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This slide presentation reviews the effort of code EA at Johnson Space Center (JSC) to identify and acquire databases and documents from the space shuttle program that are adjudged important for retention after the retirement of the space shuttle.
Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. As the Shuttle Program comes to an end we now have the time to perform limited refurbishment. Thermography has been used to monitor the state of insulation as one of the four tanks was drained of cryogen and warmed to ambient temperatures. An anomalous region of insulation detected previously with thermography was confirmed by visual inspections during this period. Thermal models and a comparison of images from the cold and warm tanks suggests that the anomalous region can be detected even without cryogen in the tank. The ability to detect and correct probable insulation voids prior to filling with cryogenic fluid can provide significant cost savings by reducing commodity boil-off over many years of use.
The Space Shuttle Main Engine (SSME) has several "redlines", which are operational limits designated to preclude a catastrophic shutdown of the SSME. The Space Shuttle Orbiter utilizes a combination of hardware and software to enable or disable the automated redline shutdown capability. The Space Shuttle is launched with the automated SSME redline limits enabled, but there are many scenarios which may result in the manual disabling of the software by the onboard crew. The operational philosophy for manually enabling and disabling the redline limits software has evolved continuously throughout the history of the Space Shuttle Program, due to events such as SSME hardware changes and updates to Space Shuttle contingency abort software. In this paper, the evolution of SSME redline limits management will be fully reviewed, including the operational scenarios which call for manual intervention, and the events that triggered changes to the philosophy. Following this review, improvements to the management of redline limits for future spacecraft will be proposed.
After propellant was loaded into the external tank (ET), the November 5, 2010 launch of Space Shuttle mission STS-133 was scrubbed due to a gaseous hydrogen leak located in a vent line near the ground umbilical and ET connection. Subsequent visual inspections identified cracks in the sprayed-on foam insulation in the forward end of the ET intertank segment, adjacent to the liquid oxygen (LOX) tank, as shown in Figure 1. These cracks necessitated repair of the foam due to debris concerns that violated launch constraints. As part of the repair process, the affected foam was removed to reveal cracks in the underlying external hat stiffeners on the intertank, as shown in Figure 2. Ultimately, five stiffeners were discovered to be cracked adjacent to the LOX tank. As the managing center for the ET Project, NASA Marshall Space Flight Center (MSFC) coordinated failure investigation and repair activities among multiple organizations, which included the ET prime contractor (Lockheed Martin Space Systems Michoud Operations), the Space Shuttle Program Office at the NASA Johnson Space Center (JSC), the NASA Kennedy Space Center (KSC), and the NASA Engineering and Safety Center (NESC). STS-133 utilized the external tank designated as ET-137. Many aspects of the investigation have been reported previously in Refs. 1-7, which focus on the root cause of the failures, the flight readiness rationale and the local analyses of the stringer failures and repair. This paper summarizes the global analyses that were conducted on ET-137 as part of the NESC effort during the investigation, which was conducted primarily to determine if the repairs that were introduced to the stringers would alter the global response of the ET. In the process of the investigation, a new STAGS tabular input capability was developed to more easily introduce the aerodynamic pressure loads using a method that could easily be extended to incorporate finite element property data such as skin and stiffener thicknesses and beam cross-sectional properties.
Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. Intrusively inspecting these tanks would mean a significant down time to the program as the cryogenic liquid and the perlite insulation would have to be removed which would be a significant task and long-term schedule disruption. A study of the tanks was performed to determine the extent to which performance and structural information could be revealed without intrusive inspection. Thermal images of the tanks were taken over a variety of environmental conditions to determine the best conditions under which to compare and use thermography as a health monitoring technique as the tanks continue to age. The settling and subsequent compaction of insulation is a serious concern for cryogenic tanks. Comparison of images from the tanks reveals significant variations in the insulation in the annual regions and point to the use of thermography as a way to monitor for insulation migration and possible compaction. These measurements, when combined with mathematical models of historical boil-off data provide key insight to the condition of the vessels. Acceptance testing methods for new tanks, before they are filled with cryogenic commodity (and thereby thermally cycled), are needed and we explore how thermography can be used to accomplish this.
Due to an aggressive schedule for the first space flight of an unmanned Orion capsule, currently known as Exploration Flight Test One (EFT1), combined with severe programmatic funding constraints, an effort was made within the Orion Program to identify heritage hardware, i.e., already existing, flight-certified components from previous manned space programs, which might be available for use on EFT1. With the end of the Space Shuttle Program, no current means exists to launch Multi-Purpose Logistics Modules (MPLMs) to the International Space Station (ISS), and so the inventory of many flight-certified Shuttle and MPLM components are available for other purposes. Two of these items are the MPLM cabin Positive Pressure Relief Assembly (PPRA), and the Shuttle Ground Support Equipment Heat Exchanger (GSE HX). In preparation for the utilization of these components by the Orion Program, analyses and testing of the hardware were performed. The PPRA had to be analyzed to determine its susceptibility to pyrotechnic shock, and vibration testing had to be performed, since those environments are predicted to be more severe during an Orion mission than those the hardware was originally designed to accommodate. The GSE HX had to be tested for performance with the Orion thermal working fluids, which are different from those used by the Space Shuttle. This paper summarizes the activities required in order to utilize heritage hardware for EFT1.
Biomedical research, both applied and basic, was conducted on every Shuttle mission from 1981 to 2011. The Space Shuttle Program enabled NASA investigators and researchers from around the world to address fundamental issues concerning living and working effectively in space. Operationally focused occupational health investigations and tests were given priority by the Shuttle crew and Shuttle Program management for the resolution of acute health issues caused by the rigors of spaceflight. The challenges of research on the Shuttle included: limited up and return mass, limited power, limited crew time, and requirements for containment of hazards. The sheer capacity of the Shuttle for crew and equipment was unsurpassed by any other launch and entry vehicle and the Shuttle Program provided more opportunity for human research than any program before or since. To take advantage of this opportunity, life sciences research programs learned how to: streamline the complicated process of integrating experiments aboard the Shuttle, design experiments and hardware within operational constraints, and integrate requirements between different experiments and with operational countermeasures. We learned how to take advantage of commercial-off-the-shelf hardware and developed a hardware certification process with the flexibility to allow for design changes between flights. We learned the importance of end-to-end testing for experiment hardware with humans-in-the-loop. Most importantly, we learned that the Shuttle Program provided an excellent platform for conducting human research and for developing the systems that are now used to optimize research on the International Space Station. This presentation will include a review of the types of experiments and medical tests flown on the Shuttle and the processes that were used to manifest and conduct the experiments. Learning Objective: This paper provides a description of the challenges related to launching and implementing biomedical experiments aboard the Space Shuttle.
Performance, weight, and reusability of the Space Shuttle Main Engine, the next generation rocket engine, are important factors in achieving the Space Shuttle mission. The design features of the engine contributing to the achievement of these engine demands are discussed. Many new fabrication methods, material applications, and innovations incorporated into the engine are presented. The engine program is now in the second year of the 47 months development period. The current status of activities in engineering, manufacturing, and test are reviewed. The Design Verification Specification approach to engine development is compared to the development programs for Saturn/Apollo engines.
The Space Shuttle program spanned more than the entire length of a solar cycle. Investigations aimed towards understanding the health risks of the astronauts from exposures to space radiation involved mostly physical measurements of the dose and the linear energy transfer (LET) spectrum. Measurement of the dose rate on the Shuttle provided invariable new data for different periods of the solar cycle, whereas measurement of the LET spectrum using the tissue equivalent proportional counter (TEPC) produced the most complete mapping of the radiation environment of the low Earth orbits (LEO). Exposures to the Shuttle astronauts were measured by the personal dosimeter worn by the crewmembers. Analysis of over 300 personal dosimeter readings indicated a dependence on the mission duration, the altitude and inclination of the orbit, and the solar cycle, with the crewmembers on the launch and repair of the Hubble telescope receiving the highest doses due to the altitude of the mission. Secondary neutrons inside the Shuttle were determined by recoil protons or with Bonner spheres, and may contribute significantly to the risks of the crewmembers. In addition, the skin dose and the doses received at different organs were compared using a human phantom onboard a Shuttle mission. A number of radiobiology investigations wer e also performed. The biological doses were determined on six astronauts/cosmonauts on long-duration Shuttle/Mir missions and on two crewmembers on a Hubble repair mission by analyzing the damages in the chromosomes of the crewmembers? white blood cells. Several experiments were also conducted to address the question of possible synergistic effects of spaceflight, microgravity in particular, on the repair of radiation-induced DNA damages. The experimental design included exposure of cells before launch, during flight, or after landing. These physical and biological studies were invaluable in predicting the health risks for astronauts on ISS and future exploration missions. Educational Objectives: A group of high school students flew color negative films on tw o Shuttle missions to detect the radiation environment in orbit. This and other experiments onboard of the Shuttle were aimed at educating the general public of the space program.
The ascent air data system of the Space Shuttle consists of a simple biconic spike probe on the nose of the external tank. Pressure measurements were calibrated in a wind tunnel to obtain vehicle attitude and speed (relative to the air) and dynamic pressure. The wind tunnel test data analysis and the calibration are discussed in terms of test problems and calibration parameter formulation. The flight pressures are traced from telemetry data to final air data products. Analysis of the flight results showed that static pressure could not be accurately determined at the higher Mach numbers (above approx. 2.0). By replacing static pressure with data from a postflight estimated trajectory the ascent air data system performance met the user requirements. Lessons learned are enumerated, the most important being the need for a thorough systems integration effort.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.
Space shuttle aerothermodynamic data, collected from a continuing series of wind tunnel tests, are permanently stored with the Data Management Services (DMS) system. Information pertaining to current baseline configuration definition is also stored. Documentation of DMS processed data arranged sequentially and by space shuttle configuration are included. An up-to-date record of all applicable aerothermodynamic data collected, processed, or summarized during the space shuttle program is provided. Tables are designed to provide suvery information to the various space shuttle managerial and technical levels.
This paper discusses the development of the Assured Shuttle Availability Project (ASA). The ASA project has been created to provide a structure by which the Space Shuttle Program (SSP) may allocate resources to hardware redesign efforts required to extend effective Space Shuttle operational life through the year 2020. Specific ASA Project goals and evaluation criteria have been set, and redesign efforts have been evaluated using systems engineering methods.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
NASA has been involved with hypersonic work since the 1950’s with a significant understanding of hypersonic flight phenomena being obtained from highly successful programs and manned orbital flights of the Mercury, Gemini, Apollo and Space Shuttle programs. Ames, Glenn, and Langley Research Centers are the lead field centers for hypersonic research and development. Marshall Space Flight Center has National Asset Test and Analysis capabilities to also support hypersonic work.
To ensure manned access to space, the Personnel Launch System (PLS) is under consideration by NASA as a complement to the Space Shuttle. Its primary mission will be to transport crew and passengers to and from the Space Station Freedom in low earth orbit (LEO). There are currently two design studies being funded: a biconic, ballistic-shaped vehicle at JSC and a lifting body concept at LaRC. In the late 1950's, both NASA and the Air Force were engaged in the study of lifting bodies for LEO vehicles. Projects included the M2F2 series, the X24 series, and the HL-10. These lifting bodies derive their lift solely from the shape of the fuselage. By the mid-1960's, full scale models were actually built and tested with some success and some failure. Langley's HL-10 was one of the most successful of these projects. However, these studies were temporarily shelved while work progressed on the Space Shuttle. Some of the test results from these studies actually led to concept refinements on certain aspects of the Space Shuttle development. Due to the more recent successes of the Space Shuttle Program and a directive to place a Space Station in orbit, there has been renewed interest in developing a lifting body vehicle as the PLS. The vehicle, the HL-20, is an LaRC Project in the Space Systems Division, involving the efforts of a number of individuals. Data on the research carried out for peer and lay review has been available in hard copy format, but a need existed for actual video footage, combined with scientific visualization technology, for presentation and archival purposes. The purpose of this project was to satisfy this need.