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NASA NTRS1994

Fatigue loads spectra derivation for the Space Shuttle: Second cycle

Some of the environments and loads experienced by the Space Shuttle or future reusable space vehicles are unique, while others are similar to those encountered by commercial and/or military aircraft. Prior to the Space Transportation System (STS) flights, fatigue loads spectra were generated for the Space Shuttle based on anticipated environments and assumptions that were shown not to be applicable to the actual flight environments the vehicle experienced. This resulted in the need to generate a new cycle of fatigue loads spectra, which was based on measured flight data as well as mission profiles, reflecting the various types of service and operations the vehicle and payloads experienced.

Ortasse, Raphael↗

NASA NTRS2011

The Legacy of Space Shuttle Flight Software

The initial goals of the Space Shuttle Program required that the avionics and software systems blaze new trails in advancing avionics system technology. Many of the requirements placed on avionics and software were accomplished for the first time on this program. Examples include comprehensive digital fly-by-wire technology, use of a digital databus for flight critical functions, fail operational/fail safe requirements, complex automated redundancy management, and the use of a high-order software language for flight software development. In order to meet the operational and safety goals of the program, the Space Shuttle software had to be extremely high quality, reliable, robust, reconfigurable and maintainable. To achieve this, the software development team evolved a software process focused on continuous process improvement and defect elimination that consistently produced highly predictable and top quality results, providing software managers the confidence needed to sign each Certificate of Flight Readiness (COFR). This process, which has been appraised at Capability Maturity Model (CMM)/Capability Maturity Model Integration (CMMI) Level 5, has resulted in one of the lowest software defect rates in the industry. This paper will present an overview of the evolution of the Primary Avionics Software System (PASS) project and processes over thirty years, an argument for strong statistical control of software processes with examples, an overview of the success story for identifying and driving out errors before flight, a case study of the few significant software issues and how they were either identified before flight or slipped through the process onto a flight vehicle, and identification of the valuable lessons learned over the life of the project.

Hickey, Christopher J.↗

NASA NTRS1987

Flow visualization study of a two-dimensional representation of the Space Shuttle launch pad configuration

The loss of the Space Shuttle Challenger was caused by the failure of the aft joint O-ring seals in its right solid rocket booster. It has been suggested by several sources that wind conditions through a reduction in temperature of the right solid rocket booster caused by the wind blowing across the cold external tank, played a role in the O-ring failure. To check the plausibility of the wind theory, an experiment was carried out in a water towing tank to visualize the flow past a two-dimensional model representing a cross section of the Space Shuttle launch configuration. The periodic formation of vortices was found to characterize the wake generated by the model. It is suggested that this organized motion in the flow is the dominant mechanism that accomplishes heat transfer from the external tank to the right solid rocket booster. Flow visualization results consisting of photographs that show instantaneous streamline patterns of the flow are presented.

Mclachland, B. G.↗

NASA NTRS1982

Space Shuttle Main Engine (SSME) Pogo testing and results

To effectively assess the Pogo stability of the space shuttle vehicle, it was necessary to characterize the structural, propellant, and propulsion dynamics subsystems. Extensive analyses and comprehensive testing programs were established early in the project as an implementation of management philosophy of Pogo prevention for space shuttle. The role of the space shuttle main engine (SSMF) in the Pogo prevention plans, the results obtained from engine ground testing with analysis, and measured data from STS-1 flight are discussed.

Fenwick, J. R.↗

NASA NTRS2010

History of Space Shuttle Main Engine Turbopump Bearing Testing at the Marshall Space Flight Center

The Space Shuttle is propelled into orbit by two solid rocket motors and three liquid fed main engines. After the solid motors fall away, the shuttle engines continue to run for a total time of 8 minutes. These engines are fed propellants by low and high pressure turbopumps. A critical part of the turbopump is the main shaft that supports the drive turbine and the pump inducer and impeller. Rolling element bearings hold the shaft in place during rotation. If the bearings were to fail, the shaft would move, allowing components to rub in a liquid oxygen or hydrogen environment, which could have catastrophic results. These bearings are required to spin at very high speeds, support radial and axial loads, and have high wear resistance without the benefit of a conventional means of lubrication. The Rocketdyne built Shuttle turbopumps demonstrated their capability to perform during launches; however, the seven hour life requirement was not being met. One of the limiting factors was the bearings. In the late 1970's, an engineering team was formed at the Marshall Space Flight Center (MSFC), to develop a test rig and plan for testing the Shuttle s main engine high pressure oxygen turbopump (HPOTP) bearings. The goals of the program were to better understand the operation of bearings in a cryogenic environment and to further develop and refine existing computer models used to predict the operational limits of these bearings. In 1982, testing began in a rig named the Bearing and Seal Material Tester or BSMT as it was commonly called. The first testing investigated the thermal margin and thermal runaway limits of the HPOTP bearings. The test rig was later used to explore potential bearing improvements in the area of increased race curvatures, new cage materials for better lubrication, new wear resistant rolling element materials, and other ideas to improve wear life. The most notable improvements during this tester s time was the incorporation of silicon nitride balls and bronze filled polytetrafluoroethylene (PTFE) cage inserts into the bearings and the anchoring of the SHABERTH bearing model and SINDA thermal computer model for cryogenic bearing analysis. In the mid 1990's, Pratt and Whitney (P&W) won the contract to deliver new high pressure turbopumps for the Shuttle s engines. P&W used two new bearing materials for the rings, Cronidur 30 and AISI 9310 steel and testing was needed on these new materials. A test rig had been designed and delivered to MSFC for testing hydrostatic bearings but with the need by Pratt to validate their bearings, the rig was reconfigured for testing of two ball bearings or a ball bearing and a roller bearing. The P&W bearings are larger than the Rocketdyne bearings and could not be installed in the BSMT. This new test rig was called the LH2 test rig and began operation in 1995. The LH2 test rig accumulated 75,000 seconds of run time in hydrogen. This test rig was valuable in two areas: validating the use of silicon nitride balls and rollers in Alternate Turbopump Development (ATD) bearings, which Pratt eventually used, and in proving the robustness of the balls and rollers after river marks appeared on the surface of the rolling elements. Individual test reports have been presented at conferences and symposiums throughout the years. This paper is a comprehensive report of all the bearing testing done at Marshall. It represents thousands of hours of dedication and labor in all engineering and technical fields that made this program a success.

Gibson, Howard↗

NASA NTRS1988

Failure mode and effects analysis (FMEA) for the Space Shuttle solid rocket motor

The recertification of the Space Shuttle Solid Rocket Booster (SRB) and Solid Rocket Motor (SRM) has included an extensive rewriting of the Failure Mode and Effects Analysis (FMEA) and Critical Items List (CIL). The evolution of the groundrules and methodology used in the analysis is discussed and compared to standard FMEA techniques. Especially highlighted are aspects of the FMEA/CIL which are unique to the analysis of an SRM. The criticality category definitions are presented and the rationale for assigning criticality is presented. The various data required by the CIL and contribution of this data to the retention rationale is also presented. As an example, the FMEA and CIL for the SRM nozzle assembly is discussed in detail. This highlights some of the difficulties associated with the analysis of a system with the unique mission requirements of the Space Shuttle.

Russell, D. L.↗

NASA NTRS1972

Use of the space shuttle to avoid spacecraft anomalies

An existing data base covering 304 spacecraft of the U.S. space program was analyzed to determine the effect on individual spacecraft failures and other anomalies that the space shuttle might have had if it had been operational throughout the period covered by the data. By combining the results of this analysis, information on the prelaunch activities of selected spacecraft programs, and shuttle capabilities data, the potential impact of the space shuttle on future space programs was derived. The shuttle was found to be highly effective in the prevention or correction of spacecraft anomalies, with 887 of 1,230 anomalies analyzed being favorably impacted by full utilization of shuttle capabilities. The shuttle was also determined to have a far-reaching and favorable influence on the design, development, and test phases of future space programs. This is documented in 37 individual statements of impact.

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NASA NTRS1997

Methyl Chloroform Elimination from the Production of Space Shuttle Sold Rocket Motors

Thiokol Space Operations manufactures the Reusable Solid Rocket Motors used to launch America's fleet of Space Shuttles. In 1989, Thiokol used more than 1.4 Mlb of methyl chloroform to produce rocket motors. The ban placed by the Environmental Protection Agency on the sale of methyl chloroform had a significant effect on future Reusable Solid Rocket Motor production. As a result, changes in the materials and processes became necessary. A multiphased plan was established by Thiokol in partnership with NASA's Marshall Space Flight Center to eliminate the use of methyl chloroform in the Reusable Solid Rocket Motor production process. Because of the extensive scope of this effort, the plan was phased to target the elimination of the majority of methyl chloroform use (90 percent) by January 1, 1996, the 3 Environmental Protection Agency deadline. Referred to as Phase I, this effort includes the elimination of two large vapor degreasers, grease diluent processes, and propellant tooling handcleaning using methyl chloroform. Meanwhile, a request was made for an essential use exemption to allow the continued use of the remaining 10 percent of methyl chloroform after the 1996 deadline, while total elimination was pursued for this final, critical phase (Phase II). This paper provides an update to three previous presentations prepared for the 1993, 1994, and 1995 CFC/Halon Alternative Conferences, and will outline the overall Ozone Depleting Compounds Elimination Program from the initial phases through the final testing and implementation phases, including facility and equipment development. Processes and materials to be discussed include low-pressure aqueous wash systems, high-pressure water blast systems- environmental shipping containers, aqueous and semi-aqueous cleaning solutions, and bond integrity and inspection criteria. Progress toward completion of facility implementation and lessons learned during the scope of the program, as well as the current development efforts and basic requirements of future methyl chloroform handcleaning elimination, will also be outlined.

Golde, Rick P.↗

NASA NTRS1977

Proceedings of the Space Shuttle Environmental Assessment Workshop on Stratospheric Effects

Various aspects of the potential environmental impact of space shuttle exhaust are explored. Topics include: (1) increased ultraviolet radiation levels in the biosphere due to destruction of atmospheric ozone; (2) climatic changes due to aerosol particles affecting the planetary albedo; (3) space shuttle propellants (including alternate formulations); and (4) measurement of space shuttle exhaust products.

Potter, A. E.↗

NASA NTRS1973

The space shuttle payload planning working groups. Volume 2: Atmospheric and space physics

The findings of the Atmospheric and Space Physics working group of the space shuttle mission planning activity are presented. The principal objectives defined by the group are: (1) to investigate the detailed mechanisms which control the near-space environment of the earth, (2) to perform plasma physics investigations not feasible in ground-based laboratories, and (3) to conduct investigations which are important in understanding planetary and cometary phenomena. The core instrumentation and laboratory configurations for conducting the investigations are defined.

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NASA NTRS1981

System analysis approach to deriving design criteria (loads) for Space Shuttle and its payloads. Volume 1: General statement of approach

Space shuttle, the most complex transportation system designed to date, illustrates the requirement for an analysis approach that considers all major disciplines simultaneously. Its unique cross coupling and high sensitivity to aerodynamic uncertainties and high performance requirements dictated a less conservative approach than those taken in programs. Analyses performed for the space shuttle and certain payloads, Space Telescope and Spacelab, are used a examples. These illustrate the requirements for system analysis approaches and criteria, including dynamic modeling requirements, test requirements control requirements and the resulting design verification approaches. A survey of the problem, potential approaches available as solutions, implications for future systems, and projected technology development areas are addressed.

Ryan, R. S.↗

NASA NTRS1970