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NASA NTRS2001

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2002

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB (Solid Rocket Booster). TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly. to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2002

Land-Breeze Forecasting

The nocturnal land breeze at the Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS) is both operationally significant and challenging to forecast. The occurrence and timing of land breezes impact low-level winds, atmospheric stability, low temperatures, and fog development. Accurate predictions of the land breeze are critical for toxic material dispersion forecasts associated with space launch missions, since wind direction and low-level stability can change noticeably with the onset of a land breeze. This report presents a seven-year observational study of land breezes over east-central Florida from 1995 to 2001. This comprehensive analysis was enabled by the high-resolution tower observations over KSC/CCAFS. Five-minute observations of winds, temperature, and moisture along with 9 15-MHz Doppler Radar Wind Profiler data were used to analyze specific land-breeze cases, while the tower data were used to construct a composite climatology. Utilities derived from this climatology were developed to assist forecasters in determining the land-breeze occurrence, timing, and movement based on predicted meteorological conditions.

Case, Jonathan L.↗

NASA NTRS2002

The Use af Ion Vapor Deposited Aluminum (IVD) for the Space Shuttle Solid Rocket Booster (SRB)

The USA LLC Materials & Processes (M&P) Engineering Department had recommended the application and evaluation of Ion Vapor Deposition (IVD) aluminum to SRB Hardware for corrosion protection and elimination of hazardous materials and processes such as cadmium plating. IVD is an environmentally friendly process that has no volatile organic compounds (VOCs), or hazardous waste residues. It lends itself to use with hardware exposed to corrosive seacoast environments as found at Kennedy Space Center (KSC), and Cape Canaveral Air Force Station (CCAFS), Florida. Lifting apparatus initially coated with cadmium plating for corrosion protection; was stripped and successfully re-coated with IVD aluminum after the cadmium plating no longer protected the GSE from corrosion, Since then, and after completion of a significant test program, the first flight application of the IVD Aluminum process on the Drogue Parachute Ratchet Assembly is scheduled for 2002.

Novak, Howard L.↗

NASA NTRS2003

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC / solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2004

A Climatological Study of Cloud to Ground Lightning Strikes in the Vicinity of the Kennedy Space Center

Lightning strike location and peak current are monitored operationally in the Kennedy Space Center (KSC)/Cape Canaveral Air Force Station (CCAFS) area by the Cloud to Ground Lightning Surveillance System (CGLSS). The present study compiles ten years of CGLSS data into a climatological database of all strikes recorded within a 20-mile radius of space shuttle launch platform LP39A, which serves as a convenient central point. The period of record (POR) for the database runs from January 1, 1993 to December 31, 2002. Histograms and cumulative probability curves are produced to determine the distribution of occurrence rates for the spectrum of strike intensities (given in kA). Further analysis of the database provides a description of both seasonal and interannual variations in the lightning distribution.

Burns, Lee↗

NASA NTRS2005

The Distribution of Cloud to Ground Lightning Strike Intensities and Associated Magnetic Inductance Fields Near the Kennedy Space Center

Lightning strike location and peak current are monitored operationally in the Kennedy Space Center (KSC) Cape Canaveral Air Force Station (CCAFS) area by the Cloud to Ground Lightning Surveillance System (CGLSS). The present study compiles ten years worth of CGLSS data into a database of near strikes. Using shuffle launch platform LP39A as a convenient central point, all strikes recorded within a 20-mile radius for the period of record O R ) from January 1, 1993 to December 31,2002 were included in the subset database. Histograms and cumulative probability curves are produced for both strike intensity (peak current, in kA) and the corresponding magnetic inductance fields (in A/m). Results for the full POR have application to launch operations lightning monitoring and post-strike test procedures.

Burns, Lee↗

NASA NTRS2007

Objective Lightning Probability Forecasting for Kennedy Space Center and Cape Canaveral Air Force Station, Phase II

This report describes the work done by the Applied Meteorology Unit (AMU) to update the lightning probability forecast equations developed in Phase I. In the time since the Phase I equations were developed, new ideas regarding certain predictors were formulated and a desire to make the tool more automated was expressed by 45 WS forecasters. Five modifications were made to the data: 1) increased the period of record from 15 to 17 years, 2) modified the valid area to match the lighting warning areas, 3) added the 1000 UTC CCAFS sounding to the other soundings in determining the flow regime, 4) used a different smoothing function for the daily climatology, and 5) determined the optimal relative humidity (RH) layer to use as a predictor. The new equations outperformed the Phase I equations in several tests, and improved the skill of the forecast over the Phase I equations by 8%. A graphical user interface (GUI) was created in the Meteorological Interactive Data Display System (MIDDS) that gathers the predictor values for the equations automatically. The GUI was transitioned to operations in May 2007 for the 2007 warm season.

Lambert, Winifred↗

NASA NTRS2008

The 2006 Cape Canaveral Air Force Station Range Reference Atmosphere Model Validation Study and Sensitivity Analysis to the National Aeronautics and Space Administration's Space Shuttle

Atmospheric parameters are essential in assessing the flight performance of aerospace vehicles. The effects of the Earth's atmosphere on aerospace vehicles influence various aspects of the vehicle during ascent ranging from its flight trajectory to the structural dynamics and aerodynamic heatmg on the vehicle. Atmospheric databases charactenzing the wind and thermodynamic environments, known as Range Reference Atmospheres (RRA), have been developed at space launch ranges by a governmental interagency working group for use by aerospace vehicle programs. The National Aeronantics and Space Administration's (NASA) Space Shuttle Program (SSP), which launches from Kennedy Space Center, utilizes atmosphenc statistics derived from the Cape Canaveral Air Force Station Range Reference Atmosphere (CCAFS RRA) database to evaluate environmental constraints on various aspects of the vehlcle during ascent.

Decker, Ryan K.↗

NASA NTRS2009

Deep Impact Delta II Launch Vehicle Cracked Thick Film Coating on Electronic Packages Technical Consultation Report

The Deep Impact spacecraft was launched on a Boeing Delta II rocket from Cape Canaveral Air Force Station (CCAFS) on January 12, 2005. Prior to the launch, the Director of the Office of Safety and Mission Assurance (OS&MA) requested the NASA Engineering and Safety Center (NESC) lead a team to render an independent opinion on the rationale for flight and the risk code assignments for the hazard of cracked Thick Film Assemblies (TFAs) in the E-packages of the Delta II launch vehicle for the Deep Impact Mission. The results of the evaluation are contained in this report.

Cameron, Kenneth D.↗

NASA NTRS2009

A Summary of NASA and USAF Hypergolic Propellant Related Spills and Fires

Several unintentional hypergolic fluid related spills, fires, and explosions from the Apollo Program, the Space Shuttle Program, the Titan Program, and a few others have occurred over the past several decades. Spill sites include the following government facilities: Kennedy Space Center (KSC), Johnson Space Center (JSC), White Sands Test Facility (WSTF), Vandenberg Air Force Base (VAFB), Cape Canaveral Air Force Station (CCAFS), Edwards Air Force Base (EAFB), Little Rock AFB, and McConnell AFB. Until now, the only method of capturing the lessons learned from these incidents has been "word of mouth" or by studying each individual incident report. The root causes and consequences of the incidents vary drastically; however, certain "themes" can be deduced and utilized for future hypergolic propellant handling. Some of those common "themes" are summarized below: (1) Improper configuration control and internal or external human performance shaping factors can lead to being falsely comfortable with a system (2) Communication breakdown can escalate an incident to a level where injuries occur and/or hardware is damaged (3) Improper propulsion system and ground support system designs can destine a system for failure (4) Improper training of technicians, engineers, and safety personnel can put lives in danger (5) Improper PPE, spill protection, and staging of fire extinguishing equipment can result in unnecessary injuries or hardware damage if an incident occurs (6) Improper procedural oversight, development, and adherence to the procedure can be detrimental and quickly lead to an undesirable incident (7) Improper materials cleanliness or compatibility and chemical reactivity can result in fires or explosions (8) Improper established "back-out" and/or emergency safing procedures can escalate an event The items listed above are only a short list of the issues that should be recognized prior to handling hypergolic fluids or processing vehicles containing hypergolic propellants. The summary of incidents in this report is intended to cover many more issues than those listed above.

Nufer, Brian M.↗

NASA NTRS2010

Exploring a Physically Based Tool for Lightning Cessation: A Preliminary Study

The University of Alabama in Huntsville (UA Huntsville) and NASA's Marshall Space Flight Center are collaborating with the 45th Weather Squadron (45WS) at Cape Canaveral Air Force Station (CCAFS) to enable improved nowcasting of lightning cessation. The project centers on use of dual-polarimetric radar capabilities, and in particular, the new C-band dual-polarimetric weather radar acquired by the 45WS. Special emphasis is placed on the development of a physically based operational algorithm to predict lightning cessation. While previous studies have developed statistically based lightning cessation algorithms, we believe that dual-polarimetric radar variables offer the possibility to improve existing algorithms through the inclusion of physically meaningful trends reflecting interactions between in-cloud electric fields and microphysics. Specifically, decades of polarimetric radar research using propagation differential phase has demonstrated the presence of distinct phase and ice crystal alignment signatures in the presence of strong electric fields associated with lightning. One question yet to be addressed is: To what extent can these ice-crystal alignment signatures be used to nowcast the cessation of lightning activity in a given storm? Accordingly, data from the UA Huntsville Advanced Radar for Meteorological and Operational Research (ARMOR) along with the North Alabama Lightning Mapping Array are used in this study to investigate the radar signatures present before and after lightning cessation. A summary of preliminary results will be presented.

Schultz, Elise V.↗

NASA NTRS2010

Statistical Short-Range Guidance for Peak Wind Forecasts on Kennedy Space Center/Cape Canaveral Air Force Station, Phase III

This final report describes the development of a peak wind forecast tool to assist forecasters in determining the probability of violating launch commit criteria (LCC) at Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS). The peak winds are an important forecast element for both the Space Shuttle and Expendable Launch Vehicle (ELV) programs. The LCC define specific peak wind thresholds for each launch operation that cannot be exceeded in order to ensure the safety of the vehicle. The 45th Weather Squadron (45 WS) has found that peak winds are a challenging parameter to forecast, particularly in the cool season months of October through April. Based on the importance of forecasting peak winds, the 45 WS tasked the Applied Meteorology Unit (AMU) to develop a short-range peak-wind forecast tool to assist in forecasting LCC violations.The tool includes climatologies of the 5-minute mean and peak winds by month, hour, and direction, and probability distributions of the peak winds as a function of the 5-minute mean wind speeds.

Crawford, Winifred↗

NASA NTRS2010

Exploring a Physically Based Tool for Lightning Cessation: Preliminary Results

The University of Alabama in Huntsville (UAHuntsville) and NASA s Marshall Space Flight Center are collaborating with the 45th Weather Squadron (45WS) at Cape Canaveral Air Force Station (CCAFS) to enable improved nowcasting of lightning cessation. The project centers on use of dual-polarimetric radar capabilities, and in particular, the new C-band dual-polarimetric weather radar acquired by the 45WS. Special emphasis is placed on the development of a physically based operational algorithm to predict lightning cessation. While previous studies have developed statistically based lightning cessation algorithms, we believe that dual-polarimetric radar variables offer the possibility to improve existing algorithms through the inclusion of physically meaningful trends reflecting interactions between in-cloud electric fields and microphysics. Specifically, decades of polarimetric radar research using propagation differential phase has demonstrated the presence of distinct phase and ice crystal alignment signatures in the presence of strong electric fields associated with lightning. One question yet to be addressed is: To what extent can these ice-crystal alignment signatures be used to nowcast the cessation of lightning activity in a given storm? Accordingly, data from the UAHuntsville Advanced Radar for Meteorological and Operational Research (ARMOR) along with the North Alabama Lightning Mapping Array are used in this study to investigate the radar signatures present before and after lightning cessation. A summary of preliminary results will be presented.

Schultz, Elsie V.↗

NASA NTRS2010

A Comparison of Tropical Storm (TS) and Non-TS Gust Factors for Assessing Peak Wind Probabilities at the Eastern Range

Peak wind speed is an important forecast element to ensure the safety of personnel and flight hardware at Kennedy Space Center (KSC) and the Cape Canaveral Air Force Station (CCAFS) in East-Central Florida. The 45th Weather Squadron (45 WS), the organization that issues forecasts for the KSC/CCAFS area, finds that peak winds are more difficult to forecast than mean winds. This difficulty motivated the 45 WS to request two independent studies. The first (Merceret 2009) was the development of a reliable model for gust factors (GF) relating the peak to the mean wind speed in tropical storms (TS). The second (Lambert et al. 2008) was a climatological study of non-TS cool season (October-April) mean and peak wind speeds by the Applied Meteorology Unit (AMU; Bauman et al. 2004) without the use of GF. Both studies presented their statistics as functions of mean wind speed and height. Most of the few comparisons of TS and non-TS GF in the literature suggest that non-TS GF at a given height and mean wind speed are smaller than the corresponding TS GF. The investigation reported here converted the non-TS peak wind statistics calculated by the AMU to the equivalent GF statistics and compared them with the previous TS GF results. The advantage of this effort over all previously reported studies of its kind is that the TS and non-TS data were taken from the same towers in the same locations. This eliminates differing surface attributes, including roughness length and thermal properties, as a major source of variance in the comparison. The goal of this study is two-fold: to determine the relationship between the non-TS and TS GF and their standard deviations (GFSD) and to determine if models similar to those developed for TS data in Merceret (2009) could be developed for the non-TS environment. The results are consistent with the literature, but include much more detailed, quantitative information on the nature of the relationship between TS and non-TS GF and GFSD as a function of height and mean wind speed.

Merceret, Francis J.↗

NASA NTRS2010

An Objective Verification of the North American Mesoscale Model for Kennedy Space Center and Cape Canaveral Air Force Station

The 45th Weather Squadron (45 WS) Launch Weather Officers (LWO's) use the 12-km resolution North American Mesoscale (NAM) model (MesoNAM) text and graphical product forecasts extensively to support launch weather operations. However, the actual performance of the model at Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS) has not been measured objectively. In order to have tangible evidence of model performance, the 45 WS tasked the Applied Meteorology Unit (AMU; Bauman et ai, 2004) to conduct a detailed statistical analysis of model output compared to observed values. The model products are provided to the 45 WS by ACTA, Inc. and include hourly forecasts from 0 to 84 hours based on model initialization times of 00, 06, 12 and 18 UTC. The objective analysis compared the MesoNAM forecast winds, temperature (T) and dew pOint (T d), as well as the changes in these parameters over time, to the observed values from the sensors in the KSC/CCAFS wind tower network shown in Table 1. These objective statistics give the forecasters knowledge of the model's strengths and weaknesses, which will result in improved forecasts for operations.

Bauman, William H., III↗

NASA NTRS2010

A Summary of NASA and USAF Hypergolic Propellant Related Spills and Fires

Nufer, Brian↗

NASA NTRS2010

Hypergolic Propellants: The Handling Hazards and Lessons Learned from Use

Nufer, Brian↗