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NASA NTRS2012

Regolith-Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

In this paper we will discuss a new mass-efficient and innovative way of protecting high-mass spacecraft during planetary Entry, Descent & Landing (EDL). Heat shields fabricated in situ can provide a thermal-protection system (TPS) for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from regolith materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Two regolith processing and manufacturing methods will be discussed: 1) Compression and sintering of the regolith to yield low density materials; 2) Formulations of a High-temperature silicone RTV (Room Temperature Vulcanizing) compound are used to bind regolith particles together. The overall positive results of torch flame impingement tests and plasma arc jet testing on the resulting samples will also be discussed.

Hogue, Michael D.↗

NASA NTRS2014

Deployment Methods for an Origami-Inspired Rigid-Foldable Array

The purpose of this work is to evaluate several deployment methods for an origami-inspired solar array at two size scales: 25-meter array and CubeSat array. The array enables rigid panel deployment and introduces new concepts for actuating CubeSat deployables. The design for the array was inspired by the origami flasher model (Lang, 1997; Shafer, 2001). Figure 1 shows the array prototyped from Garolite and Kapton film at the CubeSat scale. Prior work demonstrated that rigid panels like solar cells could successfully be folded into the final stowed configuration without requiring the panels to flex (Zirbel, Lang, Thomson, & al., 2013). The design of the array is novel and enables efficient use of space. The array can be wrapped around the central bus of the spacecraft in the case of the large array, or can accommodate storage of a small instrument payload in the case of the CubeSat array. The radial symmetry of this array around the spacecraft is ideally suited for spacecraft that need to spin. This work focuses on several actuation methods for a one-time deployment of the array. The array is launched in its stowed configuration and it will be deployed when it is in space. Concepts for both passive and active actuation were considered.

Zirbel, Shannon A.↗

NASA NTRS2015

Common Cause Failure Modeling in Space Launch Vehicles

Common Cause Failures (CCFs) are a known and documented phenomenon that defeats system redundancy. CCFs are a set of dependent type of failures that can be caused for example by system environments, manufacturing, transportation, storage, maintenance, and assembly. Since there are many factors that contribute to CCFs, they can be reduced, but are difficult to eliminate entirely. Furthermore, failure databases sometimes fail to differentiate between independent and dependent CCF. Because common cause failure data is limited in the aerospace industry, the Probabilistic Risk Assessment (PRA) Team at Bastion Technology Inc. is estimating CCF risk using generic data collected by the Nuclear Regulatory Commission (NRC). Consequently, common cause risk estimates based on this database, when applied to other industry applications, are highly uncertain. Therefore, it is important to account for a range of values for independent and CCF risk and to communicate the uncertainty to decision makers. There is an existing methodology for reducing CCF risk during design, which includes a checklist of 40+ factors grouped into eight categories. Using this checklist, an approach to produce a beta factor estimate is being investigated that quantitatively relates these factors. In this example, the checklist will be tailored to space launch vehicles, a quantitative approach will be described, and an example of the method will be presented.

Hark, Frank↗

NASA NTRS2019

Characterization of 10-ft. Diameter Aluminum Alloy 2219 Integrally Stiffened Cylinders

The integrally stiffened cylinder (ISC) process, pioneered by NASA Langley Research Center, offers significant savings for launch vehicle structures. The ISC process is a near net shape, advanced manufacturing method for fabrication of single-piece, thin-walled barrels with internal longitudinal stiffeners, eliminating the need for longitudinal welding and machining. A cost-benefit analysis of the ISC process estimated a 50 % reduction in manufacturing costs and a 10% weight savings over the current multi-piece, machined and welded construction approach for stiffened barrels. In 2017, commercial-scale manufacturing trials were pursued, leading to a successful manufacturing demonstration of 10-ft. diameter ISC barrels fabricated from Al alloy 2219. Some cracking was observed in the stiffeners during fabrication. Optical metallography was performed to evaluate the as-formed microstructures to identify potential causes of cracking, along with mechanical testing to evaluate formability. Results revealed that cracking in the stiffeners was attributed to three likely causes: 1) large Al-Cu stringer particles, 2) stick-slip friction between the mandrel and ISC due to non-optimized lubrication, and 3) differences in material flow rate between the wall and stiffener locations. Testing to gauge formability revealed a significant decrease in ductility in the longitudinal directional for the as-formed condition, attributed to reduced ductility due to the large Al-Cu stringer particles. These results provide guidance toward materials and processing modifications for future ISC forming trials.

Tayon, Wesley A.↗

NASA NTRS2019

Uncertainties for Pre- and Post-Launch Radiometric Calibration of Imaging Spectrometers for Multi-Sensor Applications

An important aspect to using imaging spectrometer data is the radiometric characterization and calibration of the sensors and validation of their data products and doing so with error budgets with known traceability. The radiometric accuracy of a given sensor is important for demonstrating the expected quality of data from the sensor. Known traceability allows data from multiple sensors to be directly comparable as will become more important in the near future with the expected launches of multiple imaging spectrometers from multiple countries, agencies, and commercial entities. The current work describes the state of pre- and post-launch radiometric absolute and relative uncertainties and their role in harmonising on-orbit data. Examples of prelaunch uncertainties based on the calibration of EnMAP and the calibration planned for the CLARREO Pathfinder Mission are presented highlighting recent work in the area of detector-based approaches using tunable laser sources. Post-launch calibration approaches for Pathfinder, EnMAP, CHIME, and DESIS including traditional vicarious calibration methods and the challenges of working with commercial data are presented. The vicarious calibration discussion relies on the example of the recently-available RadCalNet data to describe typical methods and challenges that will be faced when harmonising data between imaging spectrometers as well as with multispectral sensors.

Thome, K.↗

NASA NTRSDate not supplied

Nodal Numerical Modeling of Submerged Helium Injection in a Cryogenic Propellant Tank

Subcooling of cryogenic propellant by helium injection is one of the most effective methods for suppressing bulk boiling and keeping subcooled propellant conditions for pre-launch, launch, and post-launch pressurization applications. For tank pressurization, submerged helium injection can substantially reduce helium consumption by infusing gaseous propellant into the tank ullage. This paper presents a mathematical model of the helium bubbling process in liquid oxygen to estimate the amount of oxygen vapor absorbed by the rising helium bubbles and the amount of subcooling of liquid oxygen due to evaporative heat and mass transfer. This mathematical model was incorporated in a simulation model of tank pressurization built with Generalized Fluid System Simulation Program (GFSSP), a general-purpose flow network code developed at NASA/Marshall Space Flight Center. The numerical predictions of subcooling have been compared with the experimental data of Cho et al. which investigated the propellant subcooling effect as a function of system pressure, helium injection temperature, and flowrate for a non-drained submerged injection system. The numerical predictions of helium consumption have been compared with the test data from a NASA Centaur test vehicle which included both direct and submerged injection with draining of propellants. The numerical model developed with GFSSP has been validated against two sets of experimental data and has been shown to predict both propellant subcooling and helium consumption to within 30% in most cases. The test data used for the model validation were taken in 1-g, but the mass diffusion model was developed to be applied in both 1-g and micro-g environments.

Cryogenics↗

NASA NTRSDate not supplied

Nodal Modeling of Submerged Helium Injection Pressurization of a Cryogenic Propellant Tank

Subcooling of cryogenic propellant by helium injection is one of the most effective methods for suppressing bulk boiling and keeping subcooled propellant conditions for pre-launch, launch, and post-launch pressurization applications. For tank pressurization, submerged helium injection can substantially reduce helium consumption by infusing gaseous propellant into the tank ullage. This paper describes a thermodynamic model of the helium bubbling process in liquid oxygen to estimate the amount of oxygen vapor absorbed by the rising helium bubbles and the amount of subcooling of liquid oxygen due to evaporative heat and mass transfer. The physics of helium dissolution during the pressurization process is also modeled, primarily for liquid hydrogen propellant where the dissolution is more significant. The analyses were performed in a simulation model of tank pressurization built with Generalized Fluid System Simulation Program (GFSSP), a general-purpose flow network code developed at NASA/Marshall Space Flight Center. The numerical predictions of subcooling have been compared with the experimental data of Cho et al. which investigated the propellant subcooling effect as a function of system pressure, helium injection temperature, and flowrate for a non-drained submerged injection system. The numerical predictions of helium consumption have been compared with the test data from a NASA Centaur test vehicle which included both direct and submerged injection with draining of propellants. Hydrogen propellant testing of the Cryogenic Propellant Storage and Transfer Engineering Developmental Unit (CPST EDU) conducted at NASA/Glenn Research Facility was also analyzed. The data used for the model validation were taken in 1-g, but the model was developed to be applicable in both multi-g and micro-g environments.

tank pressurization↗

NASA NTRSDate not supplied

Performance Characteristics of a Boundary Layer Ingesting Inlet - Distortion Tolerant Fan Through CFD Code Coupling

A method of constructing a high-fidelity simulation using two NASA CFD codes, Launch Ascent and Vehicle Aerodynamics (LAVA), which is the general-purpose solver, and a turbomachinery specific code NASA-TURBO (TURBO), will be presented. Validation of the code coupling is performed through comparison to experimental data obtained in the 2017 wind tunnel test of NASA’s Boundary Layer Ingesting Inlet - Distortion Tolerant Fan (BLI2DTF). For the simulation, the external flow field is computed by LAVA utilizing a steady-state Reynolds-averaged Navier-Stokes (RANS) methodology. Data from LAVA is exchanged with TURBO, which simulated the propulsor utilizing an unsteady-RANS methodology. A sensitivity analysis is performed using averaged and instantaneous data transfer between the two codes, as well as varying the amount of simulation time TURBO computes between updates. The results of the coupled simulations appear to replicate the BLI2DTF experiment correctly. Static pressure taps leading into and around the nacelle, total pressure ratio and efficiency of the propulsor, and profiles of total temperature, pressure, and Mach number at the rear measurement plane, aft of the propulsor, are in good agreement with experimental data. These results provide confidence that the coupled simulation is behaving in a physically realizable manner.

CFD↗

NASA NTRSDate not supplied

Application of Norton-Thevenin Receptance Coupling (NTRC) to Space Launch System (SLS) Payload Coupled Loads Analysis (CLA)

Norton-Thevenin Receptance Coupling (NTRC), as described in several NASA Engineering and Safety Center (NESC) papers shows promise in enabling loads development for payloads with less computational cost and analyst time as compared to a full integrated vehicle coupled loads analysis (CLA). NTRC allows the free vehicle responses and impedance (accelerance) at the payload to vehicle interface (derived from integrated vehicle CLA) to be used with a payload model in a payload CLA. Due to the NTRC damping differing from the full integrated vehicle damping, results are slightly different, so coverage factors were developed to ensure NTRC results enveloped results from a traditional CLA. NTRC results with coverage factors were very close to full CLA results. The Space Launch System (SLS) coupled loads team has developed an implementation of the NTRC method to enable support of co-manifested payloads with analysis needs that do not fit the primary SLS load cycle schedule. The NTRC method was successfully used to support the European System Providing Refueling, Infrastructure, and Communications (ESPRIT) module for Gateway planned to fly on Artemis V and has been adopted as the SLS approach for supporting payload CLA requests that do not align with vehicle load cycles.

SLS↗

NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

NASA NTRS1990

Automated design of multiple encounter gravity-assist trajectories

Given a range of initial launch dates and a set of target planets, a new approach to planetary mission design is developed, using an automated method for finding all conic solutions. Each point on the diagrams reproduced represents a single ballistic trajectory and is computed by modeling the trajectory as a conic section and solving the corresponding Lambert problem for each set of launch and arrival dates. An example which prescribes a launch period of 1975-2050 and target planets Uranus, Saturn, Jupiter, Neptune and Pluto is described whereby, all possible grand tour missions of this class are found, including the Voyager II trajectory. It is determined that this automated design tool may be applied to a variety of multiple encounter gravity-assist trajectories that are being considered for future missions.

Longuski, James M.↗

NASA NTRS2012

Uncertainty Due to Unsteady Fluid/Structure Interaction for the Ares I Vehicle Traversing the Transonic Regime

Rapid reduced-order numerical models are being investigated as candidates to simulate the dynamics of a flexible launch vehicle during atmospheric ascent. There has also been the extension of these new approaches to include gust response. These methods are used to perform aeroelastic and gust response analyses at isolated Mach numbers. Such models require a method to time march through a succession of ascent Mach numbers. An approach is presented for interpolating reduced-order models of the unsteady aerodynamics at successive Mach numbers. The transonic Mach number range is considered here since launch vehicles can suffer the highest dynamic loads through this range. Realistic simulations of the flexible vehicle behavior as it traverses this Mach number range are presented. The response of the vehicle due to gusts is computed. Uncertainties in root mean square and maximum bending moment and crew module accelerations are presented due to assumed probability distributions in design parameters, ascent flight conditions, gusts. The primary focus is on the uncertainty introduced by modeling fidelity. It is found that an unsteady reduced order model produces larger excursions in the root mean square loading and accelerations than does a quasi-steady reduced order model.

Bartels, Robert E.↗

NASA NTRS1990

An outgassing model of non-metallic materials for the ascent of a Titan 4 launch vehicle

Outgassing of nonmetallic materials and components inside Titan IV's 2A compartment during ascent may present a problem to the payload community in relation to molecular deposition and degradation of sensitive payload surfaces. The procedure currently being developed to model the amounts, transport, and deposition of outgassed molecular contaminants onto a payload's sensitive surface consists of three phases. The first phase involves the development of a thermogravimetric method that recreates the increasing temperature and decreasing pressure profiles expected in the 2A compartment of the TIV launch vehicle during ascent. The second phase involves the determination of deposition rates of outgassed materials onto a payload surface, and the subsequent evaporation rate as a function of temperature of deposited material. The third phase takes the temperature and pressure profiles from phase one, the deposition and evaporation rates and kinetic coefficients determined in phase two, and incorporates them into the SPACE II computer program to determine which payload surfaces are most susceptible to molecular deposition from TIV's outgassing sources, and the level of permanent deposition expected on those surfaces.

Barrows, R. D.↗

NASA NTRS2004

Photogrammetry and Videogrammetry Methods for Solar Sails and Other Gossamer Structures

Ultra-lightweight and inflatable gossamer space structures are designed to be tightly packaged for launch, then deploy or inflate once in space. These properties will allow for in-space construction of very large structures 10 to 1000 meters in size such as solar sails, inflatable antennae, and space solar power stations using a single launch. Solar sails are of particular interest because of their potential for propellantless propulsion. Gossamer structures do, however, have significant complications. Their low mass and high flexibility make them very difficult to test on the ground. The added mass and stiffness of attached measurement devices can significantly alter the static and dynamic properties of the structure. This complication necessitates an alternative approach for characterization. This paper discusses the development and application of photogrammetry and videogrammetry methods for the static and dynamic characterization of gossamer structures, as four specific solar sail applications demonstrate. The applications prove that high-resolution, full-field, non-contact static measurements of solar sails using dot projection photogrammetry are possible as well as full-field, noncontact, dynamic characterization using dot projection videogrammetry.

Black, Jonathan T.↗

NASA NTRS2005

Project LAUNCH: Bringing Space into Math and Science Classrooms

Project LAUNCH is a K-12 teacher professional development program, which has been created in collaboration between the Whitaker Center for Science, Mathematics and Technology Education at Florida Gulf Coast University (FGCU), and the Florida Space Research Institute (FSRI). Utilizing Space as the overarching theme it is designed to improve mathematics and science teaching, using inquiry based, hands-on teaching practices, which are aligned with Florida s Sunshine State Standards. Many students are excited about space exploration and it provides a great venue to get them involved in science and mathematics. The scope of Project LAUNCH however goes beyond just providing competency in the subject area, as pedagogy is also an intricate part of the project. Participants were introduced to the Conceptual Change Model (CCM) [1] as a framework to model good teaching practices. As the CCM closely follows what scientists call the scientific process, this teaching method is also useful to actively engage institute participants ,as well as their students, in real science. Project LAUNCH specifically targets teachers in low performing, high socioeconomic schools, where the need for skilled teachers is most critical.

Fauerbach, M.↗

NASA NTRS2016

Source Data Applicability Impacts on Epistemic Uncertainty for Launch Vehicle Fault Tree Models

Launch vehicle systems are designed and developed using both heritage and new hardware. Design modifications to the heritage hardware to fit new functional system requirements can impact the applicability of heritage reliability data. Risk estimates for newly designed systems must be developed from generic data sources such as commercially available reliability databases using reliability prediction methodologies, such as those addressed in MIL-HDBK-217F. Failure estimates must be converted from the generic environment to the specific operating environment of the system where it is used. In addition, some qualification of applicability for the data source to the current system should be made. Characterizing data applicability under these circumstances is crucial to developing model estimations that support confident decisions on design changes and trade studies. This paper will demonstrate a data-source applicability classification method for assigning uncertainty to a target vehicle based on the source and operating environment of the originating data. The source applicability is determined using heuristic guidelines while translation of operating environments is accomplished by applying statistical methods to MIL-HDK-217F tables. The paper will provide a case study example by translating Ground Benign (GB) and Ground Mobile (GM) to the Airborne Uninhabited Fighter (AUF) environment for three electronic components often found in space launch vehicle control systems. The classification method will be followed by uncertainty-importance routines to assess the need to for more applicable data to reduce uncertainty.

Al Hassan, Mohammad↗

NASA NTRS2012

Robust, Practical Adaptive Control for Launch Vehicles

A modern mechanization of a classical adaptive control concept is presented with an application to launch vehicle attitude control systems. Due to a rigorous flight certification environment, many adaptive control concepts are infeasible when applied to high-risk aerospace systems; methods of stability analysis are either intractable for high complexity models or cannot be reconciled in light of classical requirements. Furthermore, many adaptive techniques appearing in the literature are not suitable for application to conditionally stable systems with complex flexible-body dynamics, as is often the case with launch vehicles. The present technique is a multiplicative forward loop gain adaptive law similar to that used for the NASA X-15 flight research vehicle. In digital implementation with several novel features, it is well-suited to application on aerodynamically unstable launch vehicles with thrust vector control via augmentation of the baseline attitude/attitude-rate feedback control scheme. The approach is compatible with standard design features of autopilots for launch vehicles, including phase stabilization of lateral bending and slosh via linear filters. In addition, the method of assessing flight control stability via classical gain and phase margins is not affected under reasonable assumptions. The algorithm s ability to recover from certain unstable operating regimes can in fact be understood in terms of frequency-domain criteria. Finally, simulation results are presented that confirm the ability of the algorithm to improve performance and robustness in realistic failure scenarios.

Orr, Jeb. S.↗

NASA NTRS2008

Improved Verification for Aerospace Systems

Aerospace systems are subject to many stringent performance requirements to be verified with low risk. This report investigates verification planning using conditional approaches vice the standard classical statistical methods, and usage of historical surrogate data for requirement validation and in verification planning. The example used in this report to illustrate the results of these investigations is a proposed mission assurance requirement with the concomitant maximum acceptable verification risk for the NASA Constellation Program Orion Launch Abort System (LAS). This report demonstrates the following improvements: 1) verification planning using conditional approaches vice classical statistical methods results in plans that are more achievable and feasible; 2) historical surrogate data can be used to bound validation of performance requirements; and, 3) incorporation of historical surrogate data in verification planning using conditional approaches produces even less costly and more reasonable verification plans. The procedures presented in this report may produce similar improvements and cost savings in verification for any stringent performance requirement for an aerospace system.

Powell, Mark A.↗