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The Advanced Launch System (ALS) is presented. The costs, reliability, capabilities, infrastructure are briefly described. Quality approach, failure modes, structural design, technology benefits, and key facilities are outlined. This presentation is represented by viewgraphs.
The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.
Providing routine, affordable access to a variety of orbital and deep space destinations requires an intricate network of ground, planetary surface, and space-based spaceports like those on Earth (land and sea), in various Earth orbits, and on other extraterrestrial surfaces. Advancements in technology and international collaboration are critical to establish a spaceport network that satisfies the requirements for private and government research, exploration, and commercial objectives. Technologies, interfaces, assembly techniques, and protocols must be adapted to enable mission critical capabilities and interoperability throughout the spaceport network. The conceptual space mission architecture must address the full range of required spaceport services, from managing propellants for a variety of spacecraft to governance structure. In order to accomplish affordability and sustainability goals, the network architecture must consider deriving propellants from in situ planetary resources to the maximum extent possible. Water on the Moon and Mars, Mars' atmospheric CO2, and O2 extracted from lunar regolith are examples of in situ resources that could be used to generate propellants for various spacecraft, orbital stages and trajectories, and the commodities to support habitation and human operations at these destinations. The ability to use in-space fuel depots containing in situ derived propellants would drastically reduce the mass required to launch long-duration or deep space missions from Earth's gravity well. Advances in transformative technologies and common capabilities, interfaces, umbilicals, commodities, protocols, and agreements will facilitate a cost-effective, safe, reliable infrastructure for a versatile network of Earth- and extraterrestrial spaceports. Defining a common infrastructure on Earth, planetary surfaces, and in space, as well as deriving propellants from in situ planetary resources to construct in-space propellant depots to serve the spaceport network, will reduce exploration costs due to standardization of infrastructure commonality and reduction in number and types of interfaces and commodities.
NASA’s near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center’s (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC’s Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA’s CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.
NASA's near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center's (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC's Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA's CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.
NASA s Human Research Program (HRP) conducts and coordinates research projects that provide human health and performance countermeasures, knowledge, technologies, and tools to enable safe, reliable, and productive human space exploration. The Program is divided into 6 major elements, which a) Provide the Program s knowledge and capabilities to conduct research, addressing the human health and performance risks. b) Advance the readiness levels of technology and countermeasures to the point of transfer to the customer programs and organizations. The National Space Biomedical Research Institute (NSBRI) is a partner with the HRP in developing a successful research program. 3
In support of the Exploration Vision for returning to the Moon and beyond, NASA and its partners are developing and testing critical cryogenic fluid propellant technologies that will meet the need for high performance propellants on long-term missions. Reliable knowledge of low-gravity cryogenic fluid management behavior is lacking and yet is critical in the areas of tank thermal and pressure control, fluid acquisition, mass gauging, and fluid transfer. Such knowledge can significantly reduce or even eliminate tank fluid boil-off losses for long term missions, reduce propellant launch mass and required on-orbit margins, and simplify vehicle operations. The Propulsion and Cryogenic Advanced Development (PCAD) Project is performing experimental and analytical evaluation of several areas within Cryogenic Fluid Management (CFM) to enable NASA's Exploration Vision. This paper discusses the status of the PCAD CFM technology focus areas relative to the anticipated CFM requirements to enable execution of the Vision for Space Exploration.
This final report summarizes the results of a comparative assessment of the fault tolerance and reliability of different Guidance, Navigation and Control (GN&C) architectural approaches. This study was proactively performed by a combined Massachusetts Institute of Technology (MIT) and Draper Laboratory team as a GN&C "Discipline-Advancing" activity sponsored by the NASA Engineering and Safety Center (NESC). This systematic comparative assessment of GN&C system architectural approaches was undertaken as a fundamental step towards understanding the opportunities for, and limitations of, architecting highly reliable and fault tolerant GN&C systems composed of common avionic components. The primary goal of this study was to obtain architectural 'rules of thumb' that could positively influence future designs in the direction of an optimized (i.e., most reliable and cost-efficient) GN&C system. A secondary goal was to demonstrate the application and the utility of a systematic modeling approach that maps the entire possible architecture solution space.
Space weather forecasting capabilities are becoming increasingly important to the health of advanced technological infrastructure. The Community Coordinated Modeling Center (CCMC, https://ccmc.gsfc.nasa.gov) serves as a key liaison in the US space weather program between the research and operations communities by providing a wide range of tools and capabilities that help to evaluate, compare, exercise, and archive the results of simulations of a growing list of space weather models. With its unique toolset, CCMC supports space weather research and model development that advances our understanding of space weather phenomena and improves forecasting skill, while also facilitating development of space weather applications and deployment of operational capabilities. Guided by experience from over 20 years of providing simulation services, feedback from its research, operational and educational users world-wide, recommendations from CCMC Advisory Group and Programmatic Review Panel, the CCMC has begun work on the next generation system for its simulation services and model output archives. The new system has been envisioned to employ state-of-the-art technologies and standards to provide a user-oriented experience while improving ease of access, transparency, interoperability with partner systems, and enhancing reliability by incorporating advanced automation for performance monitoring and intelligent failover. In the presentation, we will give an overview of the current CCMC ecosystem and discuss updates to some of the key services of the system, including Runs-on-Request, Instant Runs, and Continuous Runs. We will also describe how a planned expansion and standardization of data archival activities will enhance the role of CCMC as a world-class provider of heliophysics information for the research and analysis of space weather. It is our hope that this evolution of the services can further reduce the barriers and burdens on researchers, forecasters and decision makers who rely on CCMC for their daily research and operations.
Anticipated major advances in integrated circuit technology in the near future are described as well as their impact on satellite onboard signal processing systems. Dramatic improvements in chip density, speed, power consumption, and system reliability are expected from very large scale integration. Improvements are expected from very large scale integration enable more intelligence to be placed on remote sensing platforms in space, meeting the goals of NASA's information adaptive system concept, a major component of the NASA End-to-End Data System program. A forecast of VLSI technological advances is presented, including a description of the Defense Department's very high speed integrated circuit program, a seven-year research and development effort.
Three candidate hybrid propulsion (HP) concepts were identified, optimized, evaluated, and refined through an iterative process that continually forced improvement to the systems with respect to safety, reliability, cost, and performance criteria. A full scale booster meeting Advanced Solid Rocket Motor (ASRM) thrust-time constraints and a booster application for 1/4 ASRM thrust were evaluated. Trade studies and analyses were performed for each of the motor elements related to SRM technology. Based on trade study results, the optimum HP concept for both full and quarter sized systems was defined. The three candidate hybrid concepts evaluated are illustrated.
Automated fiber placement provides many advancements beyond traditional hand layups in terms of efficiency and reliability. However, there are also a variety of unique challenges that arise with automated fiber placement technology. In particular, steering of tows over doubly-curved tool surfaces can result in material overlaps and gaps due to path convergence/divergence, fiber angle deviation, as well defects in the tows themselves such as puckers and wrinkles. Minimization of these defects is traditionally considered a task for the manufacturing discipline. Manufacturing specifications are often created for these defects based on laminate testing and can be inflexible to avoid more tests. Recent efforts have been made under the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP) to develop software tools and processes that provide automated coupling between design and manufacturing disciplines. The objective of this coupling is to provide information to the design discipline on the manufacturability of a laminate while the laminate is being designed. A variety of software tools, both existing commercial tools and research tools under development, will be used to achieve this objective: HyperSizer for laminate optimization, the Computer Aided Process Planning module for selection of manufacturing process parameters, Vericut Composite Programming for tow path simulation, and COMPRO for deposition and cure defects. The newly developed “Central Optimizer” tool will be used to tie the modules together and drive the design for manufacturing process.
The problem of returning a Mars sample to Earth was considered. The model ecosystem concept was advanced as the most reliable, sensitive method for assessing the biohazard from the Mars sample before it is permitted on Earth. Two approaches to ecosystem development were studied. In the first approach, the Mars sample would be introduced into the ecosystem and exposed to conditions which are as similar to the Martian environment as the constitutent terrestrial organisms can tolerate. In the second approach, the Mars sample would be tested to determine its effects on important terrestrial cellular functions. In addition, efforts were directed toward establishing design considerations for a Mars Planetary Receiving Laboratory. The problems encountered with the Lunar Receiving Laboratory were evaluated in this context. A questionnaire was developed to obtain information regarding important experiments to be conducted in the Planetary Receiving Laboratory.
The benefits that will be offered by the NASA-sponsored communication spacecraft ACTS which is scheduled for launch in 1992 are described together with examples of demonstrations on proposed data, video, and voice applications supported by the advanced ACTS technologies. Compared to existing satellite service, the ACTS will provide lower cost, better service, greater convenience, and improved service reliability of telecommunications to customers around the world. In addition, the pioneering ACTS technology will provide many capabilities qualitatively different from those of current satellite systems, such as on-demand assignment, frequency reuse, and the flexible targeting of spot beams directly to the very-small-aperture terminals at customer premises.
NASA Lewis Research Center has organized a component technology program as part of the efforts to develop Stirling converter technology for space power applications. The Stirling Space Power Program is part of the NASA High Capacity Power Project of the Civil Space Technology Initiative (CSTI). NASA Lewis is also providing technical management for the DOE/Sandia program to develop Stirling converters for solar terrestrial power producing electricity for the utility grid. The primary contractors for the space power and solar terrestrial programs develop component technologies directly related to their goals. This Lewis component technology effort, while coordinated with the main programs, aims at longer term issues, advanced technologies, and independent assessments. An overview of work on linear alternators, engine/alternator/load interactions and controls, heat exchangers, materials, life and reliability, and bearings is presented.
At mature operations, Space Station Freedom will need more than 2000 power supplies to feed housekeeping and user loads. Advanced technology power supplies from 20 to 250 W have been hybridized for terrestrial, aerospace, and industry applications in compact, efficient, reliable, lightweight packages compatible with electromagnetic interference requirements. The use of these hybridized packages as modules, either singly or in parallel, to satisfy the wide range of user power supply needs for all elements of the station is proposed. Proposed characteristics for the power supplies include common mechanical packaging, digital control, self-protection, high efficiency at full and partial loads, synchronization capability to reduce electromagnetic interference, redundancy, and soft-start capability. The inherent reliability is improved compared with conventional discrete component power supplies because the hybrid circuits use high-reliability components such as ceramic capacitors. Reliability is further improved over conventional supplies because the hybrid packages, which may be treated as a single part, reduce the parts count in the power supply.
NASA Lewis Research Center has organized a component technology program as part of the efforts to develop Stirling converter technology for space power applications. The Stirling Space Power Program is part of the NASA High Capacity Power Project of the Civil Space Technology Initiative (CSTI). NASA Lewis is also providing technical management for the DOE/Sandia program to develop Stirling converters for solar terrestrial power producing electricity for the utility grid. The primary contractors for the space power and solar terrestrial programs develop component technologies directly related to their goals. This Lewis component technology effort, while coordinated with the main programs, aims at longer term issues, advanced technologies, and independent assessments. An overview of work on linear alternators, engine/alternator/load interactions and controls, heat exchangers, materials, life and reliability, and bearings is presented.
Auxiliary Power Units (APU's) play a critical role in space vehicles. On the space shuttle, APU's provide the hydraulic power for the aerodynamic control surfaces, rocket engine gimballing, landing gear, and brakes. Future space vehicles, such as the Reusable Launch Vehicle, will also need APU's to provide electrical power for flight control actuators and other vehicle subsystems. Vehicle designers and mission managers have identified safety, reliability, and maintenance as the primary concerns for space APU's. In 1997, the NASA Lewis Research Center initiated an advanced technology development program to address these concerns.