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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 397 records · Page 22
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NASA NTRS2000

Preliminary Analysis and Design of a Rocket Based Combined Cycle for Efficient Access to Space

Access to space is presently limited by cost. The cost of delivering a payload to low earth orbit (LEO) is on average $10,000 per pound of payload, in the United States. Much of this cost is incurred from the operation of vehicles developed with 30-40 year old technology. The old technology and design practices have resulted in expensive hardware and intensive maintenance requirements for current launch vehicles. In order to alleviate the cost factor, the technological advances throughout the next millennium must bring affordable development and a new invigorating desire to space exploration. National Aeronautical and Space Administration (NASA), Department of Defense (DOD), and private industry are addressing this issue by focusing on incremental improvements in the Earth- to Orbit (ETO) costs. These improvements have investigated two different approaches: 1) make space vehicles as inexpensive as possible (i.e. Evolved Expendable Launch Vehicle (EELV) and Delta IV) 2) make space vehicles as reusable as airplanes so that the initial cost of investment can be recaptured (i.e. Reusable Launch Vehicle (RLV), X-33, X-34, and X-37) These programs have made notable progress in new material, propulsion, structures, and avionics technologies, during the last 3-5 years. So far, these programs are targeted to reduce present costs by, as much as, five times the current cost. The year 2025 goal for continued space advancement is to have ETO costs reduced by a factor of ten (i.e., tenfold), as low as $100 - $200/lb payload. For the RLV, this goal translates into very low maintenance costs and higher expected reliability per flight must be obtained. Therefore, making higher launch rates possible. For the expendable vehicle, the cost of maintenance cost is minimal, but a greater reliability must exist to insure the payload; since, there would be no way to recover the payload if the mission was to an abort or failure. Overall the cost of vehicle, payload and operations of an expendable may be too high compared to those of the RLV.

Harris, Lawanna↗
NASA NTRS2013

Fluorocarbon Contamination from the Drill on the Mars Science Laboratory: Potential Science Impact on Detecting Martian Organics by Sample Analysis at Mars (SAM)

Polytetrafluoroethylene (PTFE or trade name: Teflon by Dupont Co.) has been detected in rocks drilled during terrestrial testing of the Mars Science Laboratory (MSL) drilling hardware. The PTFE in sediments is a wear product of the seals used in the Drill Bit Assemblies (DBAs). It is expected that the drill assembly on the MSL flight model will also shed Teflon particles into drilled samples. One of the primary goals of the Sample Analysis at Mars (SAM) instrument suite on MSL is to test for the presence of martian organics in samples. Complications introduced by the potential presence of PTFE in drilled samples to the SAM evolved gas analysis (EGA or pyrolysisquadrupole mass spectrometry, pyr-QMS) and pyrolysis- gas chromatography mass spectrometry (Pyr- GCMS) experiments was investigated.

fluorocarbon contamination↗
NASA NTRS1981

Georgia resource assessment project: Institutionalizing LANDSAT and geographic data base techniques

Digital data from LANDSAT for each 1.1-acre cell in Georgia were processed and the land cover conditions were categorized. Several test cases were completed and an operational hardware and software processing capability was established at the Georgia Institute of Technology. The operational capability was developed to process the entire state (60,000 sq. miles and 14 LANDSAT scenes) in a cooperative project between eleven divisions and agencies at the regional, state, and federal levels. Products were developed for State agencies such as in both mapped and statistical formats. A computerized geographical data base was developed for management programs. To a large extent the applications of the data base evolved as users of LANDSAT information requested that other data (i.e., soils, slope, land use, etc.) be made compatible with LANDSAT for management programs. To date, geographic data bases incorporating LANDSAT and other spatial data deal with elements of the municipal solid waste management program, and reservoir management for the Corps of Engineers. LANDSAT data are also being used for applications in wetland, wildlife, and forestry management.

Pierce, R. R.↗
NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗
NASA NTRS2014

Innovation in Deep Space Habitat Interior Design: Lessons Learned From Small Space Design in Terrestrial Architecture

Increased public awareness of carbon footprints, crowding in urban areas, and rising housing costs have spawned a 'small house movement' in the housing industry. Members of this movement desire small, yet highly functional residences which are both affordable and sensitive to consumer comfort standards. In order to create comfortable, minimum-volume interiors, recent advances have been made in furniture design and approaches to interior layout that improve both space utilization and encourage multi-functional design for small homes, apartments, naval, and recreational vehicles. Design efforts in this evolving niche of terrestrial architecture can provide useful insights leading to innovation and efficiency in the design of space habitats for future human space exploration missions. This paper highlights many of the cross-cutting architectural solutions used in small space design which are applicable to the spacecraft interior design problem. Specific solutions discussed include reconfigurable, multi-purpose spaces; collapsible or transformable furniture; multi-purpose accommodations; efficient, space saving appliances; stowable and mobile workstations; and the miniaturization of electronics and computing hardware. For each of these design features, descriptions of how they save interior volume or mitigate other small space issues such as confinement stress or crowding are discussed. Finally, recommendations are provided to provide guidance for future designs and identify potential collaborations with the small spaces design community.

Simon, Matthew A.↗
NASA NTRS1990

On-orbit assembly/servicing task definition study

The OEXP vehicles being envisioned to carry out the Presidential space goals of a lunar outpost and human exploration of Mars will require on-orbit assembly, refurbishment, checkout, and launch. The On-orbit Assembly/Servicing Task Definition Study applies the space vehicle processing experience and procedures archives resident at NASA's Kennedy Space Center (KSC) to determine the task flows, and resources/facilities necessary to process the OEXP vehicles at Space Station Freedom (SSF). This data base is examined to find the closest analogies to OEXP vehicle components and assembly/refurbishment tasks. Transition tables are generated to provide traceability from KSC hardware processing experience to analogous on-orbit processing of the OEXP vehicles. Iterations in which the task flows are broken down into realistic extravehicular activity (EVA) primitive subtasks and times, and to apply automation and robotic technology to reduce crew risks and minimize EVA time, will enhance the value and accuracy of the predicted flows. These processing scenarios and the resulting resource/facility requirements are used to determine impacts of SSF, resulting in change requests to SSF requirements for provision of 'hooks and scars' to evolve the assembly complete Space Station into a transportation node. Study results to date include assembly analysis of the Martin Marietta Phobos Gateway Vehicle, refurbishment analysis of the Martin Marietta Lunar Evolution Piloted and Cargo Vehicles, and assembly analysis of the Boeing Mars Evolution Vehicle. The results of this study will be accumulated into the vehicle processing operations data base for subsequent modeling, life cycle cost, vehicle growth, and SSF impact analysis.

Vargo, Rick↗
NASA NTRS1996

Lessons learned: DC-X

The DC-X was conceived and developed specifically to lay the ground work for significantly lowering the cost of space operations. The system design was based on an initial set of program goals and a finite, limited set of resources. The goal in its simplest terms was to demonstrate vertical landing after rotation of the vehicle from a nose-first to an engines-first altitude. Finite resources actually drove the selection of a robust design to reduce fabrication and preflight testing costs. The result was a system with a large amount of flexibility which allowed expansion of the test goals as the system, and test program, evolved. The use of the vehicle flight computer interfacing with the ground control system for flight crew training was also not an initial concept. However, by defining an architecture for the system control modes which allowed additions and modifications as learning progressed, the 6 DOF codes used for flight controls software development were transported to the operating system to be used in a simulated flight mode. Flight data reduction was also greatly improved as the program progressed, and the data needs and presentation were refined. The software, avionics hardware, and the FOCC system development proceeded ahead of the vehicle, primarily because most of the hardware elements were existing at the outset of the program. The Built-in-Test (BIT) for avionics and propulsion systems were adequate. Particularly the flight readiness system which verified the vehicle health after engine start and before throttle-up for flight.

Steinmeyer, D. A.↗
NASA NTRS2014

NASA's Space Launch System Takes Shape: Progress Toward Safe, Affordable Exploration

Development of NASA's Space Launch System exploration-class heavy lift rocket has moved from the formulation phase to implementation in 3 years and will make significant progress this year toward its first launch, slated for December 2017. In recognition of the current fiscal realities, SLS represents a safe, affordable, and evolutionary path to development of an unprecedented capability for future human and robotic exploration and use of space. Current development is focused on a configuration with a 70 metric ton (t) payload to low Earth orbit (LEO), more than double any operational vehicle. It is this version that will launch NASA's Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back, as well as the first crewed Orion flight. This configuration is also designed to evolve to 130 t lift capability that offers several benefits, such as reduced mission costs, simplified payload design, faster trip times, and lower overall risk for missions of national significance. The SLS Program formally transitioned from the formulation phase to implementation during the past year, passing its Preliminary Design Review in 2013 and completion of Key Decision Point C in early 2014. NASA has authorized the Program to move forward to Critical Design Review, scheduled for 2015. Among the Program's many accomplishments are manufacture of core stage test hardware, as well as preparations for testing the world's most powerful solid rocket boosters and the main engines that flew 135 successful Space Shuttle missions. The Program's success to date is due to prudent use of existing technology, infrastructure, and workforce; streamlined management approach; and judicious use of new technologies. The result is a launch vehicle that will carry human and robotic exploration on the history-making missions in the coming decades. This paper will discuss the program and technical successes over the past year and provide a look at the milestones and challenges ahead.

Askins, Bruce↗
NASA NTRS2014

The Max Launch Abort System - Concept, Flight Test, and Evolution

The NASA Engineering and Safety Center (NESC) is an independent engineering analysis and test organization providing support across the range of NASA programs. In 2007 NASA was developing the launch escape system for the Orion spacecraft that was evolved from the traditional tower-configuration escape systems used for the historic Mercury and Apollo spacecraft. The NESC was tasked, as a programmatic risk-reduction effort to develop and flight test an alternative to the Orion baseline escape system concept. This project became known as the Max Launch Abort System (MLAS), named in honor of Maxime Faget, the developer of the original Mercury escape system. Over the course of approximately two years the NESC performed conceptual and tradeoff analyses, designed and built full-scale flight test hardware, and conducted a flight test demonstration in July 2009. Since the flight test, the NESC has continued to further develop and refine the MLAS concept.

Gilbert, Michael G.↗
NASA NTRS2003

Case for Deploying Complex Systems Utilizing Commodity Components

When the International Space Station (ISS) finally reached an operational state, many of the Payload Operations and Integration Facility (POIF) hardware components were reaching end of life, COTS product costs were soaring, and the ISS budget was becoming severely constrained. However, most requirement development was complete. In addition, the ISS program is a fully functioning program with at least fifteen years of operational life remaining. Therefore it is critical that any upgrades, refurbishments, or enhancements be accomplished in realtime with minimal disruptions to service. For these and other reasons, it was necessary to ensure the viability of the POIF. Due to the to the breadth of capability of the POIF (a NASA ground station), it is believed that the lessons to be learned by other complex systems are applicable and any solutions garnered by the POIF are applicable to other complex systems as well. With that in mind, a number of new approaches have been investigated to increase the portability of the POIF and reduce the cost of refurbishment, operations, and maintenance. These new approaches were directed at the Total Cost of Ownership (TCO); not only the refurbishment but also current operational difficulties, licensing, and anticipation of the next refurbishment. Our basic premise is that technology had evolved dramatically since the concept of the POIF ground system and we should leverage our experience on this new technological landscape. Fortunately, Moore's law and market forces have changed the landscape considerably. These changes are manifest in five (5) ways that are particularly relevant to POIF: 1. Complex Instruction Set Computing (CISC) processors have advanced to unprecedented levels of compute capacity with a dramatic cost break, 2. Linux has become a major operating system supported by most vendors on a broad range of platforms, 3. Windows(TradeMark) based desktops are pervasive in the office environment, 4. Stable and affordable WindowsTM development environments and tools are available and offer a rich set of capabilities, 5. The WindowsTM 2000 provides a stable client platform, Therefore, five studies were proposed, developed, and are in the current process of deployment which dramatically reduces the cost of operations, maintenance, refurbishment, and deployment of a ground system. Restating and refining the basic premise stated earlier, it is possible to enhance operations through the replacement of hardware and software components with commodity based items wherever applicable. This will dramatically reduce the overall lifecycle cost of the project. The first study leveraged the POIF S secure, three-tier, web architecture to replace the client workstations with lower cost PC platforms. A second study initiated a review of COTS products to examine the level of added value of each product. This study included replacement of some COTS products with custom code, deletions, substitutions, and consolidation of COTS products. Studies three and four reviewed the server architectures of the data distribution systems and Enhanced HOSC System (EHS) command and telemetry system to propose migration to new platforms, both software and hardware. The final study reviewed current IP communication technologies, developed an operational model for flight operations, and demonstrated that voice over IP was practical and could be integrated into operations.

Bryant, Barry S.↗
NASA NTRS2017

Improved Calibration through SMAP RFI Change Detection

Anthropogenic Radio-Frequency Interference (RFI) drove both the SMAP (Soil Moisture Active Passive) microwave radiometer hardware and Level 1 science algorithm designs to use new technology and techniques for the first time on a spaceflight project. Care was taken to provide special features allowing the detection and removal of harmful interference in order to meet the error budget. Nonetheless, the project accepted a risk that RFI and its mitigation would exceed the 1.3-K error budget. Thus, RFI will likely remain a challenge afterwards due to its changing and uncertain nature. To address the challenge, we seek to answer the following questions: How does RFI evolve over the SMAP lifetime? What calibration error does the changing RFI environment cause? Can time series information be exploited to reduce these errors and improve calibration for all science products reliant upon SMAP radiometer data? In this talk, we address the first question.

Passive L-band radiometer↗
NASA NTRS2014

Hardware Design and Testing of SUPERball, A Modular Tensegrity Robot

We are developing a system of modular, autonomous "tensegrity end-caps" to enable the rapid exploration of untethered tensegrity robot morphologies and functions. By adopting a self-contained modular approach, different end-caps with various capabilities (such as peak torques, or motor speeds), can be easily combined into new tensegrity robots composed of rods, cables, and actuators of different scale (such as in length, mass, peak loads, etc). As a first step in developing this concept, we are in the process of designing and testing the end-caps for SUPERball (Spherical Underactuated Planetary Exploration Robot), a project at the Dynamic Tensegrity Robotics Lab (DTRL) within NASA Ames's Intelligent Robotics Group. This work discusses the evolving design concepts and test results that have gone into the structural, mechanical, and sensing aspects of SUPERball. This representative tensegrity end-cap design supports robust and repeatable untethered mobility tests of the SUPERball, while providing high force, high displacement actuation, with a low-friction, compliant cabling system.

Tensegrity↗
NASA NTRS1984

Space Station Data Systems development

The content and status of the evolving Space Station Data System (SSDS) development program are presented. High level system requirements and schedules are reviewed, and the challenges of SSDS development are discussed. Present content of the program consists of three major activities: (1) two contracted parallel Space Station Data System architecture studies; (2) the space station phase B definition studies to be awarded in early 1985; and (3) a test bed project for the evaluation and proof-of-concept of data systems technology for space station applications and for the advanced development of long-lead hardware and software for the initial and growth space station configurations. An overview of the present SSDS concept is provided, and the roles of NASA centers in this activity are summarized.

Bigham, J. P., Jr.↗
NASA NTRS2011

Operational Philosophy Concerning Manned Spacecraft Cabin Leaks

The last thirty years have seen the Space Shuttle as the prime United States spacecraft for manned spaceflight missions. Many lessons have been learned about spacecraft design and operation throughout these years. Over the next few decades, a large increase of manned spaceflight in the commercial sector is expected. This will result in the exposure of commercial crews and passengers to many of the same risks crews of the Space Shuttle have encountered. One of the more dire situations that can be encountered is the loss of pressure in the habitable volume of the spacecraft during on orbit operations. This is referred to as a cabin leak. This paper seeks to establish a general cabin leak response philosophy with the intent of educating future spacecraft designers and operators. After establishing a relative definition for a cabin leak, the paper covers general descriptions of detection equipment, detection methods, and general operational methods for management of a cabin leak. Subsequently, all these items are addressed from the perspective of the Space Shuttle Program, as this will be of the most value to future spacecraft due to similar operating profiles. Emphasis here is placed upon why and how these methods and philosophies have evolved to meet the Space Shuttle s needs. This includes the core ideas of: considerations of maintaining higher cabin pressures vs. lower cabin pressures, the pros and cons of a system designed to feed the leak with gas from pressurized tanks vs. using pressure suits to protect against lower cabin pressures, timeline and consumables constraints, re-entry considerations with leaks of unknown origin, and the impact the International Space Station (ISS) has had to the standard Space Shuttle cabin leak response philosophy. This last item in itself includes: procedural management differences, hardware considerations, additional capabilities due to the presence of the ISS and its resource, and ISS docking/undocking considerations with a cabin leak occurring. The paper also offers a look at how different equipment configurations on future spacecraft impact the previously defined cabin leak operational philosophy and includes additional operational methods and considerations that result due to various configurations. The intent is to showcase these various considerations and highlight the variability they allow. The paper concludes with a selection of the author s personal observations from a spacecraft operator's point of view and recommendations with the goal of improving the design and operations of future spacecraft.

DeSimpelaere, Edward↗
NASA NTRS2009

Ares I-X Roll Control System Development

Project Managers often face challenging technical, schedule and budget issues. This presentation will explore how the Ares I-X Roll Control System Integrated Product Team (IPT) mitigated challenges such as concurrent engineering requirements and environments and evolving program processes, while successfully managing an aggressive project schedule and tight budget. IPT challenges also included communications and negotiations among inter- and intra-government agencies, including the US Air Force, NASA/MSFC Propulsion Engineering, LaRC, GRC, KSC, WSTF, and the Constellation Program. In order to successfully meet these challenges it was essential that the IPT define those items that most affected the schedule critical path, define early mitigation strategies to reduce technical, schedule, and budget risks, and maintain the end-product focus of an "unmanned test flight" context for the flight hardware. The makeup of the IPT and how it would function were also important considerations. The IPT consisted of NASA/MSFC (project management, engineering, and safety/quality) and contractors (Teledyne Brown Engineering and Pratt and Whitney Rocketdyne, who supplied heritage hardware experience). The early decision to have a small focused IPT working "badgelessly" across functional lines to eliminate functional stove-piping allowed for many more tasks to be done by fewer people. It also enhanced a sense of ownership of the products, while still being able to revert back to traditional roles in order to provide the required technical independence in design reviews and verification closures. This presentation will highlight several prominent issues and discuss how they were mitigated and the resulting Lessons Learned that might benefit other projects.

Unger, Ronald J.↗
NASA NTRSDate not supplied

Evolution of Hardware and Philosophy of Emergency Response Actions on the International Space Station and Future Spacecrafts

Human spaceflight is dangerous for numerous reasons. This ranges from the dynamic environment of launching on a rocket, flying in space among the thousands and thousands pieces of space debris, to the hazards of re-entry & landing, as well as being surrounded by vehicle systems containing hazardous materials or gasses. In-flight emergencies fall into four categories: Rapid Depressurization, Fire, Toxic Spill, and Medical emergency. This paper will address the first three, which fall under the responsibility of the Environmental Control and Life Support (ECLS) Systems flight control and engineering teams. It will review the evolution of the International Space Station’s emergency response philosophy, procedures, training, and equipment changes over the years. The ISS emergency equipment has evolved over the last two decades of operations in many ways, but in some it has remained the same. The core actions the flight crew takes to ensure team safety, personal safety, vehicle safety, and equipment safety has not changed. However, the equipment and capabilities provided to them have. From early days of minimal capability when the ISS consisted of a few modules, to today’s 30,000 ft^3 vehicle with over a dozen isolatable segments. From use of Russian gas masks to positive pressure O2 masks, to the development of respirators. From a lack of procedures for a deadly ammonia leak scenario to a memorized response utilizing numerous atmosphere measurement systems. This paper will review all these various areas that fall under the umbrella of “on-board emergencies”. In addition, the comparison to the planned emergency operations on the Orion vehicle will be reviewed. The Orion vehicle differs from the ISS in that it has no isolatable volume, being approximately 2% the size of ISS, as well as not having a quick return to earth capability.

Emergency↗
NASA NTRS1990

Experimental performance and acoustic investigation of modern, counterrotating blade concepts

The aerodynamic, acoustic, and aeromechanical performance of counterrotating blade concepts were evaluated both theoretically and experimentally. Analytical methods development and design are addressed. Utilizing the analytical methods which evolved during the conduct of this work, aerodynamic and aeroacoustic predictions were developed, which were compared to NASA and GE wind tunnel test results. The detailed mechanical design and fabrication of five different composite shell/titanium spar counterrotating blade set configurations are presented. Design philosophy, analyses methods, and material geometry are addressed, as well as the influence of aerodynamics, aeromechanics, and aeroacoustics on the design procedures. Blade fabrication and quality control procedures are detailed; bench testing procedures and results of blade integrity verification are presented; and instrumentation associated with the bench testing also is identified. Additional hardware to support specialized testing is described, as are operating blade instrumentation and the associated stress limits. The five counterrotating blade concepts were scaled to a tip diameter of 2 feet, so they could be incorporated into MPS (model propulsion simulators). Aerodynamic and aeroacoustic performance testing was conducted in the NASA Lewis 8 x 6 supersonic and 9 x 15 V/STOL (vertical or short takeoff and landing) wind tunnels and in the GE freejet anechoic test chamber (Cell 41) to generate an experimental data base for these counterrotating blade designs. Test facility and MPS vehicle matrices are provided, and test procedures are presented. Effects on performance of rotor-to-rotor spacing, angle-of-attack, pylon proximity, blade number, reduced-diameter aft blades, and mismatched rotor speeds are addressed. Counterrotating blade and specialized aeromechanical hub stability test results are also furnished.

Hoff, G. E.↗
NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗