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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2008

Predicting the Acoustic Environment Induced by the Launch of the Ares I Vehicle

The exhaust plumes of launch vehicles impose severe heating rates, pressures, and vibroacoustic loads on ground support equipment (GSE) on the Mobile Launcher (ML), as well as on the vehicle itself. The vibroacoustic environment must be predicted before the criteria for the acceptance and qualification testing of GSE components and their installations can be determined. This project updates launch noise modeling.

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NASA NTRS2008

Calibrating the Helium Pressurization System for the Space Shuttle Liquid-Hydrogen Tank

Analysis of the results from the STS-114 tanking tests and subsequent launch called into question existing thermal and mass models of helium pressurization of the liquid hydrogen tank. This hydrogen tank, which makes up the bottom two-thirds of the External Tank, is pressurized prior to launch to avoid cavitation in the Shuttle Main Engine pumps. At about 2 minutes prior to launch, the main vent valve is closed, and pressurized helium flows into the tank ullage space to achieve set point pressure. As the helium gas cools, its pressure drops, calling for additional helium. Subsequent helium flows are provided in short, timed pulses. The number of pulses is taken as a rough leak indicator. An analysis of thermal models by Marshall Space Flight Center showed considerable uncertainty in the pressure-versus-time behavior of the helium ullage space and the ability to predict the number of pulses normally expected. Kennedy Space Center proposed to calibrate the dime-sized orifice, which together with valves, controls the helium flow quantity (Figure 1). Pressure and temperature sensors were installed to provide upstream and downstream measurements necessary to compute flow rate based on the orifice discharge coefficient. An assessment of flow testing with helium indicated an extremely costly use of this critical resource. In order to reduce costs, we proposed removing the orifices from each Mobile Launcher Platform (MLP) and asking Colorado Engineering Experiment Station Inc. (CEESI) to calibrate the flow. CEESI has a high-pressure air flow system with traceable flow meters capable of handling the large flow rates. However, literature research indicated that square-edged orifices of small diameters often exhibit significant hysteresis and nonrepeatability in the vicinity of choked or sonic flow. Fortunately, the MLP orifices behaved relatively well in testing (Figure 2). Using curve fitting of the air-flow data, in conjunction with ASME orifice modeling equations, a method of relating the helium mass flow to measured air flow data was obtained. This analysis showed that the highest uncertainty in flow occurred in the vicinity of the choking pressure ratio, as would be expected. In addition, analysis of typical flow pulses showed that most of the helium flow occurred either well below or well above this uncertain area. The final result is the ability to provide postlaunch estimates of helium mass flows that are within 1.5 percent of the actual value.

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NASA NTRS2009

Ares V: Game Changer for National Security Launch

NASA is designing the Ares V cargo launch vehicle to vastly expand exploration of the Moon begun in the Apollo program and enable the exploration of Mars and beyond. As the largest launcher in history, Ares V also represents a national asset offering unprecedented opportunities for new science, national security, and commercial missions of unmatched size and scope. The Ares V is the heavy-lift component of NASA's dual-launch architecture that will replace the current space shuttle fleet, complete the International Space Station, and establish a permanent human presence on the Moon as a stepping-stone to destinations beyond. During extensive independent and internal architecture and vehicle trade studies as part of the Exploration Systems Architecture Study (ESAS), NASA selected the Ares I crew launch vehicle and the Ares V to support future exploration. The smaller Ares I will launch the Orion crew exploration vehicle with four to six astronauts into orbit. The Ares V is designed to carry the Altair lunar lander into orbit, rendezvous with Orion, and send the mated spacecraft toward lunar orbit. The Ares V will be the largest and most powerful launch vehicle in history, providing unprecedented payload mass and volume to establish a permanent lunar outpost and explore significantly more of the lunar surface than was done during the Apollo missions. The Ares V consists of a Core Stage, two Reusable Solid Rocket Boosters (RSRBs), Earth Departure Stage (EDS), and a payload shroud. For lunar missions, the shroud would cover the Lunar Surface Access Module (LSAM). The Ares V Core Stage is 33 feet in diameter and 212 feet in length, making it the largest rocket stage ever built. It is the same diameter as the Saturn V first stage, the S-IC. However, its length is about the same as the combined length of the Saturn V first and second stages. The Core Stage uses a cluster of five Pratt & Whitney Rocketdyne RS-68B rocket engines, each supplying about 700,000 pounds of thrust. Its propellants are liquid hydrogen and liquid oxygen. The two solid rocket boosters provide about 3.5 million pounds of thrust at liftoff. These 5.5-segment boosters are derived from the 4-segment boosters now used on the Space Shuttle, and are similar to those used in the Ares I first stage. The EDS is powered by one J-2X engine. The J-2X, which has roughly 294,000 pounds of thrust, also powers the Ares I Upper Stage. It is derived from the J-2 that powered the Saturn V second and third stages. The EDS performs two functions. Its initial suborbital burns will place the lunar lander into a stable Earth orbit. After the Orion crew vehicle, launched separately on an Ares I, docks with the lander/EDS stack, EDS will ignite a second time to put the combined 65-metric ton vehicle into a lunar transfer orbit. When it stands on the launch pad at Kennedy Space Center late in the next decade, the Ares V stack will be approximately 381 feet tall and have a gross liftoff mass of 8.1 million pounds. The current point-of-departure design exceeds Saturn V s mass capability by approximately 40 percent. Using the current payload shroud design, Ares V can carry 315,000 pounds to 29-degree low Earth orbit (LEO) or 77,000 pounds to a geosynchronous orbit. Another unique aspect of the Ares V is the 33-foot-diameter payload shroud, which encloses approximately 30,400 cubic feet of usable volume. A larger hypothetical shroud for encapsulating larger payloads has been studied. While Ares V makes possible larger payload masses and volumes, it may alternately make possible more cost-effective mission design if the relevant payload communities are willing to consider an alternative to the existing approach that has driven them to employ complexity to solve current launch vehicle mass and volume constraints. By using Ares V s mass and volume capabilities as margin, payload designers stand to reduce development risk and cost. Significant progress has been made on the Ares V to support a plaed fiscal 2011 authority-to-proceed (ATP) milestone. The Ares V team is actively reaching out to external organizations during this early concept phase to ensure that the Ares V vehicle can be leveraged for national security, science, and commercial development needs. This presentation will discuss Ares V vehicle configuration, the path to the current concept, accomplishments to date, and potential payload utilization opportunities.

Sumrall, Phil↗
NASA NTRS2009

T-Rex: A Japanese Space Tether Experiment

Electrodynamic tether (EDT) thrusters work by virtue of the force a magnetic field exerts on a wire carrying an electrical current. The force, which acts on any charged particle moving through a magnetic field (including the electrons moving in a current-carrying wire), were concisely expressed by Lorentz in 1895 in an equation that now bears his name. The force acts in a direction perpendicular to both the direction of current flow and the magnetic field vector. Electric motors make use of this force: a wire loop in a magnetic field is made to rotate by the torque the Lorentz Force exerts on it due to an alternating current in the loop times so as to keep the torque acting in the same sense. The motion of the loop is transmitted to a shaft, thus providing work. Although the working principle of EDT thrusters is not new, its application to space transportation may be significant. In essence, an EDT thruster is just a clever way of getting an electrical current to flow in a long orbiting wire (the tether) so that the Earth s magnetic field will accelerate the wire and, consequently the payload attached to the wire. The direction of current flow in the tether, either toward or away from the Earth along the local vertical, determines whether the magnetic force will raise or lower the orbit. The bias voltage of a vertically deployed metal tether, which results just from its orbital motion (assumed eastward) through Earth s magnetic field, is positive with respect to the ambient plasma at the top and negative at the bottom. This polarization is due to the action of the Lorentz force on the electrons in the tether. Thus, the natural current flow is the result of negative electrons being attracted to the upper end and then returned to the plasma at the lower end. The magnetic force in this case has a component opposite to the direction of motion, and thus leads to a lowering of the orbit and eventually to re-entry. In this generator mode of operation the Lorentz Force serves both to drive the current and then to act on the current to decelerate the system. One of the most important features of tether thrusters is that they use renewable energy sources to drive the electrical current flow in either the orbit-raising or orbit-lowering modes. Sources inherent to Earth orbit are used. To raise the orbit, sunlight can be converted to the electrical energy required to drive the tether current. To lower the orbit, the orbital energy itself (supplied by the Earth-to-orbit launcher when it raises the system into orbit) is the energy source of the tether current via the action of the Lorentz Force. Electrodynamic tethers can be directly applied to a wide spectrum of uses in space. As a propulsion system, they include satellite de-orbit, transfer of a satellite from one orbit to another, altitude maintenance for large spacecraft such as the International Space Station, and since it works wherever there is a magnetic field and an ionosphere planetary exploration missions. An electrodynamic tether upper stage could be used as an Orbit Transfer Vehicle (OTV) to move payloads within low earth orbit. The OTV would rendezvous with the payload and launch vehicle, grapple the payload and maneuver it to a new orbital altitude or inclination without the use of boost propellant. The tug could then lower its orbit to rendezvous with the next payload and repeat the process. Conceivably, such a system could perform several orbital maneuvering assignments without resupply, making it relatively inexpensive to operate.

Johnson, Les↗
NASA NTRS2009

Constellation Launch Vehicles Overview

This slide presentation reviews the current status of the launch vehicles associated with the Constellation Program. These are the Ares I and the Ares V. An overview of the Ares launch vehicles is included. The presentation stresses that the major criteria for the Ares I launcher is the safety of the crew, and the presentation reviews the various features that are designed to assure that aim. The Ares I vehicle is being built on a foundation of proven technologies, and the Ares V will give NASA unprecedented performance and payload volume that can enable a range of future missions. The CDs contain videos of scenes from various activities surrounding the design, construction and testing of the vehicles.

Cook, Steve↗
NASA NTRS2009

COMPASS Final Report: Near Earth Asteroids Rendezvous and Sample Earth Returns (NEARER)

In this study, the Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) team completed a design for a multi-asteroid (Nereus and 1996 FG3) sample return capable spacecraft for the NASA In-Space Propulsion Office. The objective of the study was to support technology development and assess the relative benefits of different electric propulsion systems on asteroid sample return design. The design uses a single, heritage Orion solar array (SA) (approx.6.5 kW at 1 AU) to power a single NASA Evolutionary Xenon Thruster ((NEXT) a spare NEXT is carried) to propel a lander to two near Earth asteroids. After landing and gathering science samples, the Solar Electric Propulsion (SEP) vehicle spirals back to Earth where it drops off the first sample s return capsule and performs an Earth flyby to assist the craft in rendezvousing with a second asteroid, which is then sampled. The second sample is returned in a similar fashion. The vehicle, dubbed Near Earth Asteroids Rendezvous and Sample Earth Returns (NEARER), easily fits in an Atlas 401 launcher and its cost estimates put the mission in the New Frontier s (NF's) class mission.

Oleson, Steven R.↗
NASA NTRS2009

Ares V: Current Status and Future Capabilities

This slide presentation reviews the progress made in the design and development of the Ares V launch vehicle. Included in the presentation are views of the elements of the Ares V, the commonality of the Ares I and V, a chart that shows the progress made in the design of the launcher, description of the current activities around the design and preparation for the Ares V, and a slide describing the prospect of large payload volume and the flexibility that this gives to new space sciences.

Sumrall, Phil↗
NASA NTRS2010

Ares I-X Flight Test Vehicle: Stack 5 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA's Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the first modal test that was performed on the top section of the vehicle referred to as Stack 5, which consisted of the spacecraft adapter, service module, crew module and launch abort system simulators. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 5 modal test.

Buehrle, Ralph D.↗
NASA NTRS2010

Ares I-X Launch Vehicle Modal Test Measurements and Data Quality Assessments

The Ares I-X modal test program consisted of three modal tests conducted at the Vehicle Assembly Building at NASA s Kennedy Space Center. The first test was performed on the 71-foot 53,000-pound top segment of the Ares I-X launch vehicle known as Super Stack 5 and the second test was performed on the 66-foot 146,000- pound middle segment known as Super Stack 1. For these tests, two 250 lb-peak electro-dynamic shakers were used to excite bending and shell modes with the test articles resting on the floor. The third modal test was performed on the 327-foot 1,800,000-pound Ares I-X launch vehicle mounted to the Mobile Launcher Platform. The excitation for this test consisted of four 1000+ lb-peak hydraulic shakers arranged to excite the vehicle s cantilevered bending modes. Because the frequencies of interest for these modal tests ranged from 0.02 to 30 Hz, high sensitivity capacitive accelerometers were used. Excitation techniques included impact, burst random, pure random, and force controlled sine sweep. This paper provides the test details for the companion papers covering the Ares I-X finite element model calibration process. Topics to be discussed include test setups, procedures, measurements, data quality assessments, and consistency of modal parameter estimates.

Templeton, Justin D.↗
NASA NTRS2010

Ares I-X Launch Vehicle Modal Test Overview

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, is scheduled for launch in 2009. Ares IX will use a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle is not practical within project constraints, modal tests for several configurations in the nominal integration flow were defined to calibrate the FEM. A traceability study by Aerospace Corporation was used to identify the critical modes for the tested configurations. Test configurations included two partial stacks and the full Ares I-X launch vehicle on the Mobile Launcher Platform. This paper provides an overview for companion papers in the Ares I-X Modal Test Session. The requirements flow down, pre-test analysis, constraints and overall test planning are described.

Buehrle, Ralph D.↗
NASA NTRS2010

Measuring Cyclic Error in Laser Heterodyne Interferometers

An improved method and apparatus have been devised for measuring cyclic errors in the readouts of laser heterodyne interferometers that are configured and operated as displacement gauges. The cyclic errors arise as a consequence of mixing of spurious optical and electrical signals in beam launchers that are subsystems of such interferometers. The conventional approach to measurement of cyclic error involves phase measurements and yields values precise to within about 10 pm over air optical paths at laser wavelengths in the visible and near infrared. The present approach, which involves amplitude measurements instead of phase measurements, yields values precise to about .0.1 microns . about 100 times the precision of the conventional approach. In a displacement gauge of the type of interest here, the laser heterodyne interferometer is used to measure any change in distance along an optical axis between two corner-cube retroreflectors. One of the corner-cube retroreflectors is mounted on a piezoelectric transducer (see figure), which is used to introduce a low-frequency periodic displacement that can be measured by the gauges. The transducer is excited at a frequency of 9 Hz by a triangular waveform to generate a 9-Hz triangular-wave displacement having an amplitude of 25 microns. The displacement gives rise to both amplitude and phase modulation of the heterodyne signals in the gauges. The modulation includes cyclic error components, and the magnitude of the cyclic-error component of the phase modulation is what one needs to measure in order to determine the magnitude of the cyclic displacement error. The precision attainable in the conventional (phase measurement) approach to measuring cyclic error is limited because the phase measurements are af-

Ryan, Daniel↗
NASA NTRS2009

Ares I Avionics Introduction

The Ares I is the next generation human-rated launcher for the United States Constellation program. This system is required to provide single fault tolerance within defined crew safety and mission reliability limits. As part of the effort to achieve those safety goals, Ares I includes an avionics subsystem built as a multistring, voting architecture. The avionics design draws upon experience gained from building fly-by-wire systems for Shuttle, X- 38, and Seawolf. Architectural drivers for the avionics design include using proven technologies with existing suppliers of space rated parts for critical functions (to reduce overall development risk), easing the software development effort by using an off-theshelf, DO-178B certifiable, ARINC-653 operating system in the main flight computers, minimizing mutual data and power connections that might lead to a common-mode hardware failure of the redundant avionics strings, and centralizing overall Ares I command & control within the Upper Stage.

Marchant, Christopher C.↗
NASA NTRS2010

Ares I-X Flight Test Vehicle:Stack 1 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA s Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the second modal test that was performed on the middle section of the vehicle referred to as Stack 1, which consisted of the subassembly from the 5th segment simulator through the interstage. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 1 modal test.

Buehrle, Ralph D.↗
NASA NTRS2010

Operational Lessons Learned from the Ares I-X Flight Test

The Ares I-X flight test, launched in 2009, is the first test of the Ares I crew launch vehicle. This development flight test evaluated the flight dynamics, roll control, and separation events, but also provided early insights into logistical, stacking, launch, and recovery operations for Ares I. Operational lessons will be especially important for NASA as the agency makes the transition from the Space Shuttle to the Constellation Program, which is designed to be less labor-intensive. The mission team itself comprised only 700 individuals over the life of the project compared to the thousands involved in Shuttle and Apollo missions; while missions to and beyond low-Earth orbit obviously will require additional personnel, this lean approach will serve as a model for future Constellation missions. To prepare for Ares I-X, vehicle stacking and launch infrastructure had to be modified at Kennedy Space Center's Vehicle Assembly Building (VAB) as well as Launch Complex (LC) 39B. In the VAB, several platforms and other structures designed for the Shuttle s configuration had to be removed to accommodate the in-line, much taller Ares I-X. Vehicle preparation activities resulted in delays, but also in lessons learned for ground operations personnel, including hardware deliveries, cable routing, transferred work and custodial paperwork. Ares I-X also proved to be a resource challenge, as individuals and ground service equipment (GSE) supporting the mission also were required for Shuttle or Atlas V operations at LC 40/41 at Cape Canaveral Air Force Station. At LC 39B, several Shuttle-specific access arms were removed and others were added to accommodate the in-line Ares vehicle. Ground command, control, and communication (GC3) hardware was incorporated into the Mobile Launcher Platform (MLP). The lightning protection system at LC 39B was replaced by a trio of 600-foot-tall towers connected by a catenary wire to account for the much greater height of the vehicle. Like Shuttle, Ares I-X will be stacked on a MLP and rolled out to the pad on a Saturn-era crawler-transporter. While Ares I-X was only held in place by the four hold-down posts on its aft skirt during rollout, a new vehicle stabilization system (VSS) attached to the vertical service structure kept the vehicle from undue swaying prior to launch at the pad, LC 39B. Following the launch, the flight test vehicle first stage was recovered with the aid of new parachutes resized to accommodate the five-segment-long first stage, which had a much greater length and mass than the Shuttle s reusable solid rocket boosters. After splashdown, recovery divers exercised extra care when handling the first stage to ensure that the flight data recorders in the fifth segment simulator were not damaged by exposure to sea water. The data recovered from the Ares I-X flight test will be very valuable in verifying the predicted environments and models used to design the vehicle. Lessons learned from Ares I-X will be shared with the Ares Projects through written and verbal reports and through integration of mission team members into the Project workforce.

Davis, Stephan R.↗
NASA NTRS2010

Ares I-X Post Flight Ignition Overpressure Review

Ignition Overpressure (IOP) is an unsteady fluid flow and acoustic phenomena caused by the rapid expansion of gas from the rocket nozzle within a ducted launching space resulting in an initially higher amplitude pressure wave. This wave is potentially dangerous to the structural integrity of the vehicle. An in-depth look at the IOP environments resulting from the Ares I-X Solid Rocket Booster configuration showed high correlation between the pre-flight predictions and post-flight analysis results. Correlation between the chamber pressure and IOP transients showed successful acoustic mitigation, containing the strongest IOP waves below the Mobile Launch Pad deck. The flight data allowed subsequent verification and validation of Ares I-X unsteady fluid ducted launcher predictions, computational fluid dynamic models, and strong correlation with historical Shuttle data.

Alvord, David A.↗
NASA NTRS2010

From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration

In 2006, NASA selected an evolved variant of the proven Saturn/Apollo J-2 upper stage engine to power the Ares I crew launch vehicle upper stage and the Ares V cargo launch vehicle Earth departure stage (EDS) for the Constellation Program. Any design changes needed by the new engine would be based where possible on proven hardware from the Space Shuttle, commercial launchers, and other programs. In addition to the thrust and efficiency requirements needed for the Constellation reference missions, it would be an order of magnitude safer than past engines. It required the J-2X government/industry team to develop the highest performance engine of its type in history and develop it for use in two vehicles for two different missions. In the attempt to achieve these goals in the past five years, the Upper Stage Engine team has made significant progress, successfully passing System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of spring 2010, more than 100,000 experimental and development engine parts have been completed or are in various stages of manufacture. Approximately 1,300 of more than 1,600 engine drawings have been released for manufacturing. This progress has been due to a combination of factors: the heritage hardware starting point, advanced computer analysis, and early heritage and development component testing to understand performance, validate computer modeling, and inform design trades. This work will increase the odds of success as engine team prepares for powerpack and development engine hot fire testing in calendar 2011. This paper will provide an overview of the engine development program and progress to date.

Kynard, Mike↗
NASA NTRS2010

Flight Performance of the Inflatable Reentry Vehicle Experiment II

The Inflatable Reentry Vehicle Experiment II launched August 17, 2009, from NASA Wallops Flight Facility. The three mission objectives were to demonstrate inflation and re-entry survivability, assess the thermal and drag performance of the reentry vehicle, and to collect flight data for comparison with analysis and design techniques used in vehicle development. The flight was a complete success, with the re-entry vehicle separating cleanly from the launcher, inflating as planned, and demonstrating stable flight through reentry and descent while on-board systems telemetered video and flight performance data to the ground.

Dillman, Robert A.↗
NASA NTRS2010

The J-2X Upper Stage Engine: From Design to Hardware

NASA is well on its way toward developing a new generation of launch vehicles to support of national space policy to retire the Space Shuttle fleet, complete the International Space Station, and return to the Moon as the first step in resuming this nation s exploration of deep space. The Constellation Program is developing the launch vehicles, spacecraft, surface systems, and ground systems to support those plans. Two launch vehicles will support those ambitious plans the Ares I and Ares V. (Figure 1) The J-2X Upper Stage Engine is a critical element of both of these new launchers. This paper will provide an overview of the J-2X design background, progress to date in design, testing, and manufacturing. The Ares I crew launch vehicle will lift the Orion crew exploration vehicle and up to four astronauts into low Earth orbit (LEO) to rendezvous with the space station or the first leg of mission to the Moon. The Ares V cargo launch vehicle is designed to lift a lunar lander into Earth orbit where it will be docked with the Orion spacecraft, and provide the thrust for the trans-lunar journey. While these vehicles bear some visual resemblance to the 1960s-era Saturn vehicles that carried astronauts to the Moon, the Ares vehicles are designed to carry more crew and more cargo to more places to carry out more ambitious tasks than the vehicles they succeed. The government/industry team designing the Ares rockets is mining a rich history of technology and expertise from the Shuttle, Saturn and other programs and seeking commonality where feasible between the Ares crew and cargo rockets as a way to minimize risk, shorten development times, and live within the budget constraints of its original guidance.

Byrd, Thomas↗