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Orion Flight Test-1 Thermal Protection System Instrumentation

The Orion Crew Exploration Vehicle (CEV) was originally under development to provide crew transport to the International Space Station after the retirement of the Space Shuttle, and to provide a means for the eventual return of astronauts to the Moon. With the current changes in the future direction of the United States human exploration programs, the focus of the Orion project has shifted to the project s first orbital flight test, designated Orion Flight Test 1 (OFT-1). The OFT-1 is currently planned for launch in July 2013 and will demonstrate the Orion vehicle s capability for performing missions in low Earth orbit (LEO), as well as extensibility beyond LEO for select, critical areas. Among the key flight test objectives are those related to validation of the re-entry aerodynamic and aerothermal environments, and the performance of the thermal protection system (TPS) when exposed to these environments. A specific flight test trajectory has been selected to provide a high energy entry beyond that which would be experienced during a typical low Earth orbit return, given the constraints imposed by the possible launch vehicles. This trajectory resulted from a trade study that considered the relative benefit of conflicting objectives from multiple subsystems, and sought to provide the maximum integrated benefit to the re-entry state-of-the-art. In particular, the trajectory was designed to provide: a significant, measureable radiative heat flux to the windward surface; data on boundary transition from laminar to turbulent flow; and data on catalytic heating overshoot on non-ablating TPS. In order to obtain the necessary flight test data during OFT-1, the vehicle will need to have an adequate quantity of instrumentation. A collection of instrumentation is being developed for integration in the OFT-1 TPS. In part, this instrumentation builds upon the work performed for the Mars Science Laboratory Entry, Descent and Landing Instrument (MEDLI) suite to instrument the OFT-1 ablative heat shield. The MEDLI integrated sensor plugs and pressure sensors will be adapted for compatibility with the Orion TPS design. The sensor plugs will provide in-depth temperature data to support aerothermal and TPS model correlation, and the pressure sensors will provide a flush air data system for validation of the entry and descent aerodynamic environments. In addition, a radiometer design will be matured to measure the radiative component of the reentry heating at two locations on the heat shield. For the back shell, surface thermocouple and pressure port designs will be developed and applied which build upon the heritage of the Space Shuttle Program for instrumentation of reusable surface insulation (RSI) tiles. The quantity and location of the sensors has been determined to balance the needs of the reentry disciplines with the demands of the hardware development, manufacturing and integration. Measurements which provided low relative value and presented significant engineering development effort were, unfortunately, eliminated. The final TPS instrumentation has been optimized to target priority test objectives. The data obtained will serve to provide a better understanding of reentry environments for the Orion capsule design, reduce margins, and potentially reduce TPS mass or provide TPS extensibility for alternative missions.

Kowal, T. John↗

Control and Non-Payload Communications (CNPC) Prototype Radio - Generation 2 Flight Test Report

NASA Glenn Research Center conducted a series of flight tests for the purpose of evaluating air-to-ground communications links for future unmanned aircraft systems (UAS). The primary objective of the test effort was to evaluate the transition of the aircraft communications from one ground station to the next, and to monitor data flow during the "hand-off" event. To facilitate the testing, ground stations were installed at locations in Cleveland, Ohio and Albany, Ohio that each provides line-of-sight radio communications with an overflying aircraft. This report describes results from the flight tests including flight parameters, received signal strength measurements, data latency times, and performance observations for the air-to-ground channel.

Ground Stations↗

Artemis I: Test Flight Buys Down Risk for Humanity's Return to the Moon

The Artemis program successfully demonstrated its foundational deep space human transportation system during the Artemis I test flight in late 2022. This bold mission put the Artemis program on a course to accomplish increasingly complex missions to return humans to the Moon and to prepare for Mars and other destinations. The Artemis I uncrewed mission tested the Space Launch System (SLS) rocket and the Orion spacecraft using the ground processing, launch and recovery services provided by the Exploration Ground Systems (EGS) program at the Kennedy Space Center (KSC). The Artemis team accomplished key mission priorities that deliberately bought down risk for upcoming crewed missions as part of a build-up flight test strategy. The Artemis I mission priorities were 1) demonstrate Orion heatshield at lunar re-entry conditions; 2) operate systems in flight environment; and 3) retrieve the spacecraft. The successful performance and demonstration of these primary mission objectives from lift-off thru orbital insertion, translunar injection, outbound transit towards the Moon, entry into lunar orbit, coast in the lunar Distant Retrograde Orbit (DRO), exit from lunar orbit, transit back to Earth, atmospheric re-entry, descent, splashdown and recovery successfully showed that NASA has a foundational deep space transportation capability in place for human class missions. In addition to the primary mission objectives, a set of scientific payloads, approved Flight Test Objectives (FTOs) and Development Flight Test Objectives (DFTOs) were incorporated into the nominal mission plan and were designated as secondary, or priority 4, and were considered “bonus objectives” in terms of crewed flight risk buydown. During the mission, the team found itself in a position where it was comfortable achieving even more content than originally planned. As a result, DFTOs were added during the mission to further buy down risk to later crewed test flights. This paper presents an overview of the Artemis I test flight, including mission priorities and key test objectives, the launch campaign and as-flown mission profile, test objectives accomplished over the course of the 25.5- day mission, and implications to the crewed Artemis II and later test flight missions.

Artemis↗

Air Traffic Management Technology Demostration-1 (ATD-1) Avionics Phase 2 Flight Test and Results

NASA’s first Air Traffic Management Technology Demonstration (ATD-1) subproject successfully completed 19 days of flight test validation in January and February 2017 of an Interval Management (IM) avionics prototype and the procedures used to conduct IM arrival and approach operations. IM is one of the three elements integrated into NASA’s ATD-1 concept of operations with the subproject goal of improving aircraft efficiency and airport throughput during high-density arrival operations. The ATD-1 concept of operations combines advanced arrival scheduling, controller decision support tools, and interval management (IM) avionics to enable merging of multiple, time-based, efficient arrival streams. IM contributes to the operation by calculating speeds that enable an aircraft to precisely achieve a specific time or distance behind another aircraft. When precise spacing intervals can be calculated, achieved, and then maintained during high-density operations, aircraft efficiency should be improved by enabling the aircraft to remain closer to the optimum descent trajectory instead of using vectors and step-down altitudes, and airport throughput should be maintained or improved by each aircraft arriving at the runway threshold closer to the assigned spacing interval. This avionics development and flight test was conducted under a NASA contract by Boeing Research and Technology, with Boeing Commercial Aircraft, Honeywell, United Airlines, and Jeppesen as sub-contractors. The Honeywell built IM avionics were the first ever prototype built based on NASA requirements as well as developing and non-flight tested international IM standards, integrated into two test aircraft, and then flown in real-world conditions at the Grant County International Airport (KMWH). The IM prototype flown in the flight test used data from the Ownship and the assigned lead, or Target, aircraft to calculate the airspeed necessary for the Ownship to achieve the desired spacing. The flight test demonstrated that the IM avionics prototype generally met the IM requirement for spacing accuracy. However, the control laws implemented require further development to reduce the high IM speed command rate and the number of speed reversals observed during the test. Pilots assessed the IM procedure as acceptable, and issues requiring further attention were identified. In summary, the IM avionics prototype showed significant promise in contributing to the goals of improving aircraft efficiency and airport throughput. The flight test results also provided important data to the FAA and the working group developing the follow-on version of the international IM standards.

Baxley, Brian T.↗

Post-Flight Assessment of Avcoat Thermal Protection System for the Exploration Flight Test-1

On December 5, 2014 NASA conducted the first flight test of its next generation human-class Orion spacecraft. The flight was called the Exploration Flight Test -1 (EFT-1) which lasted for 4 hours and culminated into a re-entry trajectory at 9 km/s. This flight test of the 5-meter Orion Crew Module demonstrated various sub-systems including the Avcoat ablative thermal protection system (TPS) on the heat shield. The Avcoat TPS had been developed from the Apollo-era recipe with a few key modifications. The engineering for thermal sizing was supported by modeling, analysis, and ground tests in arc jet facilities. This paper will describe a postlfight analysis plan and present results from post-recovery inspections, data analysis from embedded sensors, TPS sample extraction and characterization in the laboratory. After the recovery of the vehicle, a full photographic survey and surface scans of the TPS were performed. The recovered vehicle showed physical evidence of flow disturbances, varying degrees of surface roughness, and excessive recession downstream of compression pads. The TPS recession was measured at more than 200 locations of interest on the Avcoat surface. The heat shield was then processed for sample extraction prior to TPS removal using the 7-Axis Milling machine at Marshall Space Flight Center. Around 182 rectangular TPS samples were extracted for subsequent analysis and investigation. The final paper will also present results of sample analysis. The planned investigation includes sidewall imaging, followed by image analysis to characterize TPS response by quantifying different layers in the char and pyrolysis zones. A full postmortem of the instrumentation and sensor ports will also be performed to confirm no adverse effects due to the sensors themselves. A subset of the samples will undergo structural testing and perform detailed characterization of any cracks and integrity of gore seams. Finally, the material will be characterized with layer-by-layer density measurements and SEM investigations to evaluate material morphology at microstructural level including identification of elements and compounds.

Aerothermodynamics↗

Crew Exploration Vehicle Launch Abort System Flight Test Overview

The Constellation program is an organization within NASA whose mission is to create the new generation of spacecraft that will replace the Space Shuttle after its planned retirement in 2010. In the event of a catastrophic failure on the launch pad or launch vehicle during ascent, the successful use of the launch abort system will allow crew members to escape harm. The Flight Test Office is the organization within the Constellation project that will flight-test the launch abort system on the Orion crew exploration vehicle. The Flight Test Office has proposed six tests that will demonstrate the use of the launch abort system. These flight tests will be performed at the White Sands Missile Range in New Mexico and are similar in nature to the Apollo Little Joe II tests performed in the 1960s. An overview of the launch abort system flight tests for the Orion crew exploration vehicle is given. Details on the configuration of the first pad abort flight test are discussed. Sample flight trajectories for two of the six flight tests are shown.

Williams-Hayes, Peggy S.↗

Flight testing of a luminescent surface pressure sensor

NASA ARC has conducted flight tests of a new type of aerodynamic pressure sensor based on a luminescent surface coating. Flights were conducted at the NASA ARC-Dryden Flight Research Facility. The luminescent pressure sensor is based on a surface coating which, when illuminated with ultraviolet light, emits visible light with an intensity dependent on the local air pressure on the surface. This technique makes it possible to obtain pressure data over the entire surface of an aircraft, as opposed to conventional instrumentation, which can only make measurements at pre-selected points. The objective of the flight tests was to evaluate the effectiveness and practicality of a luminescent pressure sensor in the actual flight environment. A luminescent pressure sensor was installed on a fin, the Flight Test Fixture (FTF), that is attached to the underside of an F-104 aircraft. The response of one particular surface coating was evaluated at low supersonic Mach numbers (M = 1.0-1.6) in order to provide an initial estimate of the sensor's capabilities. This memo describes the test approach, the techniques used, and the pressure sensor's behavior under flight conditions. A direct comparison between data provided by the luminescent pressure sensor and that produced by conventional pressure instrumentation shows that the luminescent sensor can provide quantitative data under flight conditions. However, the test results also show that the sensor has a number of limitations which must be addressed if this technique is to prove useful in the flight environment.

Mclachlan, B. G.↗

Pegasus Air-Launched Space Booster Flight Test Program

Pegasus is a satellite-launching space rocket dropped from a B52 carrier aircraft instead of launching vertically from a ground pad. Its three-year, privately-funded accelerated development was carried out under a demanding design-to-nonrecurring cost methodology, which imposed unique requirements on its flight test program, such as the decision not to drop an inert model from the carrier aircraft; the number and type of captive and free-flight tests; the extent of envelope exploration; and the decision to combine test and operational orbital flights. The authors believe that Pegasus may be the first vehicle where constraints in the number and type of flight tests to be carried out actually influenced the design of the vehicle. During the period November 1989 to February of 1990 a total of three captive flight tests were conducted, starting with a flutter clearing flight and culminating in a complete drop rehearsal. Starting on April 5, 1990, two combination test/operational flights were conducted. A unique aspect of the program was the degree of involvement of flight test personnel in the early design of the vehicle and, conversely, of the design team in flight testing and early flight operations. Various lessons learned as a result of this process are discussed throughout this paper.

Elias, Antonio L.↗

Flight Test Maneuvers for Efficient Aerodynamic Modeling

Novel flight test maneuvers for efficient aerodynamic modeling were developed and demonstrated in flight. Orthogonal optimized multi-sine inputs were applied to aircraft control surfaces to excite aircraft dynamic response in all six degrees of freedom simultaneously while keeping the aircraft close to chosen reference flight conditions. Each maneuver was designed for a specific modeling task that cannot be adequately or efficiently accomplished using conventional flight test maneuvers. All of the new maneuvers were first described and explained, then demonstrated on a subscale jet transport aircraft in flight. Real-time and post-flight modeling results obtained using equation-error parameter estimation in the frequency domain were used to show the effectiveness and efficiency of the new maneuvers, as well as the quality of the aerodynamic models that can be identified from the resultant flight data.

Morelli, Eugene A.↗

Space shuttle orbiter test flight series

The proposed studies on the space shuttle orbiter test taxi runs and captive flight tests were set forth. The orbiter test flights, the approach and landing tests (ALT), and the ground vibration tests were cited. Free flight plans, the space shuttle ALT crews, and 747 carrier aircraft crew were considered.

Garrett, D.↗

High-Altitude ADS-B/GPS LPV Flight Tests on a NASA ER-2 Research Airplane

The research presented in this paper describes the conceptual design of a system architecture that integrates Automatic Dependent Surveillance-Broadcast (ADS-B) and Global Positioning System (GPS) Localizer Performance Vertical (LPV) guidance technology onto a unique high-altitude research airplane: a United States Air Force (USAF) / Lockheed Martin (Bethesda, Maryland) Aeronautics U-2S airplane. The design features modern display capabilities to provide air-to-air surveillance and precision navigation, to adhere to Federal Aviation Administration (FAA) certification standards for operations in upper Class E airspace. The National Aeronautics and Space Administration (NASA) variant of the U-2S, now called the Earth Resources (ER-2) airplane, remains unrivaled in the art of sustained high-altitude flight for scientific expeditions. Capable of routinely cruising above flight level (FL) 650 that had been considered, at inception, the domain of only the most elite experimental research aircraft types. Nicknamed the Dragon Lady, this U-2S research testbed is still one of the most advanced aircraft in the world. The exceptional military design of the vehicle, security guidelines, and the performance envelope of the ER-2 posed unique challenges to the integration of modern civilian avionics. ADS-B epitomizes the next generation of surveillance technology, incorporating both air and ground aspects. ADS-B provides air traffic control (ATC) with a more accurate picture of the three-dimensional positioning of aircraft in various phases of flight, including en route, terminal, approach, and ground operations. The airborne surveillance system broadcasts its identification, position, altitude, velocity, and other information. GPS LPV represents a significant advancement in aviation technology, emphasizing the pivotal role that GPS and Performance-Based Navigation concepts will play in the foreseeable future. This technology represents a shift from sensor-based navigation to performance-based navigation, allowing for more flexible and efficient use of airspace. This research described herein is structured as follows: Section II, “Systems Background,” provides a systems background and description of an ADS-B and GPS LPV system equipped on the high-altitude ER-2 research airplane to satisfy the FAA airworthiness requirements for high-altitude flight operations. Section III, “Flight Test System,” describes the flight-test airplane systems. Section IV, “Analysis of GPS SBAS, Safety, and Ground Tests,” provides an overview of the GPS Satellite-Based Augmentation System (SBAS) and an analysis of the GPS LPV metrics, safety, and ground tests. Section V, “High-Altitude Flight Tests,” describes the high-altitude flight tests, including 3 flight-test results, analysis, human factors, and lessons learned. Section VI, the conclusion, draws insights from the lessons learned, discusses the design challenges associated with ADS-B and GPS LPV, and showcases the paramount significance of these pivotal technologies in aircraft surveillance and navigation.

Ricardo A. Arteaga↗

Recurring Causes of Human Spaceflight Mishaps during Flight Tests and Early Operations

n analysis of recurring causes underlying human spaceflight mishaps that occurred during flight tests and early operations was performed. Eight mishaps from the Apollo, Soyuz, Skylab, Space Shuttle, and Constellation Programs (i.e., the Ares-1X test flight) and commercial suborbital systems were included in the study. Detailed event analyses were performed for the historical mishaps and aggregate data analyses conducted to identify recurring issues. The nine most frequent issues were inadequate technical controls or risk management practices, incomplete procedures, system design and development issues, inadequate inspection or secondary verification requirements, failures of organizations to learn from previous incidents, inadequate schedule controls, inadequate task analyses or design processes, flaws in the design of organizations, and issues with organizational safety cultures.

Timothy S Barth↗

Detect and Avoid and Collision Avoidance Flight Test Results with ACAS Xr

In October 2023, the National Aeronautics and Space Administration (NASA) completed its Integration of Automated Systems flight test series, conducted under NASA’s Advanced Air Mobility project and in partnership with Sikorsky and the Defense Advanced Research Projects Agency (DARPA). The flight test effort included two crewed rotorcraft platforms. The first, a modified S-76B helicopter, served as the “ownship” for the duration of the flight test. The second vehicle, a modified S-70, served as the intruder aircraft. One Sikorsky pilot and one NASA test pilot was onboard each aircraft for every test point, with the NASA test pilot responsible for interacting with the research systems under test. Approximately half of the flight test was devoted to assessing the Federal Aviation Administration’s (FAA) next-generation collision avoidance system, the Airborne Collision Avoidance System X for Rotorcraft (ACAS Xr). The two configurations available within ACAS Xr – the Collision Avoidance System (CAS) configuration and the Detect and Avoid (DAA) configuration – were flown with an onboard pilot under Visual Flight Rules in controlled airspace over the Long Island Sound (Connecticut, USA). A total of 33 flight test cards were flown with ACAS Xr active. The ownship was equipped with ACAS Xr and the intruder was equipped with Automatic Dependent Surveillance-Broadcast (ADS-B). The test points were blocked by ACAS Xr configuration, with individual encounters varying the ownship speed (90 knots or 20 knots), the intruder designation (en-route, terminal area, or structured airspace), and method of RA execution (automated or manually executed). Results showed that the ACAS Xr alerting and guidance was largely effective and rated positively by the NASA test pilots, exemplified by zero instances of the pilots overriding an ACAS Xr Resolution Advisory (RA). Key areas of improvement, however, were noted, particularly with regards to the lack of an aural alert indicating a need to accelerate when receiving an RA at low speed and the occurrence of multiple RAs that the pilots found to be unacceptable.

detect and avoid↗

Detect and Avoid and Collision Avoidance Flight Test Results with ACAS Xr

In October 2023, the National Aeronautics and Space Administration (NASA) completed its Integration of Automated Systems flight test series, conducted under NASA’s Advanced Air Mobility project and in partnership with Sikorsky and the Defense Advanced Research Projects Agency (DARPA). The flight test effort included two crewed rotorcraft platforms. The first, a modified S-76B helicopter, served as the “ownship” for the duration of the flight test. The second vehicle, a modified S-70, served as the intruder aircraft. One Sikorsky pilot and one NASA test pilot was onboard each aircraft for every test point, with the NASA test pilot responsible for interacting with the research systems under test. Approximately half of the flight test was devoted to assessing the Federal Aviation Administration’s (FAA) next-generation collision avoidance system, the Airborne Collision Avoidance System X for Rotorcraft (ACAS Xr). The two configurations available within ACAS Xr – the Collision Avoidance System (CAS) configuration and the Detect and Avoid (DAA) configuration – were flown with an onboard pilot under Visual Flight Rules in controlled airspace over the Long Island Sound (Connecticut, USA). A total of 33 flight test cards were flown with ACAS Xr active. The ownship was equipped with ACAS Xr and the intruder was equipped with Automatic Dependent Surveillance-Broadcast (ADS-B). The test points were blocked by ACAS Xr configuration, with individual encounters varying the ownship speed (90 knots or 20 knots), the intruder designation (en-route, terminal area, or structured airspace), and method of RA execution (automated or manually executed). Results showed that the ACAS Xr alerting and guidance was largely effective and rated positively by the NASA test pilots, exemplified by zero instances of the pilots overriding an ACAS Xr Resolution Advisory (RA). Key areas of improvement, however, were noted, particularly with regards to the lack of an aural alert indicating a need to accelerate when receiving an RA at low speed and the occurrence of multiple RAs that the pilots found to be unacceptable.

detect and avoid↗

Scramjet Engine Flowpath Development for the Hyper-X Mach 10 Flight Test

The third flight of the Hyper-X Research Vehicle at nearly Mach 10 in November 2004 demonstrated the potential for airbreathing propulsion at hypersonic speeds. The flowpath of the scramjet engine used in the Hyper-X Research Vehicle was developed using computational fluid dynamic based design method in combination with a systematic series of ground tests in the NASA HyPulse Shock Tunnel at conditions duplicating Mach 10 flight. The test model was a true scale height and length of the internal flight engine flowpath that was partial width and truncated fore and aft. Tests were conducted using a mixture of hydrogen augmented with two-percent silane. Silane gas served as an ignition aid during the short duration of the pulse facility tests. The engine inflow values of pressure, temperature, and Mach number were parametrically varied during the ground test entries to broaden the database over the expected uncertainty in the flight conditions. A review of the ground test technique and comparisons of the ground test pressures along with selected data from the third flight are presented.

Rogers, R. C.↗

Reconstruction of the Adaptable Deployable Entry and Placement Technology Sounding Rocket One Flight Test

The Adaptable Deployable Entry and Placement Technology Sounding Rocket One flight test is a demonstration experiment for deployable atmospheric decelerator technologies. The suborbital flight test occurred on 12 September 2018, at the White Sands Missile Range. Data from on-board and ground-based sensors were collected, from which the as-flown trajectory was reconstructed using an iterative extended Kalman filter-smoother. This paper describes the methodology, test vehicle instrumentation, and data analysis results from the flight test trajectory reconstruction.

Tynis, Jake A.↗

An overview of parameter estimation techniques and applications in aircraft flight testing

Parameter estimation is discussed as it applies to aircraft flight testing, and an overview of the symposium is presented. The evolution of techniques used in flight testing is reviewed briefly, and it is pointed out how the changing character of the aircraft tested and the availability of advanced data systems have promoted this evolution. Recent advances in optimal estimation theory have stimulated widespread interest and activity in parameter estimation. The framework of these advanced techniques is outlined to set the stage for subsequent papers. The session topics are introduced and related to the requirements of flight-test research.

Rediess, H. A.↗

Historical Survey Of Flight-Testing Accidents

Report presents study of flight-testing accidents, with emphasis on limitations imposed by human factors. Covers history of flight testing from early lighter-than-air craft (including balloons) to vertical take-off airplanes to space shuttle.

Anderson, Seth B.↗