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NASA NTRS2011

Optical Property Requirements for Glasses, Ceramics and Plastics in Spacecraft Window Systems

This is a preliminary draft of a standard published by the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) that is intended to provide uniform window optical design requirements in support of the development of human-rated spaceflight hardware. The material covered in this standard is based on data from extensive testing by the Advanced Sensing and Optical Measurement Branch at NASA Langley Research Center, and compiled into requirements format by the NASA JSC Structural Engineering Division. At the time of this initial document release, a broader technical community has not reviewed this standard. The technical content of this standard is primarily based on the Constellation Program Orion Crew Exploration Vehicle Window Optical Properties Requirements, CxP 72407, Baseline. Unlike other optical requirements documents available for human rated spacecraft, this document includes requirements that ensure functionality for windows that contain glass/ceramic and/or plastic window substrate materials. These requirements were derived by measuring the optical properties of fused silica and aluminosilicate glass window assemblies and ensuring that the performance of any window assembly that includes a plastic pane or panes will meet the performance level of the all-glass assemblies. The resulting requirements are based upon the performance and parameter metrology testing of a variety of materials, including glass, transparent ceramics, acrylics, and polycarbonates. In general, these requirements are minimum specifications for each optical parameter in order to achieve the function specified for each functional category, A through D. Because acrylic materials perform at a higher level than polycarbonates in the optics regime, and CxP/Orion is planning to use acrylic in the Orion spacecraft, these requirements are based heavily on metrology from that material. As a result, two of the current Category D requirements for plastics are cited in such a way that will result in the screening out of polycarbonates. It is acknowledged that many polycarbonates can perform the functions of Category D, such as piloting and imagery with lens with apertures up to 25mm, without performance issues. Therefore, this forward warns users that certain requirements, such as birefringence and wavefront, for Category D plastics need to be revised to allow those polycarbonates that perform adequately in Category D to be accepted, while at the same time, screen out those materials that do not perform up to par. At the time of document release, the requirements in question have been identified by a TBD beside the proposed requirement criteria (which is based upon acrylic performance). Vehicles that are designed with acrylic materials for windowpanes are encouraged to use the values presented in this document for all requirements, in order to ensure adequate optical performance.

Lynda R Estes↗

NASA NTRS2012

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 temporarily 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.

Sargusingh, Miriam J.↗

NASA NTRS2012

Assessment of Microphone Phased Array for Measuring Launch Vehicle Lift-off Acoustics

The specific purpose of the present work was to demonstrate the suitability of a microphone phased array for launch acoustics applications via participation in selected firings of the Ares I Scale Model Acoustics Test. The Ares I Scale Model Acoustics Test is a part of the discontinued Constellation Program Ares I Project, but the basic understanding gained from this test is expected to help development of the Space Launch System vehicles. Correct identification of sources not only improves the predictive ability, but provides guidance for a quieter design of the launch pad and optimization of the water suppression system. This document contains the results of the NASA Engineering and Safety Center assessment.

Garcia, Roberto↗

NASA NTRS2012

Developing the Next Generation Shell Buckling Design Factors and Technologies

NASA s Shell Buckling Knockdown Factor (SBKF) Project was established in the spring of 2007 by the NASA Engineering and Safety Center (NESC) in collaboration with the Constellation Program and Exploration Systems Mission Directorate. The SBKF project has the current goal of developing less-conservative, robust shell buckling design factors (a.k.a. knockdown factors) and design and analysis technologies for light-weight stiffened metallic launch vehicle (LV) structures. Preliminary design studies indicate that implementation of these new knockdown factors can enable significant reductions in mass and mass-growth in these vehicles and can help mitigate some of NASA s LV development and performance risks. In particular, it is expected that the results from this project will help reduce the reliance on testing, provide high-fidelity estimates of structural performance, reliability, robustness, and enable increased payload capability. The SBKF project objectives and approach used to develop and validate new design technologies are presented, and provide a glimpse into the future of design of the next generation of buckling-critical launch vehicle structures.

Hilburger, Mark W.↗

NASA NTRS2012

Tensile Properties of GRCop-84

This is a chapter in the final report on GRCop-84 for the Reusable Launch Vehicle (RLV) Second Generation/Project Constellation Program. It contains information on the tensile properties of GRCop-84. GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) was produced by extrusion and Hot Isostatic Pressing (HIPing). Some of the extrusions were rolled to plate and sheet while other extrusions were drawn into tubing. The material was further subjected to various heat treatments corresponding to annealing, anticipated typical brazing conditions, an end-of-life condition and various elevated temperature exposures to attempt to improve creep resistance. As anticipated, cold work increased strength while decreasing ductility. Annealing at 600 C (1112 F) and higher temperatures was effective. An exposure for 100 h at 500 C (932 F) resulted in an increase in strength rather than the anticipated decrease. High temperature simulated-braze cycles and thermal exposures lowered the strength of GRCop-84, but the deceases were small compared to precipitation strengthened copper alloys. It was observed that the excess Cr could form large precipitates that lower the reduction in area though it appears a minimum amount is required. Overall, GRCop-84 exhibits good stability of its tensile properties, which makes it an excellent candidate for rocket engine liners and many other high temperature applications.

Ellis, David L.↗

NASA NTRS2012

Passive Thrust Oscillation Mitigation for the CEV Crew Pallet System

The Crew Exploration Vehicle (CEV) was intended to be the next-generation human spacecraft for the Constellation Program. The CEV Isolator Strut mechanism was designed to mitigate loads imparted to the CEV crew caused by the Thrust Oscillation (TO) phenomenon of the proposed Ares I Launch Vehicle (LV). The Isolator Strut was also designed to be compatible with Launch Abort (LA) contingencies and landing scenarios. Prototype struts were designed, built, and tested in component, sub-system, and system-level testing. The design of the strut, the results of the tests, and the conclusions and lessons learned from the program will be explored in this paper.

Sammons, Matthew↗

NASA NTRS2012

Materials and Process Activities for NASA's Composite Crew Module

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center (NESC) to design, build, and test a full-scale Composite Crew Module (CCM). The overall goal of the CCM 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. The materials and process activities were prioritized based on a rapid prototype approach. This approach focused developmental activities on design details with greater risk and uncertainty, such as out-of-autoclave joining, over some of the more traditional lamina and laminate building block levels. While process development and associated building block testing were performed, several anomalies were still observed at the full-scale level due to interactions between process robustness and manufacturing scale-up. This paper describes the process anomalies that were encountered during the CCM development and the subsequent root cause investigations that led to the final design solutions. These investigations highlight the importance of full-scale developmental work early in the schedule of a complex composite design/build project.

Polis, Daniel L.↗

NASA NTRS2012

Composite Interstage Structural Concept Down Select Process and Results

NASA's Advanced Composites Technologies (ACT) project evaluated several composite construction options for the Ares V Interstage to support the Constellation Program's goal of reducing the mass of vehicle dry structures. In Phase 1 of the project, eight candidate construction concepts were evaluated for the Ares V Interstage design. Trade studies were performed using finite element analyses to determine weight estimates for the construction concepts. An evaluation process was then used to down select the construction concepts down to two concepts for further consideration in Phase 2 of the project. In Phase 2 of the project, additional trade studies were performed using detailed finite element analyses of the Interstage and a final down select process was used to choose the recommended Interstage construction concept. The results of the study showed that a honeycomb sandwich design was the most favorable Interstage construction concept based on advantages in manufacturing cost. Details of the Phase 1 and Phase 2 trade studies and down select process with final results are presented in the paper.

Sleight, David W.↗

NASA NTRS2008

Orion -- Crew Exploration Vehicle (CEV) Project Overview

NASA explores for answers that power our future by building a new space exploration vehicle that will become America s human spacecraft workhorse after the shuttle is retired in 2010. The new spacecraft is called Orion. Orion is part of the Constellation Program to send human explorers back to the Moon and beyond

Naffah, Eli↗

NASA NTRS2012

Friction Pull Plug Welding in Aluminum Alloys

NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗

NASA NTRS2012

Robotic Manufacturing of 18-ft (5.5m) Diameter Cryogenic Fuel Tank Dome Assemblies for the NASA Ares I Rocket

The Ares I rocket was the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration's Constellation program. A series of full-scale Ares I development articles were constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7- axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This paper will focus on the friction stir welding of 18-ft (5.5m) diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome and two common bulkhead manufacturing development articles.

Jones, Ronald E.↗

NASA NTRS2012

An Altair Overview: Designing a Lunar Lander for 21st Century Human Space Exploration

Altair, the lunar lander element of NASA's Constellation program, was conducted in a different design environment than many other NASA projects of similar scope. Because of this relatively unique approach, there are a number of significant success stories that should be considered during the development of any future lunar landers or human spacecraft. This paper is divided into two separate themes; the first is the approach used during the conceptual design studies, including the systematic analysis cycles and the decision making process associated with each: and the second is a summary of the resulting lessons learned that were compiled after looking back at the lifetime of the Project. Altair was terminated before entering Phase B of its design, and was often criticized for being a very heavy and very large vehicle. While there was specific rationale for all of the decisions that led up to that configuration, future design cycles were specifically planned to re-address the mass challenge. Had the project continued, the deliberate, stepwise design process would have converged on an optimized lander design that balanced mass, risk, cost and capabilities. Some of the specific items that will be addressed in this paper include project development strategy, organizational approach and team dynamics, risk-informed design process, mission architecture constraints, mission key driving requirements, model-based systems engineering process, configuration studies, contingency considerations, subsystem overviews and key trade studies. The paper will conclude with a summary of the lessons identified during the Altair project and make suggestions for application to future studies.

Brown, Kendall K.↗

NASA NTRS2012

Best Practices from the Design and Development of the Ares I Launch Vehicle Roll and Reaction Control Systems

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 best practices 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. This will include detailed emphasis on task orders developed between NASA and Boeing that were used to direct specific work that needed to be accomplished. In summary, this paper attempts to capture key best practices that should be helpful in the development of future launch vehicle and spacecraft RCS designs.

Butt, Adam↗

NASA NTRS2012

Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

The NASA Orion Flight Test Office was tasked with conducting a series of flight tests in several launch abort scenarios to certify that the Orion Launch Abort System is capable of delivering astronauts aboard the Orion Crew Module to a safe environment, away from a failed booster. The first of this series was the Orion Pad Abort 1 Flight-Test Vehicle, which was successfully flown on May 6, 2010 at the White Sands Missile Range in New Mexico. This paper provides a brief overview of the three propulsive subsystems used on the Pad Abort 1 Flight-Test Vehicle. An overview of the propulsive systems originally planned for future flight-test vehicles is also provided, which also includes the cold gas Reaction Control System within the Crew Module, and the Peacekeeper first stage rocket motor encased within the Abort Test Booster aeroshell. Although the Constellation program has been cancelled and the operational role of the Orion spacecraft has significantly evolved, lessons learned from Pad Abort 1 and the other flight-test vehicles could certainly contribute to the vehicle architecture of many future human-rated space launch vehicles.

Jones, Daniel S.↗

NASA NTRS2011

Friction Pull Plug Welding in Aluminum Alloys

NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗

NASA NTRS2012

System Engineering and Technical Challenges Overcome in the J-2X Rocket Engine Development Project

Beginning in 2006, NASA initiated the J-2X engine development effort to develop an upper stage propulsion system to enable the achievement of the primary objectives of the Constellation program (CxP): provide continued access to the International Space Station following the retirement of the Space Station and return humans to the moon. The J-2X system requirements identified to accomplish this were very challenging and the time expended over the five years following the beginning of the J- 2X effort have been noteworthy in the development of innovations in both the fields for liquid rocket propulsion and system engineering.

Ballard, Richard O.↗

NASA NTRS2012

Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

Jones, Daniel S.↗

NASA NTRS2012

Exploration Space Suit Architecture and Destination Environmental-Based Technology Development

This paper continues forward where EVA Space Suit Architecture: Low Earth Orbit Vs. Moon Vs. Mars [1] left off in the development of a space suit architecture that is modular in design and could be reconfigured prior to launch or during any given mission depending on the tasks or destination. This paper will address the space suit system architecture and technologies required based upon human exploration extravehicular activity (EVA) destinations, and describe how they should evolve to meet the future exploration EVA needs of the US human space flight program.1, 2, 3 In looking forward to future US space exploration to a space suit architecture with maximum reuse of technology and functionality across a range of mission profiles and destinations, a series of exercises and analyses have provided a strong indication that the Constellation Program (CxP) space suit architecture is postured to provide a viable solution for future exploration missions4. The destination environmental analysis presented in this paper demonstrates that the modular architecture approach could provide the lowest mass and mission cost for the protection of the crew given any human mission outside of low-Earth orbit (LEO). Additionally, some of the high-level trades presented here provide a review of the environmental and non-environmental design drivers that will become increasingly important the farther away from Earth humans venture. This paper demonstrates a logical clustering of destination design environments that allows a focused approach to technology prioritization, development, and design that will maximize the return on investment, independent of any particular program, and provide architecture and design solutions for space suit systems in time or ahead of need dates for any particular crewed flight program in the future. The approach to space suit design and interface definition discussion will show how the architecture is very adaptable to programmatic and funding changes with minimal redesign effort such that the modular architecture can be quickly and efficiently honed into a specific mission point solution if required. Additionally, the modular system will allow for specific technology incorporation and upgrade as required with minimal redesign of the system.

Hill, Terry R.↗