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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

The Single Crew Module Concept for Exploration

Many concepts have been proposed for exploring space. In early 2010 presidential direction called for reconsidering the approach to address changes in exploration destinations, use of new technologies and development of new capabilities to support exploration of space. Considering the proposed new technology and capabilities that NASA was directed to pursue, the single crew module (SCM) concept for a more streamlined approach to the infrastructure and conduct of exploration missions was developed. The SCM concept combines many of the new promising technologies with a central concept of mission architectures that uses a single habitat module for all phases of an exploration mission. Integrating mission elements near Earth and fully fueling them prior to departure of the vicinity of Earth provides the capability of using the single habitat both in transit to an exploration destination and while exploring the destination. The concept employs the capability to return the habitat and interplanetary propulsion system to Earth vicinity so that those elements can be reused on subsequent exploration missions. This paper describes the SCM concept, provides a top level mass estimate for the elements needed and trades the concept against Many concepts have been proposed for exploring space. In early 2010 presidential direction called for reconsidering the approach to address changes in exploration destinations, use of new technologies and development of new capabilities to support exploration of space. Considering the proposed new technology and capabilities that NASA was directed to pursue, the single crew module (SCM) concept for a more streamlined approach to the infrastructure and conduct of exploration missions was developed. The SCM concept combines many of the new promising technologies with a central concept of mission architectures that uses a single habitat module for all phases of an exploration mission. Integrating mission elements near Earth and fully fueling them prior to departure of the vicinity of Earth provides the capability of using the single habitat both in transit to an exploration destination and while exploring the destination. The concept employs the capability to return the habitat and interplanetary propulsion system to Earth vicinity so that those elements can be reused on subsequent exploration missions. This paper describes the SCM concept, provides a top level mass estimate for the elements needed and trades the concept against Constellation approaches for Lunar, Near Earth Asteroid and Mars Surface missions.

Chambliss, Joe↗
NASA NTRS2011

Overview of Orion Crew Module and Launch Abort Vehicle Dynamic Stability

With the retirement of the Space Shuttle, NASA is designing a new spacecraft, called Orion, to fly astronauts to low earth orbit and beyond. Characterization of the dynamic stability of the Orion spacecraft is important for the design of the spacecraft and trajectory construction. Dynamic stability affects the stability and control of the Orion Crew Module during re-entry, especially below Mach = 2.0 and including flight under the drogues. The Launch Abort Vehicle is affected by dynamic stability as well, especially during the re-orientation and heatshield forward segments of the flight. The dynamic stability was assessed using the forced oscillation technique, free-to-oscillate, ballistic range, and sub-scale free-flight tests. All of the test techniques demonstrated that in heatshield-forward flight the Crew Module and Launch Abort Vehicle are dynamically unstable in a significant portion of their flight trajectory. This paper will provide a brief overview of the Orion dynamic aero program and a high-level summary of the dynamic stability characteristics of the Orion spacecraft.

D. Bruce Owens↗
NASA NTRS2009

Orion Project Crew Module Analyses Summary

This slide presentation reviews the efforts at analyzing the Crew Module (CM) for the Orion Project. The Integrated Thermal Model is described, and the on-orbit analysis for the 4 different mission phases is also described. The four mission phases are: Mission phase (1) Low Earth Orbit (LEO) International Space Station (ISS) mission (2) ISS docked (3) LEO, lunar mission and (4) Low Lunar Orbit (LLO).

Alvarez-Hernandez, Angel↗
NASA NTRS2011

Probabilistic Analysis of a Composite Crew Module

An approach for conducting reliability-based analysis (RBA) of a Composite Crew Module (CCM) is presented. The goal is to identify and quantify the benefits of probabilistic design methods for the CCM and future space vehicles. The coarse finite element model from a previous NASA Engineering and Safety Center (NESC) project is used as the baseline deterministic analysis model to evaluate the performance of the CCM using a strength-based failure index. The first step in the probabilistic analysis process is the determination of the uncertainty distributions for key parameters in the model. Analytical data from water landing simulations are used to develop an uncertainty distribution, but such data were unavailable for other load cases. The uncertainty distributions for the other load scale factors and the strength allowables are generated based on assumed coefficients of variation. Probability of first-ply failure is estimated using three methods: the first order reliability method (FORM), Monte Carlo simulation, and conditional sampling. Results for the three methods were consistent. The reliability is shown to be driven by first ply failure in one region of the CCM at the high altitude abort load set. The final predicted probability of failure is on the order of 10-11 due to the conservative nature of the factors of safety on the deterministic loads.

FROM↗
NASA NTRSDate not supplied

NASA’s Orion Crew Module Seakeeping Simulation and Test Comparisons in Ocean Wave Environments

The NASA Orion Crew Module (CM) post-landing seakeeping and uprighting capabilities are being evaluated across a variety of ocean wave conditions. This paper provides an overview of quarter-scale and full-scale test data and how it compares with the CM seakeeping dynamic simulation results evaluated using Wave Energy Convertor Simulator (WEC-Sim).This includes a discussion of the status of the dynamic modeling effort, correlation of model inputs with the wave field from the test, and a comparison of the results against the physical test data with emphasis on the full-scale results. Analysis in the frequency domain showed similar response characteristics between the model and the test and shows energy peaks corresponding to both the natural response and the forced response due to the wave environment. Time domain comparisons showed that the linear WEC-Sim model under predicted the amplitude of the pitch and roll motion of the test article, with improved matching for smaller, longer crested waves. An attempt was made to correlate the pitch/roll response to incident wave slope to account for a possible delay in the BTA’s response. The results did not show a strong relationship in the response characteristics to incident wave slope, but better correlation was seen by comparing responses in the frequency domain. Evaluation of the simulation’s ability to match test results aided in understanding the current fidelity of the CM model in WEC-Sim and identifying areas for model improvement

Abigail Lockard↗
NASA NTRS2009

Assessment of Ocean Wave Model used to Analyze the Constellation Program (CxP) Orion Project Crew Module Water Landing Conditions

Mr. Christopher Johnson, NASA's Systems Manager for the Orion Project Crew Module (CM) Landing and Recovery at the Johnson Space Center (JSC), and Mr. James Corliss, Project Engineer for the Orion CM Landing System Advanced Development Project at the Langley Research Center (LaRC) requested an independent assessment of the wave model that was developed to analyze the CM water landing conditions. A NASA Engineering and Safety Center (NESC) initial evaluation was approved November 20, 2008. Mr. Bryan Smith, NESC Chief Engineer at the NASA Glenn Research Center (GRC), was selected to lead this assessment. The Assessment Plan was presented and approved by the NESC Review Board (NRB) on December 18, 2008. The Assessment Report was presented to the NRB on March 12, 2009. This document is the final Assessment Report.

Smith, Bryan K.↗
NASA NTRS2010

Design/Development of Spacecraft and Module Crew Compartments

This slide presentation reviews the design and development of crew compartments for spacecraft and for modules. The Crew Compartment or Crew Station is defined as the spacecraft interior and all other areas the crewman interfaces inside the cabin, or may potentially interface.It uses examples from all of the human rated spacecraft. It includes information about the process, significant drivers for the design, habitability, definitions of models, mockups, prototypes and trainers, including pictures of each stage in the development from Apollo, pictures of the space shuttle trainers, and International Space Station trainers. It further reviews the size and shape of the Space Shuttle orbiter crew compartment, and the Apollo command module and the lunar module. It also has a chart which reviews the International Space Station (ISS) internal volume by stage. The placement and use of windows is also discussed. Interestingly according to the table presented, the number 1 rated piece of equipment for recreation was viewing windows. The design of crew positions and restraints, crew translation aids and hardware restraints is shown with views of the restraints and handholds used from the Apollo program through the ISS.

Goodman, Jerry R.↗
NASA NTRS1992

First Lunar Outpost crew module thermal protection design sensitivity

A thermal protection study was conducted on the first lunar outpost (FLO) crew module. The study objectives are as follows: (1) assess effects of vehicle size on aerothermodynamic environment and thermal protection system (TPS) weight; (2) assess effects of lunar-return strategies on aerothermodynamic environment and TPS weight; and (3) assess weight penalty for common TPS design for all lunar-return strategies. All material is covered in viewgraph format.

Bouslog, Stan↗
NASA NTRS2007

Astronaut Risk Levels During Crew Module (CM) Land Landing

The NASA Engineering Safety Center (NESC) is investigating the merits of water and land landings for the crew exploration vehicle (CEV). The merits of these two options are being studied in terms of cost and risk to the astronauts, vehicle, support personnel, and general public. The objective of the present work is to determine the astronaut dynamic response index (DRI), which measures injury risks. Risks are determined for a range of vertical and horizontal landing velocities. A structural model of the crew module (CM) is developed and computational simulations are performed using a transient dynamic simulation analysis code (LS-DYNA) to determine acceleration profiles. Landing acceleration profiles are input in a human factors model that determines astronaut risk levels. Details of the modeling approach, the resulting accelerations, and astronaut risk levels are provided.

Lawrence, Charles↗
NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163, (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a singlepiece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment are the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗
NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163 (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The Orion MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a single-piece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment were the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗
NASA NTRS2024

Design and Test of the Orion Crew Module Launch Abort System Hatch

The Orion spacecraft is part of NASA’s Artemis program to establish a permanent human presence on the lunar surface and further enable future crewed missions to Mars. One of the key safety features of Orion is the Launch Abort System (LAS) which pulls the Orion Crew Module (CM) away in the event of a launch vehicle malfunction. It was necessary to design a LAS hatch that allows for crew access to the CM during pad operations. This paper describes the background and evolution of the LAS hatch design, the features used to address the crew safety requirements, the testing challenges in preparation for the Artemis crewed missions, and lessons learned.

Hatch↗
NASA NTRS2024

Design and Test of the Orion Crew Module Launch Abort System Hatch

The Orion spacecraft is part of NASA’s Artemis program to establish a permanent human presence on the lunar surface and further enable future crewed missions to Mars. One of the key safety features of Orion is the Launch Abort System (LAS) which pulls the Orion Crew Module (CM) away in the event of a launch vehicle malfunction. It was necessary to design a LAS hatch that allows for crew access to the CM during pad operations. This paper describes the background and evolution of the LAS hatch design, the features used to address the crew safety requirements, the testing challenges in preparation for the Artemis crewed missions, and lessons learned.

Hatch↗
NASA NTRS2011

Development of the Orion Crew Module Static Aerodynamic Database: Hypersonic - Part 1

The Orion aerodynamic database provides force and moment coefficients given the velocity, attitude, configuration, etc. of the Crew Exploration Vehicle (CEV). The database is developed and maintained by the NASA CEV Aerosciences Project team from computational and experimental aerodynamic simulations. The database is used primarily by the Guidance, Navigation, and Control (GNC) team to design vehicle trajectories and assess flight performance. The initial hypersonic re-entry portion of the Crew Module (CM) database was developed in 2006. Updates incorporating additional data and improvements to the database formulation and uncertainty methodologies have been made since then. This paper details the process used to develop the CM database, including nominal values and uncertainties, for Mach numbers greater than 8 and angles of attack between 140deg and 180deg. The primary available data are more than 1000 viscous, reacting gas chemistry computational simulations using both the Laura and Dplr codes, over a range of Mach numbers from 2 to 37 and a range of angles of attack from 147deg to 172deg. Uncertainties were based on grid convergence, laminar-turbulent solution variations, combined altitude and code-to-code variations, and expected heatshield asymmetry. A radial basis function response surface tool, NEAR-RS, was used to fit the coefficient data smoothly in a velocity-angle-of-attack space. The resulting database is presented and includes some data comparisons and a discussion of the predicted variation of trim angle of attack and lift-to-drag ratio. The database provides a variation in trim angle of attack on the order of +/-2deg, and a range in lift-to-drag ratio of +/-0.035 for typical vehicle flight conditions.

Bibb, Karen L.↗
NASA NTRS2008

Structural Design and Analysis of the Upper Pressure Shell Section of a Composite Crew Module

This paper presents the results of the structural design and analysis of the upper pressure shell section of a carbon composite demonstration structure for the Composite Crew Module (CCM) Project. The project is managed by the NASA Engineering and Safety Center with participants from eight NASA Centers, the Air Force Research Laboratory, and multiple aerospace contractors including ATK/Swales, Northrop Grumman, Lockheed Martin, Collier Research Corporation, Genesis Engineering, and Janicki Industries. The paper discusses details of the upper pressure shell section design of the CCM and presents the structural analysis results using the HyperSizer structural sizing software and the MSC Nastran finite element analysis software. The HyperSizer results showed that the controlling load case driving most of the sizing in the upper pressure shell section was the internal pressure load case. The regions around the cutouts were controlled by internal pressure and the main parachute load cases. The global finite element analysis results showed that the majority of the elements of the CCM had a positive margin of safety with the exception of a few hot spots around the cutouts. These hot spots are currently being investigated with a more detailed analysis. Local finite element models of the Low Impact Docking System (LIDS) interface ring and the forward bay gussets with greater mesh fidelity were created for local sizing and analysis. The sizing of the LIDS interface ring was driven by the drogue parachute loads, Trans-Lunar Insertion (TLI) loads, and internal pressure. The drogue parachute loads controlled the sizing of the gusset cap on the drogue gusset and TLI loads controlled the sizing of the other five gusset caps. The main parachute loads controlled the sizing of the lower ends of the gusset caps on the main parachute fittings. The results showed that the gusset web/pressure shell and gusset web/gusset cap interfaces bonded using Pi-preform joints had local hot spots in the Pi-preform termination regions. These regions require a detailed three-dimensional analysis, which is currently being performed, to accurately address the load distribution near the Pi-preform termination in the upper and lower gusset caps.

Sleight, David W.↗
NASA NTRS2011

Feasibility of Orion Crew Module Entry on Half of Available Propellant Due to Tank Isolation Fault

The fuel tank isolation as a result of leak or rupture can leave an Orion Crew Module with only half of the loaded propellant for ISS return atmospheric entry. To assess the feasibility of returning under this condition, an analysis of various entry control options with deliberate degradation of control performance was performed. The study determined that a ballistic entry without a raise burn, a steeper flight path trajectory, relaxed atmospheric pitch/yaw rate damping, and degraded touchdown control could achieve 2-sigma requirements compliance with a 2-sigma fuel usage that is less than half of the liftoff propellant loading. The results of this analysis indicate that an entry with only half the nominal propellant load is feasible following a tank isolation fault.

Moen, Marina M.↗
NASA NTRS2012

Structural Element Testing in Support of the Design of the NASA 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). For the design and manufacturing of the CCM, the team adopted the building block approach where design and manufacturing risks were mitigated through manufacturing trials and structural testing at various levels of complexity. Following NASA's Structural Design Verification Requirements, a further objective was the verification of design analysis methods and the provision of design data for critical structural features. Test articles increasing in complexity from basic material characterization coupons through structural feature elements and large structural components, to full-scale structures were evaluated. This paper discusses only four elements tests three of which include joints and one that includes a tapering honeycomb core detail. For each test series included are specimen details, instrumentation, test results, a brief analysis description, test analysis correlation and conclusions.

Kellas, Sotiris↗