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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 NTRS2011

Seal Joint Analysis and Design for the Ares-I Upper Stage LOX Tank

The sealing capability of the Ares-I Upper Stage liquid oxygen tank-to-sump joint is assessed by analyzing the deflections of the joint components. Analyses are performed using three-dimensional symmetric wedge finite element models and the ABAQUS commercial finite element software. For the pressure loads and feedline interface loads, the analyses employ a mixed factor of safety approach to comply with the Constellation Program factor of safety requirements. Naflex pressure-assisted seals are considered first because they have been used successfully in similar seal joints in the Space Shuttle External Tank. For the baseline sump seal joint configuration with a Naflex seal, the predicted joint opening greatly exceeds the seal design specification. Three redesign options of the joint that maintain the use of a Naflex seal are studied. The joint openings for the redesigned seal joints show improvement over the baseline configuration; however, these joint openings still exceed the seal design specification. RACO pressure-assisted seals are considered next because they are known to also be used on the Space Shuttle External Tank, and the joint opening allowable is much larger than the specification for the Naflex seals. The finite element models for the RACO seal analyses are created by modifying the models that were used for the Naflex seal analyses. The analyses show that the RACO seal may provide sufficient sealing capability for the sump seal joint. The results provide reasonable data to recommend the design change and plan a testing program to determine the capability of RACO seals in the Ares-I Upper Stage liquid oxygen tank sump seal joint.

Phillips, Dawn R.↗
NASA NTRS2011

Launch Control Systems: Moving Towards a Scalable, Universal Platform for Future Space Endeavors

The redirection of NASA away from the Constellation program calls for heavy reliance on commercial launch vehicles for the near future in order to reduce costs and shift focus to research and long term space exploration. To support them, NASA will renovate Kennedy Space Center's launch facilities and make them available for commercial use. However, NASA's current launch software is deeply connected with the now-retired Space Shuttle and is otherwise not massively compatible. Therefore, a new Launch Control System must be designed that is adaptable to a variety of different launch protocols and vehicles. This paper exposits some of the features and advantages of the new system both from the perspective of the software developers and the launch engineers.

Sun, Jonathan↗
NASA NTRS2010

Evolution of Regolith Feed Systems for Lunar ISRU 02 Production Plants

The In-Situ Resource Utilization (ISRU) project of the NASA Constellation Program, Exploration Technology Development Program (ETDP) has been engaged in the design and testing of various Lunar ISRU O2 production plant prototypes that can extract chemically bound oxygen from the minerals in the lunar regolith. This work demands that lunar regolith (or simulants) shall be introduced into the O2 production plant from a holding bin or hopper and subsequently expelled from the ISRU O2 production plant for disposal. This sub-system is called the Regolith Feed System (RFS) which exists in a variety of configurations depending on the O2 production plant oxygen being used (e.g. Hydrogen Reduction, Carbothermal, Molten Oxide Electrolysis). Each configuration may use a different technology and in addition it is desirable to have heat recuperation from the spent hot regolith as an integral part of the RFS. This paper addresses the various RFS and heat recuperation technologies and system configurations that have been developed under the NASA ISRU project since 2007. In addition current design solutions and lessons learned from reduced gravity flight testing will be discussed.

Mueller, Robert P.↗
NASA NTRS2011

Optimal Terminal Descent Guidance Logic to Achieve a Soft Lunar Touchdown

Altair Lunar Lander is the linchpin in the Constellation Program for human return to the Moon. In the 2010design reference mission, Altair is to be delivered to low Earth orbit by the Ares V heavy lift launch vehicle, and after subsequent docking with Orion in LEO, the Altair/Orion stack is delivered through trans-lunar injection (TLI). The Altair/Orion stack separates from the Ares V Earth departure stage shortly after TLI and continues the flight to the Moon as a single stack. Fig. 1 depicts one version of the Altair lunar lander.

Landing↗
NASA NTRS2011

Composite Crew Module: Primary Structure

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center to design, build, and test a full-scale crew module primary structure, using carbon fiber reinforced epoxy based composite materials. The overall goal of the Composite Crew Module project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project's baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. This report discusses the project management aspects of the project including team organization, decision making, independent technical reviews, and cost and schedule management approach.

Kirsch, Michael T.↗
NASA NTRS2011

Crew Survivability After a Rapid Cabin Depressurization Event

Anecdotal evidence acquired through historic failure investigations involving rapid cabin decompression (e.g. Challenger, Columbia and Soyuz 11) show that full evacuation of the cabin atmosphere may occur within seconds. During such an event, the delta-pressure between the sealed suit ventilation system and the cabin will rise at the rate of the cabin depressurization; potentially at a rate exceeding the capability of the suit relief valve. It is possible that permanent damage to the suit pressure enclosure and ventilation loop components may occur as the integrated system may be subjected to delta pressures in excess of the design to pressures. Additionally, as the total pressure of the suit ventilation system decreases, so does the oxygen available to the crew. The crew may be subjected to a temporary incapacitating, but non-lethal, hypoxic environment. It is expected that the suit will maintain a survivable atmosphere on the crew until the vehicle pressure control system recovers or the cabin has otherwise attained a habitable environment. A common finding from the aforementioned reports indicates that the crew would have had a better chance at surviving the event had they been in a protective configuration, that is, in a survival suit. Making use of these lessons learned, the Constellation Program implemented a suit loop in the spacecraft design and required that the crew be in a protective configuration, that is suited with gloves on and visors down, during dynamic phases of flight that pose the greatest risk for a rapid and uncontrolled cabin depressurization event: ascent, entry, and docking. This paper details the evaluation performed to derive suit pressure garment and ventilation system performance parameters that would lead to the highest probability of crew survivability after an uncontrolled crew cabin depressurization event while remaining in the realm of practicality for suit design. This evaluation involved: (1) assessment of stakeholder expectations to validate the functionality being imposed; (2) review/refinement of concept of operations to establish the potential triggers for such an event and define the response of the spacecraft and suit ventilation loop pressure control systems; and (3) assessment of system capabilities with respect to structural capability and pressure control. 1 Crew and Thermal Systems Division, NASA Johnson Space Center, Mail Code: AES29, 2101 NASA Parkway, Houston,

Sargusingh, Miriam J.↗
NASA NTRS2011

NASA Planning for Orion Multi-Purpose Crew Vehicle Ground Operations

The NASA Orion Ground Processing Team was originally formed by the Kennedy Space Center (KSC) Constellation (Cx) Project Office's Orion Division to define, refine and mature pre-launch and post-landing ground operations for the Orion human spacecraft. The multidisciplined KSC Orion team consisted of KSC civil servant, SAIC, Productivity Apex, Inc. and Boeing-CAPPS engineers, project managers and safety engineers, as well as engineers from Constellation's Orion Project and Lockheed Martin Orion Prime contractor. The team evaluated the Orion design configurations as the spacecraft concept matured between Systems Design Review (SDR), Systems Requirement Review (SRR) and Preliminary Design Review (PDR). The team functionally decomposed prelaunch and post-landing steps at three levels' of detail, or tiers, beginning with functional flow block diagrams (FFBDs). The third tier FFBDs were used to build logic networks and nominal timelines. Orion ground support equipment (GSE) was identified and mapped to each step. This information was subsequently used in developing lower level operations steps in a Ground Operations Planning Document PDR product. Subject matter experts for each spacecraft and GSE subsystem were used to define 5th - 95th percentile processing times for each FFBD step, using the Delphi Method. Discrete event simulations used this information and the logic network to provide processing timeline confidence intervals for launch rate assessments. The team also used the capabilities of the KSC Visualization Lab, the FFBDs and knowledge of the spacecraft, GSE and facilities to build visualizations of Orion pre-launch and postlanding processing at KSC. Visualizations were a powerful tool for communicating planned operations within the KSC community (i.e., Ground Systems design team), and externally to the Orion Project, Lockheed Martin spacecraft designers and other Constellation Program stakeholders during the SRR to PDR timeframe. Other operations planning tools included Kaizen/Lean events, mockups and human factors analysis. The majority of products developed by this team are applicable as KSC prepares 21st Century Ground Systems for the Orion Multi-Purpose Crew Vehicle and Space Launch System.

Letchworth, Gary↗
NASA NTRS2008

Apollo Video Photogrammetry Estimation of Plume Impingement Effects

Each of the six Apollo mission landers touched down at unique sites on the lunar surface. Aside from the Apollo 12 landing site located 180 meters from the Surveyor III lander, plume impingement effects on ground hardware during the landings were largely not an issue. The Constellation Project's planned return to the moon requires numerous landings at the same site. Since the top few centimeters are loosely packed regolith, plume impingement from the lander ejects the granular material at high velocities. With high vacuum conditions on the moon (10 (exp -14) to 10 (epx -12) torr), motion of all particles is completely ballistic. Estimates from damage to the Surveyor III show that the ejected regolith particles to be anywhere 400 m/s to 2500 m/s. It is imperative to understand the physics of plume impingement to safely design landing sites for the Constellation Program.

Immer, Christopher↗
NASA NTRS2011

Solid Propulsion Systems, Subsystems, and Components Service Life Extension

The service life extension of solid propulsion systems, subsystems, and components will be discussed based on the service life extension of the Space Transportation System Reusable Solid Rocket Motor (RSRM) and Booster Separation Motors (BSM). The RSRM is certified for an age life of five years. In the aftermath of the Columbia accident there were a number of motors that were approaching the end of their five year service life certification. The RSRM Project initiated an assessment to determine if the service life of these motors could be extended. With the advent of the Constellation Program, a flight test was proposed that would utilize one of the RSRMs which had been returned from the launch site due to the expiration of its five year service life certification and twelve surplus Chemical Systems Division BSMs which had exceeded their eight year service life. The RSRM age life tracking philosophy which establishes when the clock starts for age life tracking will be described. The role of the following activities in service life extension will be discussed: subscale testing, accelerated aging, dissecting full scale aged hardware, static testing full scale aged motors, data mining industry data, and using the fleet leader approach. The service life certification and extension of the BSMs will also be presented.

Hundley, Nedra H.↗
NASA NTRS2012

Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement. Variables Acceptance Sampling Calculators: Derivations and Verification of Plans

The NASA Engineering and Safety Center was requested to improve on the Best Practices document produced for the NESC assessment, Verification of Probabilistic Requirements for the Constellation Program, by giving a recommended procedure for using acceptance sampling by variables techniques. This recommended procedure would be used as an alternative to the potentially resource-intensive acceptance sampling by attributes method given in the document. This document contains the outcome of the assessment.

Johnson, Kenneth L.↗
NASA NTRS2012

Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement. Variables Acceptance Sampling Calculators: Empirical Testing

The NASA Engineering and Safety Center was requested to improve on the Best Practices document produced for the NESC assessment, Verification of Probabilistic Requirements for the Constellation Program, by giving a recommended procedure for using acceptance sampling by variables techniques as an alternative to the potentially resource-intensive acceptance sampling by attributes method given in the document. In this paper, the results of empirical tests intended to assess the accuracy of acceptance sampling plan calculators implemented for six variable distributions are presented.

Johnson, Kenneth L.↗
NASA NTRS2011

Vehicle System Management Modeling in UML for Ares I

The Spacecraft & Vehicle Systems Department of Marshall Space Flight Center is responsible for modeling the Vehicle System Management for the Ares I vehicle which was a part of the now canceled Constellation Program. An approach to generating the requirements for the Vehicle System Management was to use the Unified Modeling Language technique to build and test a model that would fulfill the Vehicle System Management requirements. UML has been used on past projects (flight software) in the design phase of the effort but this was the first attempt to use the UML technique from a top down requirements perspective.

Pearson, Newton W.↗
NASA NTRS2011

Ground Vibration Testing Options for Space Launch Vehicles

New NASA launch vehicles will require development of robust systems in a fiscally-constrained environment. NASA, Department of Defense (DoD), and commercial space companies routinely conduct ground vibration tests as an essential part of math model validation and launch vehicle certification. Although ground vibration testing must be a part of the integrated test planning process, more affordable approaches must also be considered. A study evaluated several ground vibration test options for the NASA Constellation Program flight test vehicles, Orion-1 and Orion-2, which concluded that more affordable ground vibration test options are available. The motivation for ground vibration testing is supported by historical examples from NASA and DoD. The approach used in the present study employed surveys of ground vibration test subject-matter experts that provided data to qualitatively rank six test options. Twenty-five experts from NASA, DoD, and industry provided scoring and comments for this study. The current study determined that both element-level modal tests and integrated vehicle modal tests have technical merits. Both have been successful in validating structural dynamic math models of launch vehicles. However, element-level testing has less overall cost and schedule risk as compared to integrated vehicle testing. Future NASA launch vehicle development programs should anticipate that some structural dynamics testing will be necessary. Analysis alone will be inadequate to certify a crew-capable launch vehicle. At a minimum, component and element structural dynamic tests are recommended for new vehicle elements. Three viable structural dynamic test options were identified. Modal testing of the new vehicle elements and an integrated vehicle test on the mobile launcher provided the optimal trade between technical, cost, and schedule.

Patterson, Alan↗
NASA NTRS2011

The J-2X Fuel Turbopump - Design, Development, and Test

Pratt and Whitney Rocketdyne (PWR), a NASA subcontractor, is executing the design, development, test, and evaluation (DDT&E) of a liquid oxygen, liquid hydrogen two hundred ninety four thousand pound thrust rocket engine initially intended for the Upper Stage (US) and Earth Departure Stage (EDS) of the Constellation Program Ares-I Crew Launch Vehicle (CLV). A key element of the design approach was to base the new J-2X engine on the heritage J-2S engine with the intent of uprating the engine and incorporating SSME and RS-68 lessons learned. The J-2S engine was a design upgrade of the flight proven J-2 configuration used to put American astronauts on the moon. The J-2S Fuel Turbopump (FTP) was the first Rocketdyne-designed liquid hydrogen centrifugal pump and provided many of the early lessons learned for the Space Shuttle Main Engine High Pressure Fuel Turbopumps. This paper will discuss the design trades and analyses performed for the current J-2X FTP to increase turbine life; increase structural margins, facilitate component fabrication; expedite turbopump assembly; and increase rotordynamic stability margins. Risk mitigation tests including inducer water tests, whirligig turbine blade tests, turbine air rig tests, and workhorse gas generator tests characterized operating environments, drove design modifications, or identified performance impact. Engineering design, fabrication, analysis, and assembly activities support FTP readiness for the first J-2X engine test scheduled for July 2011.

Tellier, James G.↗
NASA NTRS2011

The J-2X Oxidizer Turbopump - Design, Development, and Test

Pratt and Whitney Rocketdyne (PWR), a NASA subcontractor, is executing the Design, Development, Test, and Evaluation (DDT&E) of a liquid oxygen, liquid hydrogen two hundred ninety-four thousand pound thrust rocket engine initially intended for the Upper Stage (US) and Earth Departure Stage (EDS) of the Constellation Program Ares-I Crew Launch Vehicle (CLV). A key element of the design approach was to base the new J-2X engine on the heritage J-2S engine which was a design upgrade of the flight proven J-2 engine used to put American astronauts on the moon. This paper will discuss the design trades and analyses performed to achieve the required uprated Oxidizer Turbopump performance; structural margins and rotordynamic margins; incorporate updated materials and fabrication capability; and reflect lessons learned from legacy and existing Liquid Rocket Propulsion Engine turbomachinery. These engineering design, analysis, fabrication and assembly activities support the Oxidizer Turbopump readiness for J-2X engine test in 2011.

Brozowski, Laura A.↗
NASA NTRS2011

Application of the Life Safety Code to a Historic Test Stand

NASA has conducted a study to assess alternatives to refurbishing existing launch vehicle modal test facilities as opposed to developing new test facilities to meet the demands of a very fiscally constrained test and evaluation environment. The results of this study showed that Marshall Space Flight Center (MSFC) Test Stand (TS) 4550 could be made compliant, within reasonable cost and schedule impacts, if safety processes and operational limitations were put in place to meet the safety codes and concerns of the Fire Marshall. Trades were performed with key selection criteria to ensure that appropriate levels of occupant safety are incorporated into test facility design modifications. In preparation for the ground vibration tests that were to be performed on the Ares I launch vehicle, the Ares Flight and Integrated Test Office (FITO) organization evaluated the available test facility options, which included the existing mothballed structural dynamic TS4550 used by Apollo and Shuttle, alternative ground vibration test facilities at other locations, and construction of a new dynamic test stand. After an exhaustive assessment of the alternatives, the results favored modifying the TS4550 because it was the lowest cost option and presented the least schedule risk to the NASA Constellation Program for Ares Integrated Vehicle Ground Vibration Test (IVGVT). As the renovation design plans and drawings were being developed for TS4550, a safety concern was discovered the original design for the construction of the test stand, originally built for the Apollo Program and renovated for the Shuttle Program, was completed before NASA s adoption of the currently imposed safety and building codes per National Fire Protection Association Life Safety Code [NFPA 101] and International Building Codes. The initial FITO assessment of the design changes, required to make TS4550 compliant with current safety and building standards, identified a significant cost increase and schedule impact. An effort was launched to thoroughly evaluate the applicable life safety requirements, examine the context in which they were derived, and determine a means by which the TS4550 modifications could be made within budget and on schedule, while still providing the occupants with appropriate levels of safety.

Askins, Bruce↗
NASA NTRS2011

NASA Ares I Launch Vehicle Roll and Reaction Control Systems Lessons Learned

On April 15, 2010 President Barak Obama made the official announcement that the Constellation Program, which included the Ares I launch vehicle, would be canceled. NASA s Ares I launch vehicle was being designed to launch the Orion Crew Exploration Vehicle, returning humans to the moon, Mars, and beyond. It consisted of a First Stage (FS) five segment solid rocket booster and a liquid J-2X Upper Stage (US) engine. Roll control for the FS was planned to be handled by a dedicated Roll Control System (RoCS), located on the connecting interstage. Induced yaw or pitch moments experienced during FS ascent would have been handled by vectoring of the booster nozzle. After FS booster separation, the US Reaction Control System (ReCS) would have provided the US Element with three degrees of freedom control as needed. The lessons learned documented in this paper will be focused on the technical designs and producibility of both systems along with the partnership between NASA and Boeing, who was on contract to build the Ares I US Element, which included the FS RoCS and US ReCS. In regards to partnership, focus will be placed on integration along with technical work accomplished by Boeing with special emphasis on each task order. In summary, this paper attempts to capture key lessons learned that should be helpful in the development of future launch vehicle RCS designs.

Butt, Adam↗
NASA NTRS2007

A Basic Comparison of the Space Shuttle Main Engine and the J-2X Engine

With the introduction of the new manned space effort through the Constellation Program, there is an interest to have a basic comparison of the current Space Shuttle Main Engine (SSME) to the J-2X engine used for the second stage of both the Ares I and Ares V rockets. This paper seeks to compare size, weight and thrust capabilities while drawing simple conclusions on differences between the two engines.

Ayer, Adam↗