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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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NASA NTRS2010

Analysis of Shroud Options in Support of the Human Exploration of Mars

In support of the Mars Design Reference Architecture (DRA) 5.0, the NASA study team analyzed several shroud options for use on the Ares V launch vehicle.1,2 These shroud options included conventional "large encapsulation" shrouds with outer diameters ranging from 8.4 to 12.9 meters (m) and overall lengths of 22.0 to 54.3 meters, along with a "nosecone-only" shroud option used for Mars transfer vehicle component delivery. Also examined was a "multi-use" aerodynamic encapsulation shroud used for launch, Mars aerocapture, and entry, descent, and landing of the cargo and habitat landers. All conventional shroud options assessed for use on the Mars launch vehicles were the standard biconic design derived from the reference shroud utilized in the Constellation Program s lunar campaign. It is the purpose of this paper to discuss the technical details of each of these shroud options including material properties, structural mass, etc., while also discussing both the volume and mass of the various space transportation and surface system payload elements required to support a "minimum launch" Mars mission strategy, as well as the synergy, potential differences and upgrade paths that may be required between the Lunar and Mars mission shrouds.

Feldman, Stuart↗
NASA NTRS2010

Altair Lander Life Support: Requirements Analysis Cycles 1 and 2

Life support systems are a critical part of human exploration beyond low earth orbit. NASA's Altair Lunar Lander has unique missions to perform and will need a unique life support system to complete them. Initial work demonstrated a feasible minimally -functional Lander design. This work was completed in Design Analysis Cycles (DAC) 1, 2, and 3 were reported in a previous paper'. On October 21, 2008, the Altair project completed the Mission Concept Review (MCR), moving the project into Phase A. In Phase A activities, the project is preparing for the System Requirements Review (SRR). Altair has conducted two Requirements Analysis Cycles (RACs) to begin this work. During this time, the life support team must examine the Altair mission concepts, Constellation Program level requirements, and interfaces with other vehicles and spacesuits to derive the right set of requirements for the new vehicle. The minimum functionality design meets some of these requirements already and can be easily adapted to meet others. But Altair must identify which will be more costly in mass, power, or other resources to meet. These especially costly requirements must be analyzed carefully to be sure they are truly necessary, and are the best way of explaining and meeting the true need. If they are necessary and clear, they become important mass threats to track at the vehicle level. If they are not clear or do not seem necessary to all stakeholders, Altair must work to redefine them or push back on the requirements writers. Additionally, the life support team is evaluating new technologies to see if they are more effective than the existing baseline design at performing necessary functions in Altair's life support system.

Anderson, Molly↗
NASA NTRS2008

Lessons Learned From The EMU Fire and How It Impacts CxP Suit Element Development and Testing

During testing a Space Shuttle Extravehicular Mobility Unit (EMU) pressure garment and life-support backpack was destroyed in a flash fire in the Johnson Space Center's Crew systems laboratory. This slide presentation reviews the accident, probable causes, the lessons learned and the effect this has on the testing and the environment for testing of the Space Suit for the Constellation Program.

Metts, Jonathan↗
NASA NTRS2010

Space Operations for a New Era of Exploration Launch Vehicles

NASA's Constellation Program is depending on the Ares Projects to deliver the crew and cargo launch capabilities needed to send human explorers to the Moon and beyond. Ares I and V will provide the core space launch capabilities needed to continue providing crew and cargo access to the International Space Station (ISS), and to build upon the U.S. history of human space exploration. Since 2005, Ares has made substantial progress on designing, developing, and testing the Ares I crew launch vehicle and has continued its in-depth studies of the Ares V cargo launch vehicles. The combined Ares I/Ares V architecture has been designed to reduce the complexity and labor intensity of ground operations for America's next journeys beyond low-Earth orbit (LEO). A deliberate effort is being made to ensure a high level of system operability to significantly increase safety and system availability as well as reduce recurring costs for this new launch vehicle. The Ares Projects goal is to instill operability as part of the vehicles requirements development, design, and operations. This simplicity will come from using simpler, proven engine designs, as in the case of the J-2X upper stage engine and RS-68 engine; improving existing hardware, as in the case of the Shuttle-heritage 5-segment solid rocket motor; and using common propulsion and instrument unit elements between Ares I and Ares V. Furthermore, lessons learned while developing Ares I will be applied directly to Ares V operations. In 2009, the Ares Projects plan to conduct the first flight test of Ares I, designated Ares I-X. Ares I-X preparations have already prompted changes to the vehicle stacking and launch infrastructure at Kennedy Space Center (KSC), including removing Shuttle-specific fixtures from the Vehicle Assembly Building (VAB) to accommodate Ares I-style stacking operations, new firing room computers and infrastructure in the VAB Launch Control Center, and new lightning protection system towers at Launch Complex 39B to accommodate the greater height of Ares I-X. In addition to lessons learned from the stacking of Ares I-X, the flight test itself promises to yield important data and operations lessons for assembling, launching, and flying Ares I.

Cook, Stephen A.↗
NASA NTRS2010

Simulation Training Versus Real Time Console Training for New Flight Controllers

For new flight controllers, the two main learning tools are simulations and real time console performance training. These benefit the new flight controllers in different ways and could possibly be improved. Simulations: a) Allow for mistakes without serious consequences. b) Lets new flight controllers learn the working style of other new flight controllers. c) Lets new flight controllers eventually begin to feel like they have mastered the sim world, so therefore they must be competent in the real time world too. Real time: a) Shows new flight controllers some of the unique problems that develop and have to be accounted for when dealing with certain payloads or systems. b) Lets new flight controllers experience handovers - gathering information from the previous shift on what the room needs to be aware of and what still needs to be done. c) Gives new flight controllers confidence that they can succeed in the position they are training for when they can solve real anomalies. How Sims could be improved and more like real-time ops for the ISS Operations Controller position: a) Operations Change Requests to review. b) Fewer anomalies (but still more than real time for practice). c) Payload Planning Manager Handover sheet for the E-1 and E-3 reviews. d) Flight note in system with at least one comment to verify for the E-1 and E-3 reviews How the real time console performance training could be improved for the ISS Operations Controller position: a) Schedule the new flight controller to be on console for four days but with a different certified person each day. This will force them to be the source of knowledge about every OCR in progress, everything that has happened in those few days, and every activity on the timeline. Constellation program flight controllers will have to learn entirely from simulations, thereby losing some of the elements that they will need to have experience with for real time ops. It may help them to practice real time console performance training in the International Space Station or Space Shuttle to gather some general anomaly resolution and day-to-day task management skills.

Heaton, Amanda↗
NASA NTRS2009

The Establishment of a New Friction Stir Welding Process Development Facility at NASA/MSFC

Full-scale weld process development is being performed at MSFC to develop the tools, fixtures, and facilities necessary for Ares I production. Full scale development in-house at MSFC fosters technical acuity within the NASA engineering community, and allows engineers to identify and correct tooling and equipment shortcomings before they become problems on the production floor. Finally, while the new weld process development facility is currently being outfitted in support of Ares I development, it has been established to support all future Constellation Program needs. In particular, both the RWT and VWT were sized with the larger Ares V hardware in mind.

Carter, Robert W.↗
NASA NTRS2010

Acoustic Measurements of Small Solid Rocket Motor

Rocket acoustic noise can induce loads and vibration on the vehicle as well as the surrounding structures. Models have been developed to predict these acoustic loads based on scaling existing solid rocket motor data. The NASA Marshall Space Flight Center acoustics team has measured several small solid rocket motors (thrust below 150,000 lbf) to anchor prediction models. This data will provide NASA the capability to predict the acoustic environments and consequent vibro-acoustic response of larger rockets (thrust above 1,000,000 lbf) such as those planned for the NASA Constellation program. This paper presents the methods used to measure acoustic data during the static firing of small solid rocket motors and the trends found in the data.

Vargas, Magda B.↗
NASA NTRS2010

Seal Analysis for the Ares-I Upper Stage Fuel Tank Manhole Cover

Techniques for studying the performance of Naflex pressure-assisted seals in the Ares-I Upper Stage liquid hydrogen tank manhole cover seal joint are explored. To assess the feasibility of using the identical seal design for the Upper Stage as was used for the Space Shuttle External Tank manhole covers, a preliminary seal deflection analysis using the ABAQUS commercial finite element software is employed. The ABAQUS analyses are performed using three-dimensional symmetric wedge finite element models. This analysis technique is validated by first modeling a heritage External Tank liquid hydrogen tank manhole cover joint and correlating the results to heritage test data. Once the technique is validated, the Upper Stage configuration is modeled. The Upper Stage analyses are performed at 1.4 times the expected pressure to comply with the Constellation Program factor of safety requirement on joint separation. Results from the analyses performed with the External Tank and Upper Stage models demonstrate the effects of several modeling assumptions on the seal deflection. The analyses for Upper Stage show that the integrity of the seal is successfully maintained.

Phillips, Dawn R.↗
NASA NTRS2010

Pressure Garment Subsystem Roadmap

The Constellation program pressure garment subsystem (PGS) team has created a technical roadmap that communicates major technical questions and how and when the questions are being answered in support of major project milestones. The roadmap is a living document that guides the team priorities. The roadmap also communicates technical reactions to changes in project priorities and funding. This paper presents the roadmap and discusses specific roadmap elements in detail as representative examples to provide insight into the meaning and use of the roadmap.

Ross, Amy J.↗
NASA NTRS2010

Overview of NASA's Thermal Control System Development for Exploration Project

NASA's Constellation Program includes the Orion, Altair, and Lunar Surface Systems project offices. The first two elements, Orion and Altair, are manned space vehicles while the third element is broader and includes several sub-elements including Rovers and a Lunar Habitat. The upcoming planned missions involving these systems and vehicles include several risks and design challenges. Due to the unique thermal environment, many of these risks and challenges are associated with the vehicles' thermal control system. NASA's Exploration Systems Mission Directorate (ESMD) includes the Exploration Technology Development Program (ETDP). ETDP consists of several technology development projects. The project chartered with mitigating the aforementioned risks and design challenges is the Thermal Control System Development for Exploration Project. The risks and design challenges are addressed through a rigorous technology development process that culminates with an integrated thermal control system test. The resulting hardware typically has a Technology Readiness Level (TRL) of six. This paper summarizes the development efforts being performed by the technology development project. The development efforts involve heat acquisition and heat rejection hardware including radiators, heat exchangers, and evaporators. The project has also been developing advanced phase change material heat sinks and performing assessments for thermal control system fluids.

Stephan, Ryan A.↗
NASA NTRS2009

An Overview of Follow-On Testing Activities of the A-3 Subscale Diffuser Test Project

An overview of NASA Stennis Space Center's (SSC) A-3 Subscale Diffuser Test (SDT) Project is presented. The original scope of the SDT Project, conducted from April 2007 to January 2008, collected data to support mitigation of risk associated with design and procurement activities of the A-3 Test Stand Project, an effort to construct a simulated altitude test facility at SSC in support of NASA's Constellation Program. Follow-on tests were conducted from May 2008 through August 2009, utilizing the SDT test setup as a testbed for additional risk mitigation activities. Included are descriptions of the Subscale Diffuser (SD) test article, the test facility configuration, and test approaches.

Ryan, James E.↗
NASA NTRS2010

Ares I First Stage Propulsion System Status

With the retirement of the Space Shuttle inevitable, the US is faced with the need to loft a reliable cost-effective, technologically viable solution to bring the nation s fleet of spacecraft back up to industry standard. It must not only support the International Space Station (ISS), it must also be capable of supporting human exploration beyond low Earth orbit (LEO). NASA created the Constellation Program to develop a new fleet including the launch vehicles, the spacecraft, and the mission architecture to meet those objectives. The Ares First Stage Team is tasked with developing a propulsion system capable of safely, dependably and repeatedly lofting that new fleet. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle were used as a starting point in the design and production of a new first stage element. While the first stage will provide the foundation, the structural backbone, power, and control for launch, the new propulsive element will also provide a greater total impulse to loft a safer, more powerful, fleet of space flight vehicles. Substantial design and system upgrades were required to meet the mass and trajectory requisites of the new fleet. Noteworthy innovations and design features include new forward structures, new propellant grain geometry, a new internal insulation system, and a state-of-the art avionics system. Additional advances were in materials and composite structures development, case bond liners, and thermal protection systems. Significant progress has been made in the design, development and testing of the propulsion and avionics systems for the new first stage element. Challenges, such as those anticipated with thrust oscillation, have been better characterized, and are being effectively mitigated. The test firing of the first development motor (DM-1) was a success that validated much of the engineering development to date. Substantive data has been collected and analyzed, allowing the Ares First Stage team to move forward, fine-tune the design, and advance to production of the second development motor (DM-2), which is now in fabrication. This paper will provide an overview of the design, development, challenges, and progress on the production of the new Ares First Stage propulsion system

Priskos, Alex S.↗
NASA NTRS2010

Ares V: Progress Toward Unprecedented Heavy Lift

Ares V represents the vehicle that will again make possible human exploration beyond low Earth orbit. The Ares V is part of NASA s Constellation Program architecture developed to support the International Space Station (ISS), establish a permanent human presence on the Moon, and explore it to an extent far greater than was possible with the Apollo Program. Ares V will carry the lunar lander to orbit where it will join the Orion crew spacecraft, launched by the smaller Ares I launch vehicle. Then the Ares V upper stage will send the Orion and lander to the Moon. Ares V is also intended to launch automated cargo landers to the Moon. The Ares vehicles are designed to employ the proven technologies and experience from the Space Shuttle, Delta IV, and earlier U.S. programs, as well as sharing common components where feasible. The Ares V is in an early stage of concept development. However, commonality allows it to benefit from development work already under way on the Ares I, including the first stage booster, and upper stage, J-2X upper stage engine. This paper will discuss progress to date on the Ares V and its potential for freeing payload designers from current mass and volume constraints. Progress includes development progress on Ares I elements that will be shared by the two launch vehicles. The Ares I first stage recently completed a successful test firing of Development Motor 1 (DM-1). The J-2X engine is proceeding with manufacturing of components for the first development engines that will be used for testing. Several component-level tests have been completed or are under way that will help verify designs and confirm solutions to design challenges. The Ares V Earth departure stage will benefit from the Ares I upper stage development, including design, manufacturing, and materials testing. NASA is also working with government and industry to collect data on flights and testing of the operational RS-68 engine and potential upgrades. The Ares V team continues to evaluate technical options, vehicle configurations, and operations concepts for the Ares V. The team recently completed a Fall Face-to-Face meeting that served as a stepping-stone to the Systems Requirements Review (SRR). This four-day meeting served as an information exchange for the various teams at several NASA field centers and supporting contractors.

Sumrall, Phil↗
NASA NTRS2010

2010 JANNAF Abstract Propulsion System Status: Ares First Stage

In November 2005, NASA created the Constellation Program to develop an entirely new fleet of spacecraft to include the Ares I Crew Launch Vehicle and the Ares V Cargo Launch vehicles. The Ares I First Stage Team has made significant progress on the design of a propulsion system capable of lofting that new fleet. To minimize technical risks and development costs, the Solid Rocket Boosters (SRBs) of Shuttle served as a starting point in the design of a new motor that would meet the requirements of those new vehicles. By bringing in a fifth segment, this new propulsive element will provide greater total impulse to loft a safer, more powerful fleet of space flight vehicles. Additional modifications include the use of composite structures, new metallic forward structures, new parachutes, a new propellant grain design, and a new nozzle. Although still ongoing and in process, significant design, development and concept testing has already been conducted. This includes a full-scale motor firing, deceleration subsystem testing, and testing of several complete avionics line replaceable units. The suborbital development flight, Ares I-X, provided the opportunity to gather critical data about the flight dynamics of the integrated launch vehicle stack. The Ares I-X test flight has also informed our Ares First Stage design. It brought a more comprehensive understanding in a number of areas, which are now being analyzed. This paper will provide an overview of the design, development, challenges, and progress on the production of the new Ares First Stage propulsion system. Challenges and mitigation strategies will be addressed. An overview will also be included of testing to date.

Tiller, Bruce K.↗
NASA NTRS2010

Combustion Stability Analyses for J-2X Gas Generator Development

The National Aeronautics and Space Administration (NASA) is developing a liquid oxygen/liquid hydrogen rocket engine for upper stage and trans-lunar applications of the Ares vehicles for the Constellation program. This engine, designated the J-2X, is a higher pressure, higher thrust variant of the Apollo-era J-2 engine. Development was contracted to Pratt & Whitney Rocketdyne in 2006. Over the past several years, development of the gas generator for the J-2X engine has progressed through a variety of workhorse injector, chamber, and feed system configurations. Several of these configurations have resulted in injection-coupled combustion instability of the gas generator assembly at the first longitudinal mode of the combustion chamber. In this paper, the longitudinal mode combustion instabilities observed on the workhorse test stand are discussed in detail. Aspects of this combustion instability have been modeled at the NASA Marshall Space Flight Center with several codes, including the Rocket Combustor Interaction Design and Analysis (ROCCID) code and a new lumped-parameter MatLab model. To accurately predict the instability characteristics of all the chamber and injector geometries and test conditions, several features of the submodels in the ROCCID suite of calculations required modification. Finite-element analyses were conducted of several complicated combustion chamber geometries to determine how to model and anchor the chamber response in ROCCID. A large suite of sensitivity calculations were conducted to determine how to model and anchor the injector response in ROCCID. These modifications and their ramification for future stability analyses of this type are discussed in detail. The lumped-parameter MatLab model of the gas generator assembly was created as an alternative calculation to the ROCCID methodology. This paper also describes this model and the stability calculations.

Hulka, J. R.↗
NASA NTRS2010

Space Suit CO2 Washout During Intravehicular Activity

Space suit carbon dioxide (CO2) washout refers to the removal of CO2 gas from the oral-nasal area of a suited astronaut's (or crewmember's) helmet using the suit's ventilation system. Inadequate washout of gases can result in diminished mental/cognitive abilities as well as headaches and light headedness. In addition to general discomfort, these ailments can impair an astronaut s ability to perform mission-critical tasks ranging from flying the space vehicle to performing lunar extravehicular activities (EVAs). During design development for NASA s Constellation Program (CxP), conflicting requirements arose between the volume of air flow that the new Orion manned space vehicle is allocated to provide to the suited crewmember and the amount of air required to achieve CO2 washout in a space suit. Historically, space suits receive 6.0 actual cubic feet per minute (acfm) of air flow, which has adequately washed out CO2 for EVAs. For CxP, the Orion vehicle will provide 4.5 acfm of air flow to the suit. A group of subject matter experts (SM Es) among the EVA Systems community came to an early consensus that 4.5 acfm may be acceptable for low metabolic rate activities. However, this value appears very risky for high metabolic rates, hence the need for further analysis and testing. An analysis was performed to validate the 4.5 acfm value and to determine if adequate CO2 washout can be achieved with the new suit helmet design concepts. The analysis included computational fluid dynamic (CFD) modeling cases, which modeled the air flow and breathing characteristics of a human wearing suit helmets. Helmet testing was performed at the National Institute of Occupational Safety and Health (NIOSH) in Pittsburgh, Pennsylvania, to provide a gross-level validation of the CFD models. Although there was not a direct data correlation between the helmet testing and the CFD modeling, the testing data showed trends that are very similar to the CFD modeling. Overall, the analysis yielded results that were better than anticipated, with a few unexpected findings that could not easily be explained. Results indicate that 4.5 acfm is acceptable for CO2 washout and helmet design. This paper summarizes the results of this CO2 washout study.

Augustine, Phillip M.↗
NASA NTRS2010

Waterhammer Testing and Modeling of the Ares I Upper Stage Reaction Control System

NASA's Ares I rocket is the agency's first step in completing the goals of the Constellation Program, which plans to deliver a new generation of space explorers into low earth orbit for future missions to the International Space Station, the moon, and other destinations within the solar system. Ares I is a two-stage rocket topped by the Orion crew capsule and its service module. The launch vehicle's First Stage is a single, five-segment reusable solid rocket booster (RSRB), derived from the Space Shuttle Program's four segment RSRB. The vehicle's Upper Stage, being designed at Marshall Space Flight Center (MSFC), is propelled by a single J-2X Main Engine fueled with liquid oxygen and liquid hydrogen. During active Upper Stage flight of the Ares I launch vehicle, the Upper Stage Reaction Control System (US ReCS) will perform attitude control operations for the vehicle. The US ReCS will provide three-axis attitude control capability (roll, pitch, and yaw) for the Upper Stage while the J-2X is not firing and roll control capability while the engine is firing. Because of the requirements imposed upon the system, the design must accommodate rapid pulsing of multiple thrusters simultaneously to maintain attitude control. In support of these design activities and in preparation for Critical Design Review, analytical models of the US ReCS propellant feed system have been developed using the Thermal Hydraulic Library of MSC.EASY5 v.2008, herein referred to as EASY5. EASY5 is a commercially available fluid system modeling package with significant history of modeling space propulsion systems. In Fall 2009, a series of development tests were conducted at MSFC on a cold-flow test article for the US ReCS, herein referred to as System Development Test Article (SDTA). A subset of those tests performed were aimed at examining the effects of waterhammer on a flight-representative system and to ensure that those effects could be quantified with analytical models and incorporated into the design of the flight system. This paper presents an overview of the test article and the test approach, along with a discussion of the analytical modeling methodology. In addition, the results of that subset of development tests, along with analytical model pre-test predictions and post-test model correlations, will also be discussed in detail.

Williams, J. Hunter↗
NASA NTRS2010

Distributed Observer Network

The Distributed Observer network (DON) is a NASA-collaborative environment that leverages game technology to bring three-dimensional simulations to conventional desktop and laptop computers in order to allow teams of engineers working on design and operations, either individually or in groups, to view and collaborate on 3D representations of data generated by authoritative tools such as Delmia Envision, Pro/Engineer, or Maya. The DON takes models and telemetry from these sources and, using commercial game engine technology, displays the simulation results in a 3D visual environment. DON has been designed to enhance accessibility and user ability to observe and analyze visual simulations in real time. A variety of NASA mission segment simulations [Synergistic Engineering Environment (SEE) data, NASA Enterprise Visualization Analysis (NEVA) ground processing simulations, the DSS simulation for lunar operations, and the Johnson Space Center (JSC) TRICK tool for guidance, navigation, and control analysis] were experimented with. Desired functionalities, [i.e. Tivo-like functions, the capability to communicate textually or via Voice-over-Internet Protocol (VoIP) among team members, and the ability to write and save notes to be accessed later] were targeted. The resulting DON application was slated for early 2008 release to support simulation use for the Constellation Program and its teams. Those using the DON connect through a client that runs on their PC or Mac. This enables them to observe and analyze the simulation data as their schedule allows, and to review it as frequently as desired. DON team members can move freely within the virtual world. Preset camera points can be established, enabling team members to jump to specific views. This improves opportunities for shared analysis of options, design reviews, tests, operations, training, and evaluations, and improves prospects for verification of requirements, issues, and approaches among dispersed teams.

Conroy, Michael↗