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Characterization of Ice for Return-to-Flight of the Space Shuttle: Soft Ice - Part 2

In support of characterizing ice debris for return-to-flight (RTF) of NASA's space shuttle, we have determined the microstructure, density and compressive strength (at -10 C at approximately 0.3 per second) of porous or soft ice that was produced from both atmospheric water and consolidated snow. The study showed that the atmospheric material was generally composed of a mixture of very fine (0.1 to 0.3 millimeters) and coarser (5 to 10 millimeter) grains, plus air bubbles distributed preferentially within the more finely-grained part of the microstructure. The snow ice was composed of even finer grains (approximately 0.05 millimeters) and contained more pores. Correspondingly, the snow ice was of lower density than the atmospheric ice and both materials were significantly less dense than hard ice. The atmospheric ice was stronger (approximately 3.8 MPa) than the snow ice (approximately 1.9 MPa), but weaker by a factor of 2 to 5 than pore-free hard ice deformed under the same conditions. Zero Values are given for Young's modulus, compressive strength and Poisson's ratio that can be used for modeling soft ice from the external tank (ET).

Schulson, Erland M.↗

After Math - Foamology and Flight Rationale

The Space Shuttle was developed by NASA to be a largely reusable launch system which could provide frequent access to low earth orbit. Like all previous launch systems, safe reentry for the crew and payload required the use of a thermal protection system (TPS). Unlike previous spacecraft though, the Shuttle's TPS was exposed from launch, making it sensitive to debris which could be generated by the vehicle on ascent. The most likely and potentially destructive source of debris was considered to be ice, which could build-up anywhere on the External Tank (ET) where there was exposed metal. Ice could form during ground operations after the cryogenic propellants had been loaded and then be knocked loose on ascent. In order to prevent both ice build-up and boil-off of the propellants, the entire ET and all protuberances (orbiter attach points, pressurization lines, propellant feed lines, etc.) were covered with a spray on foam insulation (SOFI) type TPS. Unfortunately the foam was also susceptible to liberation during ascent, and posed a debris risk of its own. During the early years of the Shuttle Program engineers spent a good deal of effort characterizing the amount of foam that was shed.

Steva, Thomas↗

External Tank Program - Legacy of Success

The largest single element of Space Shuttle is the External Tank (ET), which serves as the structural backbone of the vehicle during ascent and provides liquid propellants to the Orbiter s three Main Engines. The ET absorbs most of the seven million pounds of thrust exerted by the Solid Rocket Boosters and Main Engines. The design evolved through several block changes, reducing weight each time. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. The initial configuration, the standard weight tank, weighed 76,000 pounds and was an aluminum 2219 structure. The light weight tank weighed 66,000 pounds and flew 86 missions. The super light weight tank weighed 58,500 pounds and was primarily an aluminum-lithium structure. The final configuration and low weight enabled system level performance sufficient for assembly of the International Space Station in a high inclination orbit, vital for international cooperation. Another significant challenge was the minimization of ice formation on the cryogenic tanks. This was essential due to the system configuration and the choice of ceramic thermal protection system materials on the Orbiter. Ice would have been a major debris hazard. Spray on foam insulation materials served multiple functions including thermal insulation, conditioning of cryogenic propellants, and thermal protection for the tank structure during ascent and entry. The tank is large, and unique manufacturing facilities, tooling, and handling, and transportation operations were developed. Weld processes and tooling evolved with the design as it matured through several block changes. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the multi-decade program. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when hurricane Katrina damaged the manufacturing facility. Numerous lessons from these efforts, the manufacturing and material processing issues, the key design features, and evolution of the design will be discussed.

Pilet, Jeffery C.↗

Quantitative analysis of ice films by near-infrared spectroscopy

One of the outstanding problems in the Space Transportation System is the possibility of the ice buildup on the external fuel tank surface while it is mounted on the launch pad. During the T-2 hours (and holding) period, the frost/ice thickness on the external tank is monitored/measured. However, after the resumption of the countdown time, the tank surface can only be monitored remotely. Currently, remote sensing is done with a TV camera coupled to a thermal imaging device. This device is capable of identifying the presence of ice, especially if it is covered with a layer of frost. However, it has difficulty identifying transparent ice, and, it is not capable of determining the thickness of ice in any case. Thus, there is a need for developing a technique for measuring the thickness of frost/ice on the tank surface during this two hour period before launch. The external tank surface is flooded with sunlight (natural or simulated) before launch. It may be possible, therefore, to analyze the diffuse reflection of sunlight from the external tank to determine the presence and thickness of ice. The purpose was to investigate the feasibility of this approach. A near-infrared spectrophotometer was used to record spectra of ice. It was determined that the optimum frequencies for monitoring the ice films were 1.03 and 1.255 microns.

Keiser, Joseph T.↗

Ice/frost detection using millimeter wave radiometry

A series of ice detection tests was performed on the shuttle external tank (ET) and on ET target samples using a 35/95 GHz instrumentation radiometer. Ice was formed using liquid nitrogen and water spray inside a test enclosure containing ET spray on foam insulation samples. During cryogenic fueling operations prior to the shuttle orbiter engine firing tests, ice was formed with freon and water over a one meter square section of the ET LOX tank. Data analysis was performed on the ice signatures, collected by the radiometer, using Georgia Tech computing facilities. Data analysis technique developed include: ice signature images of scanned ET target; pixel temperature contour plots; time correlation of target data with ice present versus no ice formation; and ice signature radiometric temperature statistical data, i.e., mean, variance, and standard deviation.

Gagliano, J. A.↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

STS-121: Discovery Space Shuttle Safety Improvements Briefing

Steve Poulos, Space Shuttle Orbiter Projects Office Manager, and John Chapman, Space Shuttle External Tank Project Manager is shown in this STS-121 Space Shuttle Discovery safety improvements briefing. A graphic presentation of the gap filler installation is shown. The graphics include: 1) Protruding gap fillers during STS-114 mission; 2) STS-114 gap fillers removed on orbiter; 3) Gap filler installation prior to STS-114; 4) Post-STS-114 installation techniques; 5) Gap filler installation post STS-114; 6) Gap filler priority areas; 7) Discovery gap filler installation table and status for STS-121; 8) Damaged blanket on STS-114; 9) On-orbit photography and post-landing photography on STS-114; and 10) STS-114 insulation tiles. Poulos presents imagery that was obtained on STS-114. The imagery includes: 1) The Enhanced Launch Vehicle Imaging System (ELVIS); 2) Liquid oxygen external tank view; 3) Hand-held imagery of the external tank falling into the ocean; 4) ELVIS on STS-121, short, medium and long range camera configurations; 5) Radar capability on the ground at Kennedy Space Center, and 6) STS-121 aft external tank door tiles. Poulos says that STS-121 will have even more imagery than STS-114. John Chapman presents video animation of the external tank where modifications were made along with the ice frost ramps with extensions. Chapman explains these areas using an external tank model. Questions are then answered from the media.

Source record↗

Multispectral radiation detection of small changes in target emissivity

An investigation into the multispectral radiation detection of small changes in target emissivity has been performed by Georgia Tech. A series of ice detection measurements on the shuttle external tank (ET) were performed using an advanced instrumentation radiometer operating at 35/95 GHz. Actual shuttle ET ice detection measurements were run at NASA's National Space Technology Laboratory (NSTL) during cryogenic fueling operations prior to orbiter engine firing tests. Investigations revealed that ET icing caused an increase in surface brightness temperature and the test results further demonstrated the usefulness of millimeter wave radiometry for the detection of ice on the ET.

Gagliano, J. A.↗

Active microwave measurements of artificial sea ice

A 5 m x 15 m outdoor tank of 1.2 m depth was filled with sea water, and polarimetric radar backscatter data were collected at 1.8, 5, and 10 GHz for incidence angles 0 to 60 deg. Observations commenced with open water and continued until 30 cm of sea ice formed. The roughness of the ice surface is important in determining the general backscatter level for first-year ice. Experiments were performed to study the change in backscatter with various roughness scales. Effects of freeze and thaw conditions were also examined. Absolute backscatter levels for new to gray ice are small, except for the large, coherent returns at vertical. The backscatter responses of new, gray, rough grey, and desalinated first-year ice at linear polarization are dissimilar. This is confirmed by examining their polarization signatures.

Onstott, R. G.↗

Device Maintains Water At The Triple Point

Inexpensive device maintains water at 0.01 degree C for 10 weeks or longer. New device consists of four basic assemblies; small, commercial chest freezer containing insulated water tank; insulated copper cell holder; "ice switch" for cycling freezer compressor and externally-mounted air pump for circulation. Access hole in freezer lid allows triple point measurements without opening lid. Modified freezer used to calibrate standard platinum resistance thermomenters.

West, J. W.↗

Debris/ice/TPS assessment and integrated photographic analysis for Shuttle Mission STS-51

A debris/ice/thermal protection system (TPS) assessment and integrated photographic analysis was conducted for shuttle mission STS-51. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the external tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography was analyzed after launch to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the debris/ice/TPS conditions and integrated photographic analysis of Shuttle mission STS-51 and the resulting effect on the Space Shuttle Program.

Katnik, Gregory N.↗

Debris/Ice/TPS assessment and integrated photographic analysis for Shuttle Mission STS-61

A debris/ice/thermal protection system (TPS) assessment and integrated photographic analysis was conducted for shuttle mission STS-61. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the external tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/TPS conditions and integrated photographic analysis of shuttle mission STS-61, and the resulting effect on the space shuttle program.

Katnik, Gregory N.↗

Debris/ice/TPS assessment and integrated photographic analysis for Shuttle mission STS-58

A debris/ice/thermal protection system (TPS) assessment and integrated photographic analysis was conducted for Shuttle mission STS-58. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the External Tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. The ice/debris/TPS conditions and integrated photographic analysis of Shuttle mission STS-58, and the resulting effect on the Space Shuttle Program are documented.

Davis, J. Bradley↗

Debris/ice/TPS assessment and integrated photographic analysis for Shuttle mission STS-60

A debris/ice/thermal protection system (TPS) assessment and integrated photographic analysis was conducted for Shuttle mission STS-60. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the External Tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/TPS conditions and integrated photographic analysis of Shuttle mission STS-60, and the resulting effect on the Space Shuttle Program.

Katnik, Gregory N.↗

Debris/ice/TPS assessment and integrated photographic analysis for Shuttle Mission STS-59

A debris/ice/thermal protection system assessment and integrated photographic analysis was conducted for shuttle mission STS-59. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the external tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by an on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/ thermal protection system conditions and integrated photographic analysis of shuttle mission STS-59, and the resulting effect on the Space Shuttle Program.

Katnik, Gregory N.↗

Debris/ice/TPS assessment and integrated photographic analysis of Shuttle Mission STS-65

A debris/ice/thermal protection system assessment and integrated photographic analysis was conducted for shuttle mission STS-65. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the external tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/thermal protection system conditions and integrated photographic analysis of shuttle mission STS-65, and the resulting effect on the Space Shuttle Program.

Katnik, Gregory N.↗

Debris/ice/TPS assessment and integrated photographic analysis of Shuttle Mission STS-64 on 9 August 1994

A debris/ice/thermal protection system assessment and integrated photographic analysis was conducted for Shuttle mission STS-64. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the External Tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report documents the ice/debris/thermal protection system conditions and integrated photographic analysis of Shuttle mission STS-64, and the resulting effect on the Space Shuttle Program.

Davis, J. Bradley↗

Debris/ice/TPS assessment and integrated photographic analysis of Shuttle mission STS-68

A debris/ice/thermal protection system assessment and integrated photographic analysis was conducted for Shuttle mission STS-68. Debris inspections of the flight elements and launch pad were performed before and after launch. Icing conditions on the External Tank were assessed by the use of computer programs, nomographs, and infrared scanner data during cryogenic loading of the vehicle followed by on-pad visual inspection. High speed photography of the launch was analyzed to identify ice/debris sources and evaluate potential vehicle damage and/or in-flight anomalies. This report-documents the ice/debris/thermal protection system conditions and integrated photographic analysis of Shuttle mission STS-68, and the resulting effect on the Space Shuttle Program.

Rivera, Jorge E.↗