoffs and performance
Saturn launch vehicle gust penetration loads, presenting separated flow and associated time lag effects
Launch vehicles for space telecommunications applications, considering payload capacity for missions involving earth resources, radio and visual astronomy and meteorology
System between the Titan/Centaur launch vehicle and its aerodynamic shroud is described. The system provides a precise spring constant and is capable of being inactivated during flight. Design requirements, design details, and the test program are discussed. The conventional English system of units was used during this development program for all principal measurements and calculations.
Current launch vehicle design emphasis is on low life-cycle cost. This paper applies total quality management (TQM) principles to a conventional systems design analysis process to provide low-cost, high-reliability designs. Suggested TQM techniques include Steward's systems information flow matrix method, quality leverage principle, quality through robustness and function deployment, Pareto's principle, Pugh's selection and enhancement criteria, and other design process procedures. TQM quality performance at least-cost can be realized through competent concurrent engineering teams and brilliance of their technical leadership.
A next generation reusable launch vehicle (RLV) will require thermally efficient and light-weight cryogenic propellant tank structures. Since these tanks will be weight-critical, analytical tools must be developed to aid in sizing the thickness of insulation layers and structural geometry for optimal performance. Finite element method (FEM) models of the tank and insulation layers were created to analyze the thermal performance of the cryogenic insulation layer and thermal protection system (TPS) of the tanks. The thermal conditions of ground-hold and re-entry/soak-through for a typical RLV mission were used in the thermal sizing study. A general-purpose nonlinear FEM analysis code, capable of using temperature and pressure dependent material properties, was used as the thermal analysis code. Mechanical loads from ground handling and proof-pressure testing were used to size the structural geometry of an aluminum cryogenic tank wall. Nonlinear deterministic optimization and reliability optimization techniques were the analytical tools used to size the geometry of the isogrid stiffeners and thickness of the skin. The results from the sizing study indicate that a commercial FEM code can be used for thermal analyses to size the insulation thicknesses where the temperature and pressure were varied. The results from the structural sizing study show that using combined deterministic and reliability optimization techniques can obtain alternate and lighter designs than the designs obtained from deterministic optimization methods alone.
Both uncrewed and crewed launch vehicles (LV) require Flight Termination Systems (FTS) for Range Safety to protect the public and ground assets in the event of a LV failure. Flight crew safety in this context is an added consideration for human spaceflight. The FTS is an electroexplosive system that activates destruct charges to rupture propellant tanks and shutdown engines during flight termination. Commercially available FTS units have been developed for uncrewed applications and are now being repurposed to crewed applications. A consequence of using these systems is that they are designed for public and ground crew safety, though inadequate for flight crew safety. Missing are Human Space Flight (HSF) design controls for inadvertent activation during crewed ascent and protection for crew emergency abort.
NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. The metal microstructure and possible defects are different from other weld processes. Friction plug welds will be used to close out the hole remaining in the radial welds when friction stir welded. This plug welding also has unique challenges in inspection. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.
The Launcher Stabilization System (LSS) is a pneumatic/hydraulic ground system used to support an Atlas launch vehicle prior to launch. The redesign and development activity undertaken to achieve an LSS with increased load capacity and a redundant hydraulic system for the Atlas 2 launch vehicle are described.
The United States (U.S.) space exploration policy has directed the National Aeronautics and Space Administration (NASA) to retire the Space Shuttle and to replace it with a new generation of space transportation systems for crew and cargo travel to the International Space Station, the Moon, Mars, and beyond. As part of the Constellation Program, engineers at NASA's Marshall Space Flight Center in Huntsville, Alabama are working to design and build the Ares I, the first of two large launch vehicles to return humans to the Moon. A deliberate effort is being made to ensure a high level of operability in order to significantly increase safety and availability as well as reduce recurring costs of this new launch vehicle. It is the Ares Project's goal to instill operability as part of the requirements development, design and operations of the vehicle. This paper will identify important factors in launch vehicle design that affect the operability and availability of the system. Similarities and differences in operational constraints will also be compared between the Saturn V, Space Shuttle and current Ares I design. Finally, potential improvements in operations and operability for large launch vehicles will be addressed. From the examples presented, the paper will discuss potential improvements for operability for future launch vehicles.
Sharp body designs for future reusable launch vehicles offer a number of attractive features including allowing zero staging, enabling airbreathing and lofting ascents, and potentially providing global cross range re-entries with continuous communications. The Slender Hypersonic Aerothermodynamic Research Program (SHARP) was initiated by NASA Ames to demonstrate sharp, passive leading edge designs for hypersonic vehicles, incorporating new ultra-high temperature ceramics. This paper will discuss how SHARP will provide an important technology base for making sharp body hypersonic vehicle designs a reality, and how this activity fits into NASA's overall program for developing next generation reusable launch vehicles.
Space launch vehicles use day-of-launch steering commands based upon the upper-level (UL) atmospheric environments in order to alleviate wind induced structural loading and optimize ascent trajectory. Historically, UL wind measurements to support launch operations at the National Aeronautics and Space Administration's (NASA) Kennedy Space Center (KSC), co-located on the United States Air Force's Eastern Range (ER) at the Cape Canaveral Air Force Station use high-resolution (HR) rawinsondes. One inherent limitation with rawinsondes is the approximately one-hour sampling time necessary to measure tropospheric winds. Additionally, rawinsonde drift during ascent due to the ambient wind environment can result in the balloon being hundreds of kilometers down range, which results in questioning whether the measured winds represent the wind environment the vehicle will experience during ascent. This paper will describe the use of balloon profile databases to statistically assess the drift distance away from the ER launch complexes during HR rawinsonde ascent as a function of season. Will also discuss an alternative method to measure UL wind environments in closer proximity to the vehicle trajectory when launching from the ER.
Saturn Launch Vehicle Program technical equipment and engineering techniques for solving structural, propulsion, launch and control problems
Space launch vehicles incorporate upper-level wind assessments to determine wind effects on the vehicle and for a commit to launch decision. These assessments make use of wind profiles measured hours prior to launch and may not represent the actual wind the vehicle will fly through. Uncertainty in the winds over the time period between the assessment and launch introduces uncertainty in assessment of vehicle controllability and structural integrity that must be accounted for to ensure launch safety. Temporal wind pairs are used in engineering development of allowances to mitigate uncertainty. Five sets of temporal wind pairs at various times (0.75, 1.5, 2, 3 and 4-hrs) at the United States Air Force Eastern Range and Western Range, as well as the National Aeronautics and Space Administration's Wallops Flight Facility are developed for use in upper-level wind assessments on vehicle performance. Historical databases are compiled from balloon-based and vertically pointing Doppler radar wind profiler systems. Various automated and manual quality control procedures are used to remove unacceptable profiles. Statistical analyses on the resultant wind pairs from each site are performed to determine if the observed extreme wind changes in the sample pairs are representative of extreme temporal wind change. Wind change samples in the Eastern Range and Western Range databases characterize extreme wind change. However, the small sample sizes in the Wallops Flight Facility databases yield low confidence that the sample population characterizes extreme wind change that could occur.
Space launch vehicles incorporate upper-level wind assessments to determine wind effects on the vehicle and for a commit to launch decision. These assessments make use of wind profiles measured hours prior to launch and may not represent the actual wind the vehicle will fly through. Uncertainty in the winds over the time period between the assessment and launch introduces uncertainty in assessment of vehicle controllability and structural integrity that must be accounted for to ensure launch safety. Temporal wind pairs are used in engineering development of allowances to mitigate uncertainty. Five sets of temporal wind pairs at various times (0.75, 1.5, 2, 3 and 4-hrs) at the United States Air Force Eastern Range and Western Range, as well as the National Aeronautics and Space Administration's Wallops Flight Facility are developed for use in upper-level wind assessments on vehicle performance. Historical databases are compiled from balloon-based and vertically pointing Doppler radar wind profiler systems. Various automated and manual quality control procedures are used to remove unacceptable profiles. Statistical analyses on the resultant wind pairs from each site are performed to determine if the observed extreme wind changes in the sample pairs are representative of extreme temporal wind change. Wind change samples in the Eastern Range and Western Range databases characterize extreme wind change. However, the small sample sizes in the Wallops Flight Facility databases yield low confidence that the sample population characterizes extreme wind change that could occur.
Description of the Delta Model 904 and the Thor/Agena Model 9A4 scientific and applications satellite launch vehicles, with projections of future growth and launch costs. These launch vehicles are shown to offer scientific and applications satellite mission planners a broad spectrum in performance capabilities together with unprecedented mission flexibility. Depending on the mission, these two medium class launch vehicles can be configured on the new universal boattail (UBT) Thor booster in either two or three stages with thrust augmentation of the UBT ranging from three to nine strap-on solid propellant motors. Both vehicles incorporate strapdown inertial guidance systems that allow flexible mission programming by computer so ftware changes rather than by adjustments.
Iterative guidance solution for injecting Saturn launch vehicle into earth orbit