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NASA NTRS2002

A Fully Redundant On-Line Mass Spectrometer System Used to Monitor Cryogenic Fuel Leaks on the Space Shuttle

An on-line gas monitoring system was developed to replace the older systems used to monitor for cryogenic leaks on the Space Shuttles before launch. The system uses a mass spectrometer to monitor multiple locations in the process, which allows the system to monitor all gas constituents of interest in a nearly simultaneous manner. The system is fully redundant and meets all requirements for ground support equipment (GSE). This includes ruggedness to withstand launch on the Mobile Launcher Platform (MLP), ease of operation, and minimal operator intervention. The system can be fully automated so that an operator is notified when an unusual situation or fault is detected. User inputs are through personal computer using mouse and keyboard commands. The graphical user for detecting cryogenic leaks, many other gas constituents could be monitored using the Hazardous Gas Detection System (HGDS) 2000.

Griffin, Timothy P.↗

NASA NTRS2002

Automated CFD Parameter Studies on Distributed Parallel Computers

The objective of the current work is to build a prototype software system which will automated the process of running CFD jobs on Information Power Grid (IPG) resources. This system should remove the need for user monitoring and intervention of every single CFD job. It should enable the use of many different computers to populate a massive run matrix in the shortest time possible. Such a software system has been developed, and is known as the AeroDB script system. The approach taken for the development of AeroDB was to build several discrete modules. These include a database, a job-launcher module, a run-manager module to monitor each individual job, and a web-based user portal for monitoring of the progress of the parameter study. The details of the design of AeroDB are presented in the following section. The following section provides the results of a parameter study which was performed using AeroDB for the analysis of a reusable launch vehicle (RLV). The paper concludes with a section on the lessons learned in this effort, and ideas for future work in this area.

Rogers, Stuart E.↗

NASA NTRS2003

Legacy and Emergence of Spaceport Technology Development at the Kennedy Space Center

Kennedy Space Center (KSC) has a long and successful legacy in the checkout and launch of missiles and space vehicles. These operations have become significantly more complex, and their evolution has driven the need for many technology developments. Unanticipated events have also underscored the need for a local, highly responsive technology development and testing capability. This evolution is briefly described, as well as the increasing level of technology capability at KSC. The importance of these technologies in achieving past national space goals suggests that the accomplishment of low-cost and reliable access to space will depend critically upon KSC's future success in developing spaceport technologies. This paper concludes with a description KSC's current organizational approach and major thrust areas in technology development. The first phase of our historical review focuses on the development and testing of field- deployable short- and intermediate-range ballistic missiles (1953 to 1958). These vehicles are later pressed into service as space launchers. The second phase involves the development of large space lift vehicles culminating in the Saturn V launches (1959 to 1975). The third phase addresses the development and operations of the partially reusable launch vehicle, Space Shuttle (1976 to 2000). In the current era, KSC is teaming with the U.S. Air Force (AF), industry, academia, and other partners to identify and develop Spaceport and Range Technologies necessary to achieve national space goals of lower-cost and higher-reliability space flight.

Starr, Stanley↗

NASA NTRS2003

In-Space Propulsion: Where We Stand and What's Next

The focus of this paper will be on the three stages of in-space transportation propulsion systems, now commonly referred to as in-space propulsion (ISP); i.e., the transfer of payloads from low-Earth orbits into higher orbits or into trajectories for planetary encounters, including planetary landers and sample return launchers, if required. Functions required at the operational location where ISP must provide thrust for orbit include maintenance, position control, stationkeeping, and spacecraft altitude control; i.e., proper pointing and dynamic stability in inertial space; and the third function set to enable operations at various planetary locations, such as atmospheric entry and capture, descent to the surface and ascent, back to rendezvous orbit. The discussion will concentrate on where ISP stands today and some observations of what might be next in line for new ISP technologies and systems for near-term and future flight applications. The architectural choices that are applicable for ISP will also be described and discussed in detail.

Sackheim, Robert L.↗

NASA NTRS2004

Automated Euler and Navier-Stokes Database Generation for a Glide-Back Booster

The past two decades have seen a sustained increase in the use of high fidelity Computational Fluid Dynamics (CFD) in basic research, aircraft design, and the analysis of post-design issues. As the fidelity of a CFD method increases, the number of cases that can be readily and affordably computed greatly diminishes. However, computer speeds now exceed 2 GHz, hundreds of processors are currently available and more affordable, and advances in parallel CFD algorithms scale more readily with large numbers of processors. All of these factors make it feasible to compute thousands of high fidelity cases. However, there still remains the overwhelming task of monitoring the solution process. This paper presents an approach to automate the CFD solution process. A new software tool, AeroDB, is used to compute thousands of Euler and Navier-Stokes solutions for a 2nd generation glide-back booster in one week. The solution process exploits a common job-submission grid environment, the NASA Information Power Grid (IPG), using 13 computers located at 4 different geographical sites. Process automation and web-based access to a MySql database greatly reduces the user workload, removing much of the tedium and tendency for user input errors. The AeroDB framework is shown. The user submits/deletes jobs, monitors AeroDB's progress, and retrieves data and plots via a web portal. Once a job is in the database, a job launcher uses an IPG resource broker to decide which computers are best suited to run the job. Job/code requirements, the number of CPUs free on a remote system, and queue lengths are some of the parameters the broker takes into account. The Globus software provides secure services for user authentication, remote shell execution, and secure file transfers over an open network. AeroDB automatically decides when a job is completed. Currently, the Cart3D unstructured flow solver is used for the Euler equations, and the Overflow structured overset flow solver is used for the Navier-Stokes equations. Other codes can be readily included into the AeroDB framework.

Chaderjian, Neal M.↗

NASA NTRS2004

Comparing NASA and ESA Cost Estimating Methods for Human Missions to Mars

To compare working methodologies between the cost engineering functions in NASA Marshall Space Flight Center (MSFC) and ESA European Space Research and Technology Centre (ESTEC), as well as to set-up cost engineering capabilities for future manned Mars projects and other studies which involve similar subsystem technologies in MSFC and ESTEC, a demonstration cost estimate exercise was organized. This exercise was a direct way of enhancing not only cooperation between agencies but also both agencies commitment to credible cost analyses. Cost engineers in MSFC and ESTEC independently prepared life-cycle cost estimates for a reference human Mars project and subsequently compared the results and estimate methods in detail. As a non-sensitive, public domain reference case for human Mars projects, the Mars Direct concept was chosen. In this paper the results of the exercise are shown; the differences and similarities in estimate methodologies, philosophies, and databases between MSFC and ESTEC, as well as the estimate results for the Mars Direct concept. The most significant differences are explained and possible estimate improvements identified. In addition, the Mars Direct plan and the extensive cost breakdown structure jointly set-up by MSFC and ESTEC for this concept are presented. It was found that NASA applied estimate models mainly based on historic Apollo and Space Shuttle cost data, taking into account the changes in technology since then. ESA used models mostly based on European satellite and launcher cost data, taking into account the higher equipment and testing standards for human space flight. Most of NASA's and ESA s estimates for the Mars Direct case are comparable, but there are some important, consistent differences in the estimates for: 1) Large Structures and Thermal Control subsystems; 2) System Level Management, Engineering, Product Assurance and Assembly, Integration and Test/Verification activities; 3) Mission Control; 4) Space Agency Program Level activities.

Hunt, Charles D.↗

NASA NTRS2004

Advanced Technology Lifecycle Analysis System (ATLAS)

Developing credible mass and cost estimates for space exploration and development architectures require multidisciplinary analysis based on physics calculations, and parametric estimates derived from historical systems. Within the National Aeronautics and Space Administration (NASA), concurrent engineering environment (CEE) activities integrate discipline oriented analysis tools through a computer network and accumulate the results of a multidisciplinary analysis team via a centralized database or spreadsheet Each minute of a design and analysis study within a concurrent engineering environment is expensive due the size of the team and supporting equipment The Advanced Technology Lifecycle Analysis System (ATLAS) reduces the cost of architecture analysis by capturing the knowledge of discipline experts into system oriented spreadsheet models. A framework with a user interface presents a library of system models to an architecture analyst. The analyst selects models of launchers, in-space transportation systems, and excursion vehicles, as well as space and surface infrastructure such as propellant depots, habitats, and solar power satellites. After assembling the architecture from the selected models, the analyst can create a campaign comprised of missions spanning several years. The ATLAS controller passes analyst specified parameters to the models and data among the models. An integrator workbook calls a history based parametric analysis cost model to determine the costs. Also, the integrator estimates the flight rates, launched masses, and architecture benefits over the years of the campaign. An accumulator workbook presents the analytical results in a series of bar graphs. In no way does ATLAS compete with a CEE; instead, ATLAS complements a CEE by ensuring that the time of the experts is well spent Using ATLAS, an architecture analyst can perform technology sensitivity analysis, study many scenarios, and see the impact of design decisions. When the analyst is satisfied with the system configurations, technology portfolios, and deployment strategies, he or she can present the concepts to a team, which will conduct a detailed, discipline-oriented analysis within a CEE. An analog to this approach is the music industry where a songwriter creates the lyrics and music before entering a recording studio.

O'Neil, Daniel A.↗

NASA NTRS2005

Shuttle-Derived Launch Vehicles' Capablities: An Overview

Shuttle-Derived Launch Vehicle (SDLV) concepts have been developed by a collaborative team comprising the Johnson Space Center, Marshall Space Flight Center, Kennedy Space Center, ATK-Thiokol, Lockheed Martin Space Systems Company, The Boeing Company, and United Space Alliance. The purpose of this study was to provide timely information on a full spectrum of low-risk, cost-effective options for STS-Derived Launch Vehicle concepts to support the definition of crew and cargo launch requirements for the Space Exploration Vision. Since the SDLV options use high-reliability hardware, existing facilities, and proven processes, they can provide relatively low-risk capabilities to launch extremely large payloads to low Earth orbit. This capability to reliably lift very large, high-dollar-value payloads could reduce mission operational risks by minimizing the number of complex on-orbit operations compared to architectures based on multiple smaller launchers. The SDLV options also offer several logical spiral development paths for larger exploration payloads. All of these development paths make practical and cost-effective use of existing Space Shuttle Program (SSP) hardware, infrastructure, and launch and flight operations systems. By utilizing these existing assets, the SDLV project could support the safe and orderly transition of the current SSP through the planned end of life in 2010. The SDLV concept definition work during 2004 focused on three main configuration alternatives: a side-mount heavy lifter (approximately 77 MT payload), an in-line medium lifter (approximately 22 MT Crew Exploration Vehicle payload), and an in-line heavy lifter (greater than 100 MT payload). This paper provides an overview of the configuration, performance capabilities, reliability estimates, concept of operations, and development plans for each of the various SDLV alternatives. While development, production, and operations costs have been estimated for each of the SDLV configuration alternatives, these proprietary data have not been included in this paper.

Rothschild, William J.↗

NASA NTRS2005

Trial by Fire

Boeing is preparing a range of Delta IV Heavy launcher options for NASA Crew Exploration Vehicle (CEV) and unmanned cargo transportation architectures to the Moon and Mars, now that the massive new rocket has been flight tested. The December 21 launch of the 232-ft. vehicle on 2 million lb. thrust marked the largest all-liquid expendable booster flown since the last Saturn V in 1973. A second Delta IV Heavy mission is scheduled for this summer carrying a U.S. Air Force missile warning satellite. The first launch carried a dummy payload. Boeing wants NASA to consider the Delta IV Heavy for manned CEV missions, but is also pushing the Heavy for unmanned exploration launch roles. One Delta IV Medium version could also be a CEV player. Boeing says even modest upgrades could double the Delta Heavy's Earth orbit capability to more than 50 metric tons, including being able to fire up to 20 metric tons on escape trajectories to Mars.

Covault, Craig↗

NASA NTRS2005

Large Liquid Rocket Testing: Strategies and Challenges

Rocket propulsion development is enabled by rigorous ground testing in order to mitigate the propulsion systems risks that are inherent in space flight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth. In particular, large liquid rocket propulsion development and testing over the past five decades of human and robotic space flight has involved a combination of component-level testing and engine-level testing to first demonstrate that the propulsion devices were designed to meet the specified requirements for the Earth to Orbit launchers that they powered. This was followed by a vigorous test campaign to demonstrate the designed propulsion articles over the required operational envelope, and over robust margins, such that a sufficiently reliable propulsion system is delivered prior to first flight. It is possible that hundreds of tests, and on the order of a hundred thousand test seconds, are needed to achieve a high-reliability, flight-ready, liquid rocket engine system. This paper overviews aspects of earlier and recent experience of liquid rocket propulsion testing at NASA Stennis Space Center, where full scale flight engines and flight stages, as well as a significant amount of development testing has taken place in the past decade. The liquid rocket testing experience discussed includes testing of engine components (gas generators, preburners, thrust chambers, pumps, powerheads), as well as engine systems and complete stages. The number of tests, accumulated test seconds, and years of test stand occupancy needed to meet varying test objectives, will be selectively discussed and compared for the wide variety of ground test work that has been conducted at Stennis for subscale and full scale liquid rocket devices. Since rocket propulsion is a crucial long-lead element of any space system acquisition or development, the appropriate plan and strategy must be put in place at the outset of the development effort. A deferment of this test planning, or inattention to strategy, will compromise the ability of the development program to achieve its systems reliability requirements and/or its development milestones. It is important for the government leadership and support team, as well as the vehicle and propulsion development team, to give early consideration to this aspect of space propulsion and space transportation work.

Rahman, Shamim A.↗

NASA NTRS2006

Development and Testing of an Axial Halbach Magnetic Bearing

The NASA Glenn Research Center has developed and tested a revolutionary Axial Halbach Magnetic Bearing. The objective of this work is to develop a viable non-contact magnetic thrust bearing utilizing Halbach arrays for all-electric flight, and many other applications. This concept will help to reduce harmful emissions, reduce the Nation s dependence on fossil fuels and mitigate many of the concerns and limitations encountered in conventional axial bearings such as bearing wear, leaks, seals and friction loss. The Axial Halbach Magnetic Bearing is inherently stable and requires no active feedback control system or superconductivity as required in many magnetic bearing designs. The Axial Halbach Magnetic Bearing is useful for very high speed applications including turbines, instrumentation, medical systems, computer memory systems, and space power systems such as flywheels. Magnetic fields suspend and support a rotor assembly within a stator. Advanced technologies developed for particle accelerators, and currently under development for maglev trains and rocket launchers, served as the basis for this application. Experimental hardware was successfully designed and developed to validate the basic principles and analyses. The report concludes that the implementation of Axial Halbach Magnetic Bearings can provide significant improvements in rotational system performance and reliability.

Eichenberg, Dennis J.↗

NASA NTRS2006

Development and Testing of a Radial Halbach Magnetic Bearing

The NASA John H. Glenn Research Center has developed and tested a revolutionary Radial Halbach Magnetic Bearing. The objective of this work is to develop a viable non-contact magnetic bearing utilizing Halbach arrays for all-electric flight, and many other applications. This concept will help reduce harmful emissions, reduce the Nation s dependence on fossil fuels and mitigate many of the concerns and limitations encountered in conventional axial bearings such as bearing wear, leaks, seals and friction loss. The Radial Halbach Magnetic Bearing is inherently stable and requires no active feedback control system or superconductivity as required in many magnetic bearing designs. The Radial Halbach Magnetic Bearing is useful for very high speed applications including turbines, instrumentation, medical applications, manufacturing equipment, and space power systems such as flywheels. Magnetic fields suspend and support a rotor assembly within a stator. Advanced technologies developed for particle accelerators, and currently under development for maglev trains and rocket launchers, served as the basis for this application. Experimental hardware was successfully designed and developed to validate the basic principles and analyses. The report concludes that the implementation of Radial Halbach Magnetic Bearings can provide significant improvements in rotational system performance and reliability.

Eichenberg, Dennis J.↗

NASA NTRS2007

Electric Propulsion Upper-Stage for Launch Vehicle Capability Enhancement

The NASA In-Space Propulsion Technology Project Office initiated a preliminary study to evaluate the performance benefits of a solar electric propulsion (SEP) upper-stage with existing and near-term small launch vehicles. The analysis included circular and elliptical Low Earth Orbit (LEO) to Geosynchronous Earth Orbit (GEO) transfers, and LEO to Low Lunar Orbit (LLO) applications. SEP subsystem options included state-of-the-art and near-term solar arrays and electric thrusters. In-depth evaluations of the Aerojet BPT-4000 Hall thruster and NEXT gridded ion engine were conducted to compare performance, cost and revenue potential. Preliminary results indicate that Hall thruster technology is favored for low-cost, low power SEP stages, while gridded-ion engines are favored for higher power SEP systems unfettered by transfer time constraints. A low-cost point design is presented that details one possible stage configuration and outlines system limitations, in particular fairing volume constraints. The results demonstrate mission enhancements to large and medium class launch vehicles, and mission enabling performance when SEP system upper stages are mounted to low-cost launchers such as the Minotaur and Falcon 1. Study results indicate the potential use of SEP upper stages to double GEO payload mass capability and to possibly enable launch on demand capability for GEO assets. Transition from government to commercial applications, with associated cost/benefit analysis, has also been assessed. The sensitivity of system performance to specific impulse, array power, thruster size, and component costs are also discussed.

Kemp, Gregory E.↗

NASA NTRS2004

Laser Metrology in the Micro-Arcsecond Metrology Testbed

The Space Interferometer Mission (SIM), scheduled for launch in 2009, is a space-born visible light stellar interferometer capable of micro-arcsecond-level astrometry. The Micro-Arcsecond Metrology testbed (MAM) is the ground-based testbed that incorporates all the functionalities of SIM minus the telescope, for mission-enabling technology development and verification. MAM employs a laser heterodyne metrology system using the Sub-Aperture Vertex-to-Vertex (SAVV) concept. In this paper, we describe the development and modification of the SAVV metrology launchers and the metrology instrument electronics, precision alignments and pointing control, locating cyclic error sources in the MAM testbed and methods to mitigate the cyclic errors, as well as the performance under the MAM performance metrics.

interferometry↗

NASA NTRS2006

The Road to Mach 10: A History of the X-43A Hypersonic Flight Test Program at NASA Dryden -- Origins to First Flight

The NASA Dryden Flight Research Center, in partnership with the NASA Langley Research Center and industrial contractors, conducted the first flight tests of a supersonic combustion ramjet (scramjet) in 2004. This was a revolutionary airbreathing engine able to operate at speeds above Mach 5, which carries potential for both high-speed atmospheric flight and as a space launcher. For the Dryden engineers, the X-43 program was the culmination of a nearly 60-year history of flight research, going back to the early days of supersonic flight, and to rocket planes such as the X-1, D-558-II Skyrocket, and the X-15. For the propulsion community, it marked a turning point in a quest that had taken nearly as long. The scramjet engine did not arise from the work of a single individual or from a single technological breakthrough. It evolved instead from work under way on ramjets in the early 1950s, and from research programs at the National Advisory Committee for Aeronautics (NACA) Lewis Research Center, at the U.S. Army Aberdeen Proving Ground, and by the U.S. Navy. Studies developed in the course of these disparate projects raised the possibility of supersonic combustion. Many researchers had considered the notion impractical due to the difficulty of stabilizing a flame front in a supersonic airflow. NACA researchers at Lewis attempted to test the idea's feasibility by burning aluminum borohydride in a supersonic wind tunnel. Sustained burning was believed to have been observed at Mach 1.5, Mach 2, and Mach 3 for as long as two seconds.

Peebles, Curtis↗

NASA NTRS2007

Rapid Contingency Simulation Modeling of the NASA Crew Launch Vehicle

The NASA Crew Launch Vehicle is a two-stage orbital launcher designed to meet NASA's current as well as future needs for human space flight. In order to free the designers to explore more possibilities during the design phase, a need exists for the ability to quickly perform simulation on both the baseline vehicle as well as the vehicle after proposed changes due to mission planning, vehicle configuration and avionics changes, proposed new guidance and control algorithms, and any other contingencies the designers may wish to consider. Further, after the vehicle is designed and built, the need will remain for such analysis in the event of future mission planning. An easily reconfigurable, modular, nonlinear six-degree-of-freedom simulation matching NASA Marshall's in-house high-fidelity simulator is created with the ability to quickly perform simulation and analysis of the Crew Launch Vehicle throughout the entire launch profile. Simulation results are presented and discussed, and an example comparison fly-off between two candidate controllers is presented.

Betts, Kevin M.↗

NASA NTRS2007

New Lubricants Protect Machines and the Environment

In 1994, NASA and Lockheed Martin Space Operations commissioned Sun Coast Chemicals of Daytona Inc to develop a new type of lubricant that would be safe for the environment and help "grease the wheels" of the shuttle-bearing launcher platform. Founded in 1989, Sun Coast Chemicals is known amongst the racing circuit for effective lubricants that help overcome engine and transmission problems related to heat and wear damage. In a matter of weeks, Sun Coast Chemical produced the biodegradable, high-performance X-1R Crawler Track Lube. In 1996, Sun Coast Chemical determined there was a market for this new development, and introduced three derivative products, Train Track Lubricant, Penetrating Spray Lubricant, and Biodegradable Hydraulic Fluid, and then quickly followed with a gun lubricant/cleaner and a fishing rod and reel lubricant. Just recently, Sun Coast introduced the X-1R Corporation, which folds the high-performance, environmentally safe benefits into a full line of standard automotive and specially formulated racing products. The entire X-1R automotive product line has stood up to rigorous testing by groups such as the American Society of Mechanical Engineers, the Swedish National Testing and Research Institute, the Department of Mechanical Engineering at Oakland University (Rochester, Michigan), and Morgan-McClure Motorsports (Abingdon, Virginia). The X-1R Corporation also markets "handy packs" for simple jobs around the house, consisting of a multi-purpose, multi-use lubricant and grease. In 2003, The X-1R Corporation teamed up with Philadelphia-based Penn Tackle Manufacturing Co., a leading manufacturer of fishing tackle since 1932, to jointly develop and market a line of advanced lubrication products for saltwater and freshwater anglers

Source record↗

NASA NTRS2008

A Brief History of Meteoroid and Orbital Debris Shielding Technology for US Manned Spacecraft

Meteoroid and orbital debris shielding has played an important role from the beginning of manned spaceflight. During the early 60 s, meteoroid protection drove requirements for new meteor and micrometeoroid impact science. Meteoroid protection also stimulated advances in the technology of hypervelocity impact launchers and impact damage assessment methodologies. The first phase of meteoroid shielding assessments closed in the early 70 s with the end of the Apollo program. The second phase of meteoroid protection technology began in the early 80 s when it was determined that there is a manmade Earth orbital debris belt that poses a significant risk to LEO manned spacecraft. The severity of the Earth orbital debris environment has dictated changes in Space Shuttle and ISS operations as well as driven advances in shielding technology and assessment methodologies. A timeline of shielding technology and assessment methodology advances is presented along with a summary of risk assessment results.

Bjorkman, Michael D.↗