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NASA NTRS2007

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew access to the International Space Station (ISS) and, together with the Ares V Cargo Launch Vehicle (CaLV), serves as one component of a future launch capability for human exploration of the Moon. During the system requirements definition process and early design cycles, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements: the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine, will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle dynamic test (IVDT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, and a highaltitude actuation of the launch abort system (LAS) following separation. The Orion-1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Cockrell, Charles E., Jr.↗

NASA NTRS1993

Nickel-hydrogen CPV battery update

The multicell common pressure vessel (CPV) nickel hydrogen battery manufactured by Johnson Controls Battery Group, Inc. has completed full flight qualification, including random vibration at 19.5 g for two minutes in each axis, electrical characterization in a thermal vacuum chamber, and mass-spectroscopy vessel leak detection. A first launch is scheduled for late in 1992 or early 1993 by the Naval Research Laboratory (NRL). Specifics of the launch date are not available at this time due to the classified nature of the program. Release of orbital data for the battery is anticipated following the launch.

Jones, Kenneth R.↗

NASA NTRS1996

An optimal user-interface for EPIMS database conversions and SSQ 25002 EEE parts screening

The Electrical, Electronic, and Electromechanical (EEE) Parts Information Management System (EPIMS) database was selected by the International Space Station Parts Control Board for providing parts information to NASA managers and contractors. Parts data is transferred to the EPIMS database by converting parts list data to the EP1MS Data Exchange File Format. In general, parts list information received from contractors and suppliers does not convert directly into the EPIMS Data Exchange File Format. Often parts lists use different variable and record field assignments. Many of the EPES variables are not defined in the parts lists received. The objective of this work was to develop an automated system for translating parts lists into the EPIMS Data Exchange File Format for upload into the EPIMS database. Once EEE parts information has been transferred to the EPIMS database it is necessary to screen parts data in accordance with the provisions of the SSQ 25002 Supplemental List of Qualified Electrical, Electronic, and Electromechanical Parts, Manufacturers, and Laboratories (QEPM&L). The SSQ 2S002 standards are used to identify parts which satisfy the requirements for spacecraft applications. An additional objective for this work was to develop an automated system which would screen EEE parts information against the SSQ 2S002 to inform managers of the qualification status of parts used in spacecraft applications. The EPIMS Database Conversion and SSQ 25002 User Interfaces are designed to interface through the World-Wide-Web(WWW)/Internet to provide accessibility by NASA managers and contractors.

Watson, John C.↗

NASA NTRSDate not supplied

Automated Probabilistic Finite Element Model Calibration Tool Based on Uncertainty Quantification and Machine Learning

Qualification and certification of safety critical parts is a hurdle to the adoption of metallic additively manufactured components for aerospace vehicle applications. Challenges include variability in part properties due to inconsistent defect distribution and microstructure. Understanding of the process through finite element modeling (FEM), and process control through in-situ monitoring, may result in significant improvements; however, solutions useful to manufacturers will require large volumes of data and automated data utilization. Toward this end, a generalizable automated FEM calibration paradigm is developed. This paradigm leverages existing and novel tools from machine learning and uncertainty quantification to enable the automatic calibration of FEMs without requiring prior knowledge of the model performance across input parameter space, including meshing and solver settings, which can require time consuming manual model probing or cause noisy and inconsistent predictions. The result is a probabilistic distribution of calibrated and validated FEM input parameters targeting measured data.

Additive manufacturing model calibration finite el↗

NASA NTRS2001

Update: HFC 245fa Blown Foam Development with External Tank Spray Foams

The Marshall Space Flight Center (MSFC) Thermal Protection Systems (TPS) Materials Research Laboratory is currently investigating environmentally friendly blowing agents for use in the insulations of the Space Shuttle's External Tank. The original TPS foam materials of the External Tank were blown with chlorofluorocarbon 11, which is now regulated because of its high Ozone Depletion Potential (ODP). Hydrochlorofluorocarbons (HCFCs), with an ODP that is one tenth that of CFCs, have been widely adopted as an interim blowing agent in urethane insulations. In FY96, Lockheed Martin completed the production qualification and validation of HCFC 141b blown insulations. Because of the expected limited commercial lifetime of HCFC 141b, research efforts are underway to identify and develop alternatives with zero ODP. HFC245fa (1,1,1,3,3-pentaflouropropane) has been chosen by the manufacturer as a third-generation blowing agent to be marketed commercially. Preliminary work evaluating this third-generation candidate has demonstrated promising material mechanical property data. Favorable results from small-scale spray activities have justified evaluations using production foam processing spray parameters. With the scale-up of the spray equipment, however, additional processing issues have been identified. This paper will present data collected to date regarding the use of this blowing agent in External Tank spray foams.

Davis, S.↗

NASA NTRS2005

Performance of a Light-Weight Ablative Thermal Protection Material for the Stardust Mission Sample Return Capsule

New tests and analyses are reported that were carried out to resolve testing uncertainties in the original development and qualification of a lightweight ablative material used for the Stardust spacecraft forebody heat shield. These additional arcjet tests and analyses confirmed the ablative and thermal performance of low density Phenolic Impregnated Carbon Ablator (PICA) material used for the Stardust design. Testing was done under conditions that simulate the peak convective heating conditions (1200 W/cm2 and 0.5 atm) expected during Earth entry of the Stardust Sample Return Capsule. Test data and predictions from an ablative material response computer code for the in-depth temperatures were compared to guide iterative adjustment of material thermophysical properties used in the code so that the measured and predicted temperatures agreed. The PICA recession rates and maximum internal temperatures were satisfactorily predicted by the computer code with the revised properties. Predicted recession rates were also in acceptable agreement with measured rates for heating conditions 37% greater than the nominal peak heating rate of 1200 W/sq cm. The measured in-depth temperature response data show consistent temperature rise deviations that may be caused by an undocumented endothermic process within the PICA material that is not accurately modeled by the computer code. Predictions of the Stardust heat shield performance based on the present evaluation provide evidence that the maximum adhesive bondline temperature will be much lower than the maximum allowable of 250 C and an earlier design prediction. The re-evaluation also suggests that even with a 25 percent increase in peak heating rates, the total recession of the heat shield would be a small fraction of the as-designed thickness. These results give confidence in the Stardust heat shield design and confirm the potential of PICA material for use in new planetary probe and sample return applications.

Covington, M. A.↗

NASA NTRS2008

Integrated Testing Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I crew launch vehicle is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew and cargo access to the International Space Station (ISS) and, together with the Ares V cargo launch vehicle, serves as a critical component of NASA's future human exploration of the Moon. During the preliminary design phase, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements - including the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine - will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the upper stage Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle ground vibration test (IVGVT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, validate the ability of the upper stage to manage cryogenic propellants to achieve upper stage engine start conditions, and a high-altitude demonstration of the launch abort system (LAS) following stage separation. The Orion 1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Taylor, James L.↗

NASA NTRS1973

Development and in-flight performance of the Mariner 9 spacecraft propulsion system

On November 14, 1971, Mariner 9 was decelerated into orbit about Mars by a 1334 N (300 lbf) liquid bipropellant propulsion system. This paper describes and summarizes the development and in-flight performance of this pressure-fed, nitrogen tetroxide/monomethyl hydrazine bipropellant system. The design of all Mariner propulsion subsystems has been predicted upon the premise that simplicity of approach, coupled with thorough qualification and margin-limits testing, is the key to cost-effective reliability. The qualification test program and analytical modeling are also discussed. Since the propulsion subsystem is modular in nature, it was completely checked, serviced, and tested independent of the spacecraft. Proper prediction of in-flight performance required the development of three significant modeling tools to predict and account for nitrogen saturation of the propellant during the six-month coast period and to predict and statistically analyze in-flight data.

Evans, D. D.↗

NASA NTRS2003

Terrain Portrayal for Head-Down Displays Flight Test

The Synthetic Vision Systems General Aviation (SVS-GA) element of NASA's Aviation Safety Program is developing technology to eliminate low visibility induced General Aviation (GA) accidents through the application of synthetic vision techniques. SVS displays present computer generated 3-dimensional imagery of the surrounding terrain to greatly enhance pilot's situation awareness (SA), reducing or eliminating Controlled Flight into Terrain (CFIT), as well as Low-Visibility Loss of Control (LVLOC) accidents. In addition to substantial safety benefits, SVS displays have many potential operational benefits that can lead to flight in instrument meteorological conditions (IMC) resembling those conducted in visual meteorological conditions (VMC). Potential benefits could include lower landing minimums, more approach options, reduced training time, etc. SVS conducted research will develop display concepts providing the pilot with an unobstructed view of the outside terrain, regardless of weather conditions and time of day. A critical component of SVS displays is the appropriate presentation of terrain to the pilot. The relationship between the realism of the terrain presentation and resulting enhancements of pilot SA and pilot performance has been largely undefined. Comprised of coordinated simulation and flight test efforts, the terrain portrayal for head-down displays (TP-HDD) test series examined the effects of two primary elements of terrain portrayal: variations of digital elevation model (DEM) resolution and terrain texturing. Variations in DEM resolution ranged from sparsely spaced (30 arc-sec/2,953ft) to very closely spaced data (1 arc-sec/98 ft). Variations in texture involved three primary methods: constant color, elevation-based generic, and photo-realistic, along with a secondary depth cue enhancer in the form of a fishnet grid overlay. The TP-HDD test series was designed to provide comprehensive data to enable design trades to optimize all SVS applications, as well as develop requirements and recommendations to facilitate the implementation and certification of SVS displays. The TP-HDD flight experiment utilized the NASA LaRC Cessna 206 Stationaire and evaluated eight terrain portrayal concepts in an effort to confirm and extend results from the previously conducted TP-HDD simulation experiment. A total of 15 evaluation pilots, of various qualifications, accumulated over 75 hours of dedicated research flight time at Newport News (PHF) and Roanoke (ROA), VA, airports from August through October, 2002. This report will present results from the portion of testing conducted at Roanoke, VA.

Hughes, Monica F.↗

NASA NTRS2012

Review of the Aerodynamic Acceptance Test and Application to Anti-Icing Fluids Testing in the NRC Propulsion and Icing Wind Tunnel

In recent years, the FAA has worked with Transport Canada, National Research Council of Canada (NRC) and APS Aviation, Inc. to develop allowance times for aircraft operations in ice-pellet precipitation. These allowance times are critical to ensure safety and efficient operation of commercial and cargo flights. Wind-tunnel testing with uncontaminated anti-icing fluids and fluids contaminated with simulated ice-pellets had been carried out at the NRC Propulsion and Icing Wind Tunnel (PIWT) to better understand the flowoff characteristics and resulting aerodynamic effects. The percent lift loss on the thin, high-performance wing model tested in the PIWT was determined at 8 angle of attack and used as one of the evaluation criteria in determining the allowance times. Because it was unclear as to how performance degradations measured on this model were relevant to an actual airplane configuration, some means of interpreting the wing model lift loss was deemed necessary. In this report, the lift loss was related to the loss in maximum lift of a Boeing 737-200ADV airplane through the Aerodynamic Acceptance Test (AAT) performed for fluids qualification. This report provides a review of the research basis of the AAT in order to understand how this correlation was applied. A loss in maximum lift coefficient of 5.24 percent on the B737-200ADV airplane (which was adopted as the threshold in the AAT) corresponds to a lift loss of 7.3 percent on the PIWT model at 8 degrees angle of attack. There is significant scatter in the data used to develop the correlation related to varying effects of the various antiicing fluids that were tested and other factors. A statistical analysis indicated the upper limit of lift loss on the PIWT model was 9.2 percent. Therefore, for cases resulting in PIWT model lift loss from 7.3 to 9.2 percent, extra scrutiny of the visual observations is required in evaluating fluid performance with contamination. Additional research may result in future changes to this correlation.

Broeren, Andy P.↗

NASA NTRS2006

Space Flight Qualification on a Multi-Fiber Ribbon Cable and Array Connector Assembly

NASA's Goddard Space Flight Center (GSFC) cooperatively with Sandia National Laboratories completed a series of tests on three separate configurations of multi-fiber ribbon cable and MTP connector assemblies. These tests simulate the aging process of components during launch and long-term space environmental exposure. The multi-fiber ribbon cable assembly was constructed of non-outgassing materials, with radiation-hardened, graded index 100/140-micron optical fiber. The results of this characterization presented here include vibration testing, thermal vacuum monitoring, and extended radiation exposure testing data.

Xiaodan, Linda Jin↗

NASA NTRS2005

Development of Sensors for Aerospace Applications

Advances in technology have led to the availability of smaller and more accurate sensors. Computer power to process large amounts of data is no longer the prevailing issue; thus multiple and redundant sensors can be used to obtain more accurate and comprehensive measurements in a space vehicle. The successful integration and commercialization of micro- and nanotechnology for aerospace applications require that a close and interactive relationship be developed between the technology provider and the end user early in the project. Close coordination between the developers and the end users is critical since qualification for flight is time-consuming and expensive. The successful integration of micro- and nanotechnology into space vehicles requires a coordinated effort throughout the design, development, installation, and integration processes

Medelius, Pedro↗

NASA NTRS2005

Performance Qualification Test of the ISS Water Processor Assembly (WPA) Expendables

The Water Processor Assembly (WPA) for use on the International Space Station (ISS) includes various technologies for the treatment of waste water. These technologies include filtration, ion exchange, adsorption, catalytic oxidation, and iodination. The WPA hardware implementing portions of these technologies, including the Particulate Filter, Multifiltration Bed, Ion Exchange Bed, and Microbial Check Valve, was recently qualified for chemical performance at the Marshall Space Flight Center. Waste water representing the quality of that produced on the ISS was generated by test subjects and processed by the WPA. Water quality analysis and instrumentation data was acquired throughout the test to monitor hardware performance. This paper documents operation of the test and the assessment of the hardware performance.

Carter, Layne↗

NASA NTRS2009

Ablation and Thermal Response Property Model Validation for Phenolic Impregnated Carbon Ablator

Phenolic Impregnated Carbon Ablator was the heatshield material for the Stardust probe and is also a candidate heatshield material for the Orion Crew Module. As part of the heatshield qualification for Orion, physical and thermal properties were measured for newly manufactured material, included emissivity, heat capacity, thermal conductivity, elemental composition, and thermal decomposition rates. Based on these properties, an ablation and thermal-response model was developed for temperatures up to 3500 K and pressures up to 100 kPa. The model includes orthotropic and pressure-dependent thermal conductivity. In this work, model validation is accomplished by comparison of predictions with data from many arcjet tests conducted over a range of stagnation heat flux and pressure from 107 Watts per square centimeter at 2.3 kPa to 1100 Watts per square centimeter at 84 kPa. Over the entire range of test conditions, model predictions compare well with measured recession, maximum surface temperatures, and in depth temperatures.

Milos, F. S.↗

NASA NTRS1977

Remote sensing-aided systems for snow qualification, evapotranspiration estimation, and their application in hydrologic models

The design of general remote sensing-aided methodologies was studied to provide the estimates of several important inputs to water yield forecast models. These input parameters are snow area extent, snow water content, and evapotranspiration. The study area is Feather River Watershed (780,000 hectares), Northern California. The general approach involved a stepwise sequence of identification of the required information, sample design, measurement/estimation, and evaluation of results. All the relevent and available information types needed in the estimation process are being defined. These include Landsat, meteorological satellite, and aircraft imagery, topographic and geologic data, ground truth data, and climatic data from ground stations. A cost-effective multistage sampling approach was employed in quantification of all the required parameters. The physical and statistical models for both snow quantification and evapotranspiration estimation was developed. These models use the information obtained by aerial and ground data through appropriate statistical sampling design.

Korram, S.↗

NASA NTRS1981

A review of in-flight emergencies in the ASRS data base

A series of 154 in-flight emergencies as reported to the Aviation Safety Reporting System are described. The various types of emergencies are examined and an attempt is made to determine the human errors and other factors associated with each incident, as well as the measures taken to resolve the emergency. It is concluded that nearly one half of those emergencies reported were related to failure or malfunction of aircraft subsystems. Of all the emergencies, nearly one quarter were associated with power plant failure. Other frequently encountered emergency types are associated with operation in instrument meteorological conditions without appropriate clearance or qualification, and with low fuel state situations. Human error is prominently featured in many of the incidents, appearing in the actions of pilots and air traffic controllers.

Porter, R. F.↗

NASA NTRS1972

Development and in-flight performance of the Mariner 9 spacecraft propulsion system

On November 14, 1971, Mariner 9 was decelerated into orbit about Mars by a 1334-newton (300-lbf) liquid bipropellant propulsion system. The development and in-flight performance are described and summarized of this pressure-fed, nitrogen tetroxide/monomethyl hydrazine bipropellant system. The design of all Mariner propulsion subsystems has been predicated upon the premise that simplicity of approach, coupled with thorough qualification and margin-limits testing, is the key to cost-effective reliability. The qualification test program and analytical modeling of the Mariner 9 subsystem are discussed. Since the propulsion subsystem is modular in nature, it was completely checked, serviced, and tested independent of the spacecraft. Proper prediction of in-flight performance required the development of three significant modeling tools to predict and account for nitrogen saturation of the propellant during the six-month coast period and to predict and statistically analyze in-flight data. The flight performance of the subsystem was excellent, as were the performance prediction correlations. These correlations are presented.

Evans, D. D.↗

NASA NTRS2002

ISS Material Science Research Rack HWIL Interface Simulation

In this paper, the first Material Science Research Rack (MSRR-1) hardware-in-the-loop (HWIL) interface simulation is described. Dynamic Concepts developed this HWIL simulation system with funding and management provided by the Flight Software group (ED14) of NASA-MSFC's Avionics Department. The HWIL system has been used both as a flight software development environment and as a software qualification tool. To fulfill these roles, the HWIL simulator accurately models the system dynamics of many MSRR-1 subsystems and emulates most of the internal interface signals. The modeled subsystems include the Experiment Modules, the Thermal Environment Control System, the Vacuum Access System, the Solid State Power Controller Module, and the Active Rack Isolation Systems. The emulated signals reside on three separate MIL-STD-1553B digital communication buses, the ISS Medium Rate Data Link, and several analog controller and sensor signals. To enhance the range of testing, it was necessary to simulate several off-nominal conditions that may occur in the interfacing subsystems.

Williams, Philip J.↗