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NASA NTRS1988

Space Station maintenance concept study

The relationships among NASA Space Station operational constraints and logistical requirements are presently investigated. The concepts studied locate organizational, intermediate, and depot maintenance at the Space Station, at the Kennedy Space Center (KSC), and at a depot remote from the KSC. Measures of reliability, maintainability, and availability were selected; a life-cycle study was then conducted to ascertain the optimum Space Station system maintenance concept. The results obtained indicate that orbital replacement unit MTBFs should not be less than 36,000 hours.

Nelson, Eric E.↗

NASA NTRS1995

Reliability and Maintainability model (RAM) user and maintenance manual

This report documents the procedures for utilizing and maintaining the Reliability and Maintainability Model (RAM) developed by the University of Dayton for the NASA Langley Research Center (LaRC). The RAM model predicts reliability and maintainability (R&M) parameters for conceptual space vehicles using parametric relationships between vehicle design and performance characteristics and subsystem mean time between maintenance actions (MTBM) and manhours per maintenance action (MH/MA). These parametric relationships were developed using aircraft R&M data from over thirty different military aircraft of all types. This report describes the general methodology used within the model, the execution and computational sequence, the input screens and data, the output displays and reports, and study analyses and procedures. A source listing is provided.

Ebeling, Charles E.↗

NASA NTRS1983

A multi-item maintenance center inventory model for low-demand reparable items

In many military and commercial contexts, complex equipment undergoes scheduled maintenance overhauls at regular intervals during which all failed components are replaced. Failure to have replacements on hand for all failed parts requires emergency measures at premium cost. When reparable parts are highly reliable and expensive, both holding and shortage costs are high. This model determines the reparable parts inventory for a maintenance center under three alternative criteria: (1) maximizing job-completion rate subject to constraint on total holding costs, (2) minimizing total holding costs plus expected job noncompletion costs, and (3) minimizing total holding costs subject to a required minimum job-completion rate. Exact solutions may be obtained using dynamic programming. Approximate solutions, found easily by marginal analysis, have readily computed bounds on possible error. The solution methods for the three formulations are illustrated in a simple example.

Schaefer, M. K.↗

NASA NTRS1985

Measuring the impact of computer resource quality on the software development process and product

The availability and quality of computer resources during the software development process was speculated to have measurable, significant impact on the efficiency of the development process and the quality of the resulting product. Environment components such as the types of tools, machine responsiveness, and quantity of direct access storage may play a major role in the effort to produce the product and in its subsequent quality as measured by factors such as reliability and ease of maintenance. During the past six years, the NASA Goddard Space Flight Center has conducted experiments with software projects in an attempt to better understand the impact of software development methodologies, environments, and general technologies on the software process and product. Data was extracted and examined from nearly 50 software development projects. All were related to support of satellite flight dynamics ground-based computations. The relationship between computer resources and the software development process and product as exemplified by the subject NASA data was examined. Based upon the results, a number of computer resource-related implications are provided.

Mcgarry, Frank↗

NASA NTRS2003

Radial Clearance Found To Play a Key Role in the Performance of Compliant Foil Air Bearings

Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution, which supports gas turbine engines with hydrodynamic bearings that use air instead of oil as the working fluid. These types of bearings have been around for almost 50 years and have found a home in several commercial applications, such as in air cycle machines, turbocompressors, and microturbines, but are now being aggressively pursued for use in small and midrange aircraft gas turbine engines. Benefits include higher operating speeds and temperatures, lower maintenance costs, and greater reliability. The Oil-Free Turbomachinery team at the NASA Glenn Research Center is working to foster the transition of Oil-Free technology into gas turbine engines by performing in-house experiments on foil air bearings in order to gain a greater insight into their complex operating principles. A research program recently undertaken at Glenn focused on the concept of radial clearance and its influence on bearing performance. The tests were conducted on foil bearings with different radial clearances. As defined for a foil bearing, radial clearance is a measure of the small amount of shaft radial motion that is present from play that exists in the elastic support structure, such as between the top and bump foils and the bump foils and bearing shell (see the drawing). With an insufficient amount of radial clearance, the bearing imparts a high preload on the shaft, which when excessive, can reduce the loadcarrying capability of the bearing. On the other hand, systems using foil bearings with excessive radial clearance may experience rotordynamic instabilities because of low bearing preload. Therefore, without a more thorough understanding of radial clearance, it is difficult to accurately predict the performance of a given bearing design. The test program demonstrated that there is a direct correlation between radial clearance and the performance of foil air bearings. As shown in the graph, an optimum radial clearance exists that will maximize the amount of load that the bearing is capable of supporting. With respect to this optimum, two different performance regimes were observed that are a function of the amount of radial clearance. Tests showed that bearings with radial clearances below the optimum in regime I were susceptible to sudden seizure, a failure mode indicative of thermal runaway caused by high preload. The high preload is in response to an insufficient amount of radial clearance available to accommodate the thermal growth of the bearing and shaft. However, radial clearances greater than the optimum in regime II resulted in low bearing preloads that did not cause any heat-related problems, and the failure mode was due to fluid-film breakdown. In fact, bearings operating with radial clearances twice as much as the optimum suffered a decrease in the maximum load capacity of only about 20 percent. Therefore, special attention has to be given to the range of operating conditions expected in the bearing/shaft system since changes in temperature, centrifugal, and hydrodynamic effects can all affect radial clearance. This enhanced understanding of foil air bearing behavior will greatly aid our efforts to transition Oil-Free technology to future aircraft engines.

Radil, Kevin C.↗

NASA NTRS1998

Improving Safety and Reliability of Space Auxiliary Power Units

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.

Viterna, Larry A.↗

NASA NTRS1996

Reliability and Maintainability Model (RAM): User and Maintenance Manual: Improved Supportability Analysis - Part 2

This report documents the procedures for utilizing and maintaining the Reliability & Maintainability Model (RAM) developed by the University of Dayton for the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC). The purpose of the grant is to provide support to NASA in establishing operational and support parameters and costs of proposed space systems. As part of this research objective, the model described here was developed. This Manual updates and supersedes the 1995 RAM User and Maintenance Manual. Changes and enhancements from the 1995 version of the model are primarily a result of the addition of more recent aircraft and shuttle R&M data.

Ebeling, Charles E.↗

NASA NTRS2001

Space Shuttle Main Engine Joint Data List Applying Today's Desktop Technologies to Facilitate Engine Processing

Boeing-Rocketdyne's Space Shuttle Main Engine (SSME) is the world's first large reusable liquid rocket engine. The space shuttle propulsion system has three SSMEs, each weighing 7,400 lbs and providing 470,000 lbs of thrust at 100% rated power level. To ensure required safety and reliability levels are achieved with the reusable engines, each SSME is partially disassembled, inspected, reassembled, and retested at Kennedy Space Center between each flight. Maintenance processing must be performed very carefully to replace any suspect components, maintain proper engine configuration, and avoid introduction of contaminants that could affect performance and safety. The long service life, and number, complexity, and pedigree of SSME components makes logistics functions extremely critical. One SSME logistics challenge is documenting the assembly and disassembly of the complex joint configurations. This data (joint nomenclature, seal and fastener identification and orientation, assembly sequence, fastener torques, etc.) must be available to technicians and engineers during processing. Various assembly drawings and procedures contain this information, but in this format the required (practical) joint data can be hard to find, due to the continued use of archaic engineering drawings and microfilm for field site use. Additionally, the release system must traverse 2,500 miles between design center and field site, across three time zones, which adds communication challenges and time lags for critical engine configuration data. To aid in information accessibility, a Joint Data List (JDL) was developed that allows efficient access to practical joint data. The published JDL has been a very useful logistics product, providing illustrations and information on the latest SSME configuration. The JDL identifies over 3,350 unique parts across seven fluid systems, over 300 joints, times two distinct engine configurations. The JDL system was recently converted to a web-based, navigable electronic manual that contains all the required data and illustrations in expanded view format using standard PC products (Word, Excel, PDF, Photoshop). The logistics of accurately releasing this information to field personnel was greatly enhanced via the utilization of common office products to produce a more user-friendly format than was originally developed under contract to NASA. This was done without reinventing the system, which would be cost prohibitive on a program of this maturity. The brunt of the joint part tracking is done within the logistics organization and disseminated to all field sites, without duplicating effort at each site. The JDL is easily accessible across the country via the NASA intranet directly at the SSME workstand. The advent of this logistics data product has greatly enhanced the reliability of tracking dynamic changes to the SSME and greatly reduces engineering change turnaround time and potential for errors. Since the inception of the JDL system in 1997, no discrepant parts have propagated to engine assembly operations. This presentation focuses on the challenges overcome and the techniques used to apply today's desktop technologies to an existing logistics data source.

Jacobs, Kenneth↗

NASA NTRS1993

Study of hydraulic actuation system for Space Shuttle main engine propellant valves

Recent performance concerns involving the Space Shuttle Main Engine Propellant Valve Actuator assemblies prompted the NASA Marshall Space Flight Center to request an independent design assessment. Moog Inc. responded to this request and received a study contract with objectives of increasing valve reliability, decreasing maintenance costs while preserving the existing design interfaces. The results of the Propellant Valve Actuation System review focus on contamination control and the bypass valve design. Three proof of concept bypass valves employing design changes were built and successfully tested. Test results are presented.

Ewel, Bob↗

NASA NTRS2004

Performance of a Fuel-Cell-Powered, Small Electric Airplane Assessed

Rapidly emerging fuel-cell-power technologies may be used to launch a new revolution of electric propulsion systems for light aircraft. Future small electric airplanes using fuel cell technologies hold the promise of high reliability, low maintenance, low noise, and - with the exception of water vapor - zero emissions. An analytical feasibility and performance assessment was conducted by NASA Glenn Research Center's Airbreathing Systems Analysis Office of a fuel-cell-powered, propeller-driven, small electric airplane based on a model of the MCR-01 two-place kitplane (Dyn'Aero, Darois, France). This assessment was conducted in parallel with an ongoing effort by the Advanced Technology Products Corporation and the Foundation for Advancing Science and Technology Education. Their project - partially funded by a NASA grant - is to design, build, and fly the first manned, continuously propelled, nongliding electric airplane. In our study, an analytical performance model of a proton exchange membrane (PEM) fuel cell propulsion system was developed and applied to a notional, two-place light airplane modeled after the MCR-01 kitplane. The PEM fuel cell stack was fed pure hydrogen fuel and humidified ambient air via a small automotive centrifugal supercharger. The fuel cell performance models were based on chemical reaction analyses calibrated with published data from the fledgling U.S. automotive fuel cell industry. Electric propeller motors, rated at two shaft power levels in separate assessments, were used to directly drive a two-bladed, variable-pitch propeller. Fuel sources considered were compressed hydrogen gas and cryogenic liquid hydrogen. Both of these fuel sources provided pure, contaminant-free hydrogen for the PEM cells.

Berton, Jeffrey J.↗

NASA NTRS2005

Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment

Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.

Calle, L. M.↗

NASA NTRS2004

Electrochemical Investigation of Corrosion in the Space Shuttle Launch Environment

Calle, L. M.↗

NASA NTRS2004

Waste Processing Research and Technology Development at NASA Ames Research Center

The current "store and return" approach for handling waste products generated during low Earth orbit missions will not meet the requirements for future human missions identified in NASA s new Exploration vision. The objective is to develop appropriate reliable waste management systems that minimize maintenance and crew time, while maintaining crew health and safety, as well as providing protection of planetary surfaces. Solid waste management requirements for these missions include waste volume reduction, stabilization and storage, water recovery, and ultimately recovery of carbon dioxide, nutrients and other resources from a fully regenerative food production life support system. This paper identifies the key drivers for waste management technology development within NASA, and provides a roadmap for the developmental sequence and progression of technologies. Recent results of research and technology development activities at NASA Ames Research Center on candidate waste management technologies with emphasis on compaction, lyophilization, and incineration are discussed.

Fisher, John↗

NASA NTRS2002

Structural Health Monitoring Sensor Development at NASA Langley Research Center

NASA is applying considerable effort on the development of sensor technology for structural health monitoring (SHM). This research is targeted toward increasing the safety and reliability of aerospace vehicles, while reducing operating and maintenance costs. Research programs are focused on applications to both aircraft and space vehicles. Sensor technologies under development span a wide range including fiber-optic sensing, active and passive acoustic sensors, electromagnetic sensors, wireless sensing systems, MEMS, and nanosensors. Because of their numerous advantages for aerospace applications, fiber-optic sensors are one of the leading candidates and are the major focus of this presentation. In addition, recent advances in active and passive acoustic sensing will also be discussed.

Prosser, W. H.↗

NASA NTRS2003

An Analytical Performance Assessment of a Fuel Cell-powered, Small Electric Airplane

Rapidly emerging fuel cell power technologies may be used to launch a new revolution of electric propulsion systems for light aircraft. Future small electric airplanes using fuel cell technologies hold the promise of high reliability, low maintenance, low noise, and with exception of water vapor zero emissions. This paper describes an analytical feasibility and performance assessment conducted by NASA's Glenn Research Center of a fuel cell-powered, propeller-driven, small electric airplane based on a model of the MCR 01 two-place kitplane.

Berton, Jeffrey J.↗

NASA NTRS2007

Autonomic Computing for Spacecraft Ground Systems

Autonomic computing for spacecraft ground systems increases the system reliability and reduces the cost of spacecraft operations and software maintenance. In this paper, we present an autonomic computing solution for spacecraft ground systems at NASA Goddard Space Flight Center (GSFC), which consists of an open standard for a message oriented architecture referred to as the GMSEC architecture (Goddard Mission Services Evolution Center), and an autonomic computing tool, the Criteria Action Table (CAT). This solution has been used in many upgraded ground systems for NASA 's missions, and provides a framework for developing solutions with higher autonomic maturity.

Li, Zhenping↗

NASA NTRS1994

A proven approach for more effective software development and maintenance

Modern space flight mission operations and associated ground data systems are increasingly dependent upon reliable, quality software. Critical functions such as command load preparation, health and status monitoring, communications link scheduling and conflict resolution, and transparent gateway protocol conversion are routinely performed by software. Given budget constraints and the ever increasing capabilities of processor technology, the next generation of control centers and data systems will be even more dependent upon software across all aspects of performance. A key challenge now is to implement improved engineering, management, and assurance processes for the development and maintenance of that software; processes that cost less, yield higher quality products, and that self-correct for continual improvement evolution. The NASA Goddard Space Flight Center has a unique experience base that can be readily tapped to help solve the software challenge. Over the past eighteen years, the Software Engineering Laboratory within the code 500 Flight Dynamics Division has evolved a software development and maintenance methodology that accommodates the unique characteristics of an organization while optimizing and continually improving the organization's software capabilities. This methodology relies upon measurement, analysis, and feedback much analogous to that of control loop systems. It is an approach with a time-tested track record proven through repeated applications across a broad range of operational software development and maintenance projects. This paper describes the software improvement methodology employed by the Software Engineering Laboratory, and how it has been exploited within the Flight Dynamics Division with GSFC Code 500. Examples of specific improvement in the software itself and its processes are presented to illustrate the effectiveness of the methodology. Finally, the initial findings are given when this methodology was applied across the mission operations and ground data systems software domains throughout Code 500.

Pajerski, Rose↗

NASA NTRS2011

Developing Flexible, High Performance Polymers with Self-Healing Capabilities

Flexible, high performance polymers such as polyimides are often employed in aerospace applications. They typically find uses in areas where improved physical characteristics such as fire resistance, long term thermal stability, and solvent resistance are required. It is anticipated that such polymers could find uses in future long duration exploration missions as well. Their use would be even more advantageous if self-healing capability or mechanisms could be incorporated into these polymers. Such innovative approaches are currently being studied at the NASA Kennedy Space Center for use in high performance wiring systems or inflatable and habitation structures. Self-healing or self-sealing capability would significantly reduce maintenance requirements, and increase the safety and reliability performance of the systems into which these polymers would be incorporated. Many unique challenges need to be overcome in order to incorporate a self-healing mechanism into flexible, high performance polymers. Significant research into the incorporation of a self-healing mechanism into structural composites has been carried out over the past decade by a number of groups, notable among them being the University of I1linois [I]. Various mechanisms for the introduction of self-healing have been investigated. Examples of these are: 1) Microcapsule-based healant delivery. 2) Vascular network delivery. 3) Damage induced triggering of latent substrate properties. Successful self-healing has been demonstrated in structural epoxy systems with almost complete reestablishment of composite strength being achieved through the use of microcapsulation technology. However, the incorporation of a self-healing mechanism into a system in which the material is flexible, or a thin film, is much more challenging. In the case of using microencapsulation, healant core content must be small enough to reside in films less than 0.1 millimeters thick, and must overcome significant capillary and surface tension forces to flow, mix and react to achieve healing. Vascular networks small enough to fit into such films must also overcome these same flow limitations. Self-healing has also been demonstrated in ionomeric substrates such as Surlyn , wherein the heat generated by a projectile impact triggers the latent ability of this substrate to flow back to its original shape. Recent work using Diels-Alder reactions have shown promise in bringing about actual reforming of broken chemical bonds to achieve self-healing [2]. All self-healing mechanisms that rely on the use of inherent latent substrate properties require some degree of polymer chain flow to achieve any significant level of healing.

Jolley, Scott T.↗