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At least 379 records · Page 21

Application of an Elongated Kelvin Model to Space Shuttle Foams

Spray-on foam insulation is applied to the exterior of the Space Shuttle s External Tank to limit propellant boil-off and to prevent ice formation. The Space Shuttle foams are rigid closed-cell polyurethane foams. The two foams used most extensively on the Space Shuttle External Tank are BX-265 and NCFI24-124. Since the catastrophic loss of the Space Shuttle Columbia, numerous studies have been conducted to mitigate the likelihood and the severity of foam shedding during the Shuttle s ascent to space. Due to the foaming and rising process, the foam microstructures are elongated in the rise direction. As a result, these two foams exhibit a non-isotropic mechanical behavior. In this paper, a detailed microstructural characterization of the two foams is presented. The key features of the foam cells are summarized and the average cell dimensions in the two foams are compared. Experimental studies to measure the room temperature mechanical response of the two foams in the two principal material directions (parallel to the rise and perpendicular to the rise) are also reported. The measured elastic modulus, proportional limit stress, ultimate tensile stress and the Poisson s ratios for the two foams are compared. The generalized elongated Kelvin foam model previously developed by the authors is reviewed and the equations which result from this model are presented. The resulting equations show that the ratio of the elastic modulus in the rise direction to that in the perpendicular-to-rise direction as well as the ratio of the strengths in the two material directions is only a function of the microstructural dimensions. Using the measured microstructural dimensions and the measured stiffness ratio, the foam tensile strength ratio and Poisson s ratios are predicted for both foams. The predicted tensile strength ratio is in close agreement with the measured strength ratios for both BX-265 and NCFI24-124. The comparison between the predicted Poisson s ratios and the measured values is not as favorable.

Sullivan, Roy M.↗

The calibration and flight test performance of the space shuttle orbiter air data system

The Space Shuttle air data system (ADS) is used by the guidance, navigation and control system (GN&C) to guide the vehicle to a safe landing. In addition, postflight aerodynamic analysis requires a precise knowledge of flight conditions. Since the orbiter is essentially an unpowered vehicle, the conventional methods of obtaining the ADS calibration were not available; therefore, the calibration was derived using a unique and extensive wind tunnel test program. This test program included subsonic tests with a 0.36-scale orbiter model, transonic and supersonic tests with a smaller 0.2-scale model, and numerous ADS probe-alone tests. The wind tunnel calibration was further refined with subsonic results from the approach and landing test (ALT) program, thus producing the ADS calibration for the orbital flight test (OFT) program. The calibration of the Space Shuttle ADS and its performance during flight are discussed in this paper. A brief description of the system is followed by a discussion of the calibration methodology, and then by a review of the wind tunnel and flight test programs. Finally, the flight results are presented, including an evaluation of the system performance for on-board systems use and a description of the calibration refinements developed to provide the best possible air data for postflight analysis work.

Dean, A. S.↗

Characterization of Space Shuttle Thermal Protection System (TPS) Materials for Return-to-Flight following the Shuttle Columbia Accident Investigation

During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included

Wingard, Doug↗

Payload retention fittings for space shuttle payload ground handling mechanism

New ground fittings for Space Shuttle payload handling were designed, built, and tested by Government and contractor personnel at the NASA John F. Kennedy Space Center (KSC), Florida, from May 1981 through November 1982. Design evolution of the Space Shuttle Orbiter payload retention fittings, which contained a load-sensitive split bushing in a pillow-block housing, created an incompatibility between the interfacing ground and airborne equipment. New fittings were designed and successfully used beginning with the fifth Space Shuttle flight, STS-5. An active hydraulic spring system containing a gas accumulator in the hydraulic system provided the load relief required to protect the Orbiter bushing from damage.

Cassisi, V.↗

Shuttle cryogenics supply system. Optimization study. Volume 5 B-4: Programmers manual for space shuttle orbit injection analysis (SOPSA)

A computer program for space shuttle orbit injection propulsion system analysis (SOPSA) is described to show the operational characteristics and the computer system requirements. The program was developed as an analytical tool to aid in the preliminary design of propellant feed systems for the space shuttle orbiter main engines. The primary purpose of the program is to evaluate the propellant tank ullage pressure requirements imposed by the need to accelerate propellants rapidly during the engine start sequence. The SOPSA program will generate parametric feed system pressure histories and weight data for a range of nominal feedline sizes.

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Food packages for Space Shuttle

The paper reviews food packaging techniques used in space flight missions and describes the system developed for the Space Shuttle. Attention is directed to bite-size food cubes used in Gemini, Gemini rehydratable food packages, Apollo spoon-bowl rehydratable packages, thermostabilized flex pouch for Apollo, tear-top commercial food cans used in Skylab, polyethylene beverage containers, Skylab rehydratable food package, Space Shuttle food package configuration, duck-bill septum rehydration device, and a drinking/dispensing nozzle for Space Shuttle liquids. Constraints and testing of packaging is considered, a comparison of food package materials is presented, and typical Shuttle foods and beverages are listed.

Fohey, M. F.↗

Planned development of the space shuttle vehicle

Information pertaining to the planned development of the space shuttle vehicle is presented. The package contains: (1) President's statement; (2) Dr. Fletcher's statement; (3) space shuttle fact sheet; (4) important reasons for the space shuttle.

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Role of Process Control in Improving Space Vehicle Safety A Space Shuttle External Tank Example

Developing a safe and reliable space vehicle requires good design and good manufacturing, or in other words "design it right and build it right". A great design can be hard to build or manufacture mainly due to difficulties related to quality. Specifically, process control can be a challenge. As a result, the system suffers from low quality which leads to low reliability and high system risk. The Space Shuttle has experienced some of those cases, but has overcome these difficulties through extensive redesign efforts and process enhancements. One example is the design of the hot gas temperature sensor on the Space Shuttle Main Engine (SSME), which resulted in failure of the sensor in flight and led to a redesign of the sensor. The most recent example is the Space Shuttle External Tank (ET) Thermal Protection System (TPS) reliability issues that contributed to the Columbia accident. As a result, extensive redesign and process enhancement activities have been performed over the last two years to minimize the sensitivities and difficulties of the manual TPS application process.

Safie, Fayssal M.↗

Test and analysis procedures for updating math models of Space Shuttle payloads

Over the next decade or more, the Space Shuttle will continue to be the primary transportation system for delivering payloads to Earth orbit. Although a number of payloads have already been successfully carried by the Space Shuttle in the payload bay of the Orbiter vehicle, there continues to be a need for evaluation of the procedures used for verifying and updating the math models of the payloads. The verified payload math models is combined with an Orbiter math model for the coupled-loads analysis, which is required before any payload can fly. Several test procedures were employed for obtaining data for use in verifying payload math models and for carrying out the updating of the payload math models. Research was directed at the evaluation of test/update procedures for use in the verification of Space Shuttle payload math models. The following research tasks are summarized: (1) a study of free-interface test procedures; (2) a literature survey and evaluation of model update procedures; and (3) the design and construction of a laboratory payload simulator.

Craig, Roy R., Jr.↗

The space shuttle launch vehicle aerodynamic verification challenges

The Space Shuttle aerodynamics and performance communities were challenged to verify the Space Shuttle vehicle (SSV) aerodynamics and system performance by flight measurements. Historically, launch vehicle flight test programs which faced these same challenges were unmanned instrumented flights of simple aerodynamically shaped vehicles. However, the manned SSV flight test program made these challenges more complex because of the unique aerodynamic configuration powered by the first man-rated solid rocket boosters (SRB). The analyses of flight data did not verify the aerodynamics or performance preflight predictions of the first flight of the Space Transportation System (STS-1). However, these analyses have defined the SSV aerodynamics and verified system performance. The aerodynamics community also was challenged to understand the discrepancy between the wind tunnel and flight defined aerodynamics. The preflight analysis challenges, the aerodynamic extraction challenges, and the postflight analyses challenges which led to the SSV system performance verification and which will lead to the verification of the operational ascent aerodynamics data base are presented.

Wallace, R. O.↗

Space Shuttle Launch Probability Analysis: Understanding History so We Can Predict the Future

The Space Shuttle was launched 135 times and nearly half of those launches required 2 or more launch attempts. The Space Shuttle launch countdown historical data of 250 launch attempts provides a wealth of data that is important to analyze for strictly historical purposes as well as for use in predicting future launch vehicle launch countdown performance. This paper provides a statistical analysis of all Space Shuttle launch attempts including the empirical probability of launch on any given attempt and the cumulative probability of launch relative to the planned launch date at the start of the initial launch countdown. This information can be used to facilitate launch probability predictions of future launch vehicles such as NASA's Space Shuttle derived SLS. Understanding the cumulative probability of launch is particularly important for missions to Mars since the launch opportunities are relatively short in duration and one must wait for 2 years before a subsequent attempt can begin.

Cates, Grant R.↗

Earth Observatory Satellite system definition study. Report 6: Space shuttle interfaces/utilization

An analysis was conducted to determine the compatibility of the Earth Observatory Satellite (EOS) with the space shuttle. The mechanical interfaces and provisions required for a launch or retrieval of the EOS by the space shuttle are summarized. The space shuttle flight support equipment required for the operation is defined. Diagrams of the space shuttle in various configurations are provised to show the mission capability with the EOS. The subjects considered are as follows: (1) structural and mechanical interfaces, (2) spacecraft retention and deployment, (3) spacecraft retrieval, (4) electrical interfaces, (5) payload shuttle operations, (6) shuttle mode cost analysis, (7) shuttle orbit trades, and (8) safety considerations.

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Characterization of Space Shuttle Reusable Rocket Motor Static Test Stand Thrust Measurements

Space Shuttle Reusable Solid Rocket Motors (RSRM) are static tested at two ATK Thiokol Propulsion facilities in Utah, T-24 and T-97. The newer T-97 static test facility was recently upgraded to allow thrust measurement capability. All previous static test motor thrust measurements have been taken at T-24; data from these tests were used to characterize thrust parameters and requirement limits for flight motors. Validation of the new T-97 thrust measurement system is required prior to use for official RSRM performance assessments. Since thrust cannot be measured on RSRM flight motors, flight motor measured chamber pressure and a nominal thrust-to-pressure relationship (based on static test motor thrust and pressure measurements) are used to reconstruct flight motor performance. Historical static test and flight motor performance data are used in conjunction with production subscale test data to predict RSRM performance. The predicted motor performance is provided to support Space Shuttle trajectory and system loads analyses. Therefore, an accurate nominal thrust-to-pressure (F/P) relationship is critical for accurate RSRM flight motor performance and Space Shuttle analyses. Flight Support Motors (FSM) 7, 8, and 9 provided thrust data for the validation of the T-97 thrust measurement system. The T-97 thrust data were analyzed and compared to thrust previously measured at T-24 to verify measured thrust data and identify any test-stand bias. The T-97 FIP data were consistent and within the T-24 static test statistical family expectation. The FSMs 7-9 thrust data met all NASA contract requirements, and the test stand is now verified for future thrust measurements.

Mart L. Cook↗

Workforce Transition Strategy: Initial Report. Space Shuttle and Constellation Workforce Focus

The transition from Space Shuttle to Constellation over the next few years provides a rare opportunity to reinvigorate the Nation's space exploration capabilities. During that time, NASA's greatest challenge and top priority will be to safely fly out the Space Shuttle manifest, complete assembly of the International Space Station (ISS), and honor commitments to our international partners prior to retiring the Shuttle in 2010, all while developing the new Constellation space systems and preparing them for flight as soon as possible after the Shuttles last mission.

Workforce Transition Strategy↗

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗

Economics in ground operations of the Space Shuttle

The physical configuration, task versatility, and typical mission profile of the Space Shuttle are illustrated and described, and a comparison of shuttle and expendable rocket costs is discussed, with special emphasis upon savings to be achieved in ground operations. A review of economies achieved by engineering design improvements covers the automated checkout by onboard shuttle systems, the automated launch processing system, the new maintenance concept, and the analogy of Space Shuttle and airline repetitive operations. The Space Shuttle is shown to represent a new level in space flight technology, particularly, the sophistication of the systems and procedures devised for its support and ground operations.

Gray, R. H.↗

Preliminary Shuttle Space Suit Shielding Model

There are two space suits in current usage within the space program: EMU [2] and Orlan-M Space Suit . The Shuttle space suit components are discussed elsewhere [2,5,6] and serve as a guide to development of the current model. The present model is somewhat simplified in details which are considered to be second order in their effects on exposures. A more systematic approach is ongoing on a part-by-part basis with the most important ones in terms of exposure contributions being addressed first with detailed studies of the relatively thin space suit fabric as the first example . Additional studies to validate the model of the head coverings (bubble, helmet, visors.. .) will be undertaken in the near future. The purpose of this paper is to present the details of the model as it is now and to examine its impact on estimates of astronaut health risks. In this respect, the nonuniform distribution of mass of the space suit provides increased shielding in some directions and some organs. These effects can be most important in terms of health risks and especially critical to evaluation of potential early radiation effects .

Anderson, Brooke M.↗

Independent verification and validation for Space Shuttle flight software

The Committee for Review of Oversight Mechanisms for Space Shuttle Software was asked by the National Aeronautics and Space Administration's (NASA) Office of Space Flight to determine the need to continue independent verification and validation (IV&V) for Space Shuttle flight software. The Committee found that the current IV&V process is necessary to maintain NASA's stringent safety and quality requirements for man-rated vehicles. Therefore, the Committee does not support NASA's plan to eliminate funding for the IV&V effort in fiscal year 1993. The Committee believes that the Space Shuttle software development process is not adequate without IV&V and that elimination of IV&V as currently practiced will adversely affect the overall quality and safety of the software, both now and in the future. Furthermore, the Committee was told that no organization within NASA has the expertise or the manpower to replace the current IV&V function in a timely fashion, nor will building this expertise elsewhere necessarily reduce cost. Thus, the Committee does not recommend moving IV&V functions to other organizations within NASA unless the current IV&V is maintained for as long as it takes to build comparable expertise in the replacing organization.

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