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NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS2010

Orbital Debris Detection and Tracking Strategies for the NASA/AFRL Meter Class Autonomous Telescope (MCAT)

MCAT (Meter-Class Autonomous Telescope) is a 1.3m f/4 Ritchey-Chr tien on a double horseshoe equatorial mount that will be deployed in early 2011 to the western pacific island of Legan in the Kwajalein Atoll to perform orbital debris observations. MCAT will be capable of tracking earth orbital objects at all inclinations and at altitudes from 200 km to geosynchronous. MCAT s primary objective is the detection of new orbital debris in both low-inclination low-earth orbits (LEO) and at geosynchronous earth orbit (GEO). MCAT was thus designed with a fast focal ratio and a large unvignetted image circle able to accommodate a detector sized to yield a large field of view. The selected primary detector is a close-cycle cooled 4Kx4K 15um pixel CCD camera that yields a 0.9 degree diagonal field. For orbital debris detection in widely spaced angular rate regimes, the camera must offer low read-noise performance over a wide range of framing rates. MCAT s 4-port camera operates from 100 kHz to 1.5 MHz per port at 2 e- and 10 e- read noise respectively. This enables low-noise multi-second exposures for GEO observations as well as rapid (several frames per second) exposures for LEO. GEO observations will be performed using a counter-sidereal time delay integration (TDI) technique which NASA has used successfully in the past. For MCAT the GEO survey, detection, and follow-up prediction algorithms will be automated. These algorithms will be detailed herein. For LEO observations two methods will be employed. The first, Orbit Survey Mode (OSM), will scan specific orbital inclination and altitude regimes, detect new orbital debris objects against trailed background stars, and adjust the telescope track to follow the detected object. The second, Stare and Chase Mode (SCM), will perform a stare, then detect and track objects that enter the field of view which satisfy specific rate and brightness criteria. As with GEO, the LEO operational modes will be fully automated and will be described herein. The automation of photometric and astrometric processing (thus streamlining data collection for environmental modeling) will also be discussed.

Mulrooney, M.↗

NASA NTRS1971

Investigation of techniques for improving Saturn 5 RF tracking and ranging systems

Results of theoretical analyses of 12 problems are presented and comparisons of theoretical and experimental results are given. The investigations covered were: (1) techniques for improving the Saturn radar altimeter, (2) performance of the phase lock loop of the offset Doppler transponder, (3) signal processing equipment design for an orbital altitude radar return experiment, (4) spectral studies of signals present in the command and communication system (CCS) up-link transmitter, (5) intermodulation in the CCS down-link data demodulators, (6) error rate performance of the CCS transponder command demodulator, (7) flame attenuation effects on telemetry transmissions during Saturn launches, (8) design of a digital television system which converts a standard monochrome picture to a slow-scan picture, (9) methods of obtaining an additional CCS 72-kilobit/sec telemetry channel, (10) computation of the CCS S-band down-link spectra, (11) modeling of portions of the communications systems, and (12) modeling of a telemetry transmitter.

Walsh, J. R., Jr.↗

NASA NTRS1973

Long-term cryogenic space storage system

Discussion of the design, fabrication and testing of a 225-cu ft spherical cryogenic storage system for long-term subcritical applications under zero-g conditions in storing subcritical cryogens for space vehicle propulsion systems. The insulation system design, the analytical methods used, and the correlation between the performance test results and analytical predictions are described. The best available multilayer insulation materials and state-of-the-art thermal protection concepts were applied in the design, providing a boiloff rate of 0.152 lb/hr, or 0.032% per day, and an overall heat flux of 0.066 Btu/sq ft hr based on a 200 sq ft surface area. A six to eighteen month cryogenic storage is provided by this system for space applications.

Hopkins, R. A.↗

NASA NTRS1982

An evaluation of an ICCD imager of dynamic range expansion technique and application of insitu procedures for life-time extension

Research toward practical implementation of the Intensified Charge Coupled Device (ICCD) as a photon-counting array detector for astronomy is reported. The first area of concentration was to determine the rate and extent of the lifetime limiting damage to the CCD caused by the impact of high energy electrons, and to find whether various methods of annealing the damage were productive. The second effort was to determine the performance of the ICCD in a photon-counting mode to produce extended dynamic range measurements. There are two main effects that appear as the practical results of the electron damage to the CCD. One is an increase in the leakage current, i.e., the normal thermal generation of charge carriers in the silicon that provides a background dark signal that adds to the light produced image. In an undamaged CCD, the leakage current is usually fairly uniform across the photosensitive area of the silicon chip, with the exception of various bright pixels which have an anomalous leakage current well above the overall level.

Currie, D. G.↗

NASA NTRS1985

Texture classification by local rank correlation

A new approach to texture classification based on local rank correlation is proposed here. Its performance is compared with Laws' method which uses local convolution with feature masks. In the experiments, texture samples are classified based on their distribution of local statistics, either rank correlations or convolutions. The new method achieves generally optimal classification rates. It appears to be more robust because local order statistics are unaffected by local sample differences due to monotonic shifts of texture gray values and are less sensitive to noise.

Harwood, D.↗

NASA NTRS1993

Coupling finite and boundary element methods for 2-D elasticity problems

A finite element-boundary element (FE-BE) coupling method for two-dimensional elasticity problems is developed based on a weighted residual variational method in which a portion of the domain of interest is modeled by FEs and the remainder of the region by BEs. The performance of the FE-BE coupling method is demonstrated via applications to a simple 'patch test' problem and three-crack problems. The method passed the patch tests for various modeling configurations and yielded accurate strain energy release rates for the crack problems studied.

Krishnamurthy, T.↗

NASA NTRS1996

Numerical Investigation of Slag Behavior for RSRM

It is known that the flow field of the redesigned solid rocket motor (RSRM) is very complicated due to the complex characteristics of turbulent multi-phase flow, chemical reaction, particle combustion, evaporation, breakup and agglomeration etc. It requires multi-phase calculations, chemical reaction simulation, and particle combustion, evaporation, and breakup models to obtain a better understanding of thermophysics for the RSRM design using numerical methods. Also, the slag buildup due to the molten particles is another factor affecting the performance of the RSRM. To achieve this goal, the volume of fluid (VOF) method is used to capture the free surface motion so as to simulate the accumulation of the molten particles (slag) of the RSRM. A finite rate chemistry model is used to simulate the chemical reaction effects. For multi-phase calculations, the Hermsen combustion model is used for the aluminum particle combustion analysis and the Taylor Analogy Breakup (TAB) model is used for the particle breakup analysis. An interphase mas-exchange model introduced by Spalding is used for the evaporation calculation. The particle trajectories are calculated using a one-step implicit method for several groups of particle sizes by which the drag forces and heat fluxes are then coupled with the gas phase equations. The preliminary results predicted a reasonable physical simulation of the particle effects using a simple two dimensional solid rocket motor configuration. It shows that the AL/AL2O3 particle sizes are reduced due to the combustion, evaporation, and breakup. The flow field is disturbed by the particles. Mach number distributions in the nozzle are deformed due to the effect of particle concentrations away from the center line.

Liaw, P.↗

NASA NTRS2011

A Globally Stable Lyapunov Pointing and Rate Controller for the Magnetospheric MultiScale Mission (MMS)

The Magnetospheric MultiScale Mission (MMS) is scheduled to launch in late 2014. Its primary goal is to discover the fundamental plasma physics processes of reconnection in the Earth's magnetosphere. Each of the four MMS spacecraft is spin-stabilized at a nominal rate of 3 RPM. Traditional spin-stabilized spacecraft have used a number of separate modes to control nutation, spin rate, and precession. To reduce the number of modes and simplify operations, the Delta-H control mode is designed to accomplish nutation control, spin rate control, and precession control simultaneously. A nonlinear design technique, Lyapunov's method, is used to design the Delta-H control mode. A global spin rate controller selected as the baseline controller for MMS, proved to be insufficient due to an ambiguity in the attitude. Lyapunov's design method was used to solve this ambiguity, resulting in a controller that meets the design goals. Simulation results show the advantage of the pointing and rate controller for maneuvers larger than 90 deg and provide insight into the performance of this controller.

Shah, Neerav↗

NASA NTRS2018

Design of Distributed Mail-Slot Propulsion System on a Hybrid Wingbody Aircraft

This paper deals with designing a thrust distribution strategy when a Turboelectric Distributed Propulsion (TeDP) system of 16 embedded propulsors is installed on an aerodynamically optimized hybrid wing-body configuration. This HWB previously designed to satisfy conditions of trim, longitudinally static stability and specific cargo space is employed as the baseline configuration for the current study of seeking an optimal propulsion/power system. According to the nature of the entrance flow condition for each distributed propulsion passage in hybrid wing-body aircraft, the ingested boundary layer thickness differs and results in different propulsive reaction. An optimal distribution of thrust and power output is determined by how the system utilizes the propulsive characteristics of each passage. The design space and the number of design variables are selected and described accordingly. An actuator disk model is employed to model thrust generation and shaft power from the propulsor. To carry out the optimization of the propulsion/power system on a computationally expensive CFD model, a Kriging method in conjunction with a Genetic Algorithm (GA) is applied. Throughout the design process, the propulsion performances of the sampled propulsion/power system are analyzed and compared to those of a clean flow engine. The performance metrics includes mass flow rate, fan pressure ratio besides the thrust and shaft power. Minimization of total shaft power from the distributed engine is performed at multiple thrust levels. The benefit of boundary layer ingestion propulsion system is quantified via comparison of thrust equivalent, shaft power and mass flow equivalent clean flow engines with CFD based system design.

Hybrid Wingbody↗

NASA NTRSDate not supplied

Loci/STREAM Sharp Interface Model Validation of Cryogenic Propellant Tank Self-Pressurization

This paper documents a model validation effort for the prediction of cryogenic propellant tank selfpressurization physics using the Loci/STREAM sharp interface CFD model developed at NASA MSFC. Cryogenic fluid management (CFM) applications for long duration spaceflight missions require accurate modeling of heat transfer and thermodynamics. Therefore, detailed validation of those physics is important to ensure simulation accuracy. In the past, the MSFC Propulsion Fluid Dynamics Branch has validated and used the Loci/STREAM Volume of Fluid (VOF) module extensively for propellant slosh applications, which are dominated by fluid motion. For cases where the interface gas/liquid interface is essentially static, the Loci/STREAM sharp interface was developed for more rapid and efficient CFM analysis. In the present study, Loci/STREAM sharp interface simulations were compared with the NASA K-site self-pressurization experiment of a flight weight, partially full, LH2 tank in normal gravity. This study investigated several parametric effects and made a number of important observations on the performance of the Loci/STREAM sharp interface method: - First, a homogeneous model was derived to verify the CFD model. The homogeneous model assumes both gas and liquid phases are uniform and are at saturation temperature. The predicted pressure rise rates at 3.5 W/m2 and 2.0 W/m2 with a 49% fill level are all lower than the experimental measurement. This is expected due to the observed temperature stratification near the gas-liquid interface during testing. - The k-w and k-e turbulence models predict comparable pressurization rates, which are much lower than the experiment measurement. On the other hand, the pressure values and pressurization rates from both models are almost the same as those of the homogeneous model. The current turbulence model is too diffusive and is not capable of capturing the thermal stratification in the liquid and ullage. - When using the laminar flow model, the pressurization rate is found to be very close to the experimental value when a quasi-steady flow field is allowed to develop by continuously venting the tank prior to pressurization as was done during testing. On the other hand, without initial venting, the rate is not constant. Additionally, the development time to reach a quasi-steady flow field differed from the experiment due to the lack of turbulent mixing away from the gas-liquid interface that is expected in reality. - Using the laminar flow model and appropriate initial conditioning, the pressurization rate is within 15% of the experimental value for 49% fill level at 3.5 W/m 2 and is within 18% for 2.0 W/m 2 heat loading. - Using the laminar flow model and appropriate initial conditioning, the pressurization rate is within 18% of the experimental value for a 29% fill level and within 15% for an 83% fill level.

H. Q. Yang↗

NASA NTRS2001

Real-Time Adaptive Control Allocation Applied to a High Performance Aircraft

Abstract This paper presents the development and application of one approach to the control of aircraft with large numbers of control effectors. This approach, referred to as real-time adaptive control allocation, combines a nonlinear method for control allocation with actuator failure detection and isolation. The control allocator maps moment (or angular acceleration) commands into physical control effector commands as functions of individual control effectiveness and availability. The actuator failure detection and isolation algorithm is a model-based approach that uses models of the actuators to predict actuator behavior and an adaptive decision threshold to achieve acceptable false alarm/missed detection rates. This integrated approach provides control reconfiguration when an aircraft is subjected to actuator failure, thereby improving maneuverability and survivability of the degraded aircraft. This method is demonstrated on a next generation military aircraft Lockheed-Martin Innovative Control Effector) simulation that has been modified to include a novel nonlinear fluid flow control control effector based on passive porosity. Desktop and real-time piloted simulation results demonstrate the performance of this integrated adaptive control allocation approach.

Davidson, John B.↗

NASA NTRSDate not supplied

Four Problematic Methods in Reliability Analysis

Some basic methods used in reliability analysis are problematic because they produce incorrect and overoptimistic predictions. Initially gratifying forecasts are often invalidated by testing and operational experience. The problematic methods in reliability analysis include estimating the system failure rate as the sum of component failure rates, assuming that reliability growth continues indefinitely during testing, overestimating the benefits of redundancy, and using the fault tolerance count instead of a detailed reliability analysis. Reliability analysis can produce more optimism than accuracy. This bug may now be a feature. The optimistic bias inevitable in project planning should be corrected by realistic reliability analysis that reflects relevant experience. That the repeated poor performance of reliability analysis is found to be surprising suggests willful blindness. Rigorous methods and impartial critical review are necessary to improve reliability analysis.

Reliability analysis↗

NASA NTRSDate not supplied

Four Problematic Methods in Reliability Analysis

Reliability analysis↗

NASA NTRS1978

Nitrogen tetroxide scrubber data analysis

A major difficulty in the analysis of scrubber data is that of separating the physical effects, such as mass transfer, from the physico-chemical effects, such as reaction rates. This is especially true for the absorbtion of nitrogen tetroxide in the various liquids that were tested in the NASA-Kennedy Space Center Hypergolic Toxic Scrubber Program. A fruitful approach to correlating the data for outlet concentrations was to treat the overall absorbtion as a pseudo first-order absorbtion equation. This approach provided a method for normalizing the data to constant inlet concentration, constant sump liquor condition, and constant scrubbing time, and permitted evaluation of the test and fluid parameters that affected both absorbtion rate and scrubbing time. The analysis indicated that scrubber performance may be improved by optimizing liquor concentrations and liquor flowrate distributions.

Simon, E. D.↗

NASA NTRS1990

Scientific applications of frequency-stabilized laser technology in space

A synoptic investigation of the uses of frequency-stabilized lasers for scientific applications in space is presented. It begins by summarizing properties of lasers, characterizing their frequency stability, and describing limitations and techniques to achieve certain levels of frequency stability. Limits to precision set by laser frequency stability for various kinds of measurements are investigated and compared with other sources of error. These other sources include photon-counting statistics, scattered laser light, fluctuations in laser power, and intensity distribution across the beam, propagation effects, mechanical and thermal noise, and radiation pressure. Methods are explored to improve the sensitivity of laser-based interferometric and range-rate measurements. Several specific types of science experiments that rely on highly precise measurements made with lasers are analyzed, and anticipated errors and overall performance are discussed. Qualitative descriptions are given of a number of other possible science applications involving frequency-stabilized lasers and related laser technology in space. These applications will warrant more careful analysis as technology develops.

Schumaker, Bonny L.↗

NASA NTRS2011

Demonstration of a Fiber Optic Regression Probe in a High-Temperature Flow

The capability to provide localized, real-time monitoring of material regression rates in various applications has the potential to provide a new stream of data for development testing of various components and systems, as well as serving as a monitoring tool in flight applications. These applications include, but are not limited to, the regression of a combusting solid fuel surface, the ablation of the throat in a chemical rocket or the heat shield of an aeroshell, and the monitoring of erosion in long-life plasma thrusters. The rate of regression in the first application is very fast, while the second and third are increasingly slower. A recent fundamental sensor development effort has led to a novel regression, erosion, and ablation sensor technology (REAST). The REAST sensor allows for measurement of real-time surface erosion rates at a discrete surface location. The sensor is optical, using two different, co-located fiber-optics to perform the regression measurement. The disparate optical transmission properties of the two fiber-optics makes it possible to measure the regression rate by monitoring the relative light attenuation through the fibers. As the fibers regress along with the parent material in which they are embedded, the relative light intensities through the two fibers changes, providing a measure of the regression rate. The optical nature of the system makes it relatively easy to use in a variety of harsh, high temperature environments, and it is also unaffected by the presence of electric and magnetic fields. In addition, the sensor could be used to perform optical spectroscopy on the light emitted by a process and collected by fibers, giving localized measurements of various properties. The capability to perform an in-situ measurement of material regression rates is useful in addressing a variety of physical issues in various applications. An in-situ measurement allows for real-time data regarding the erosion rates, providing a quick method for empirically anchoring any analysis geared towards lifetime qualification. Erosion rate data over an operating envelope could also be useful in the modeling detailed physical processes. The sensor has been embedded in many regressing media to demonstrate the capabilities in a number of regressing environments. In the present work, sensors were installed in the eroding/regressing throat region of a converging-diverging flow, with the working gas heated to high temperatures by means of a high-pressure arc discharge at steady-state discharge power levels up to 500 kW. The amount of regression observed in each material sample was quantified using a later profilometer, which was compared to the in-situ erosion measurements to demonstrate the efficacy of the measurement technique in very harsh, high-temperature environments.

Korman, Valentin↗

NASA NTRS2012

Timescale Correlation between Marine Atmospheric Exposure and Accelerated Corrosion Testing - Part 2

Evaluation of metals to predict service life of metal-based structures in corrosive environments has long relied on atmospheric exposure test sites. Traditional accelerated corrosion testing relies on mimicking the exposure conditions, often incorporating salt spray and ultraviolet (UV) radiation, and exposing the metal to continuous or cyclic conditions similar to those of the corrosive environment. Their reliability to correlate to atmospheric exposure test results is often a concern when determining the timescale to which the accelerated tests can be related. Accelerated corrosion testing has yet to be universally accepted as a useful tool in predicting the long-term service life of a metal, despite its ability to rapidly induce corrosion. Although visual and mass loss methods of evaluating corrosion are the standard, and their use is crucial, a method that correlates timescales from accelerated testing to atmospheric exposure would be very valuable. This paper presents work that began with the characterization of the atmospheric environment at the Kennedy Space Center (KSC) Beachside Corrosion Test Site. The chemical changes that occur on low carbon steel, during atmospheric and accelerated corrosion conditions, were investigated using surface chemistry analytical methods. The corrosion rates and behaviors of panels subjected to long-term and accelerated corrosion conditions, involving neutral salt fog and alternating seawater spray, were compared to identify possible timescale correlations between accelerated and long-term corrosion performance. The results, as well as preliminary findings on the correlation investigation, are presented.

Montgomery, Eliza L.↗