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NASA NTRS1980

Planned observations of the diffuse sky radiation during shuttle mission STS-4

The planned space shuttle mission STS-4 will use the Skylab flight spare ten-color (near UV to near IR) photopolarimeter with boresighted 16 mm camera. This 164-hour mission will observe the zodiacal light to within approximately 20 deg of the sun (in and out of the ecliptic). The mission consists of several distinct phases: (1) tail-to-sun (TTS), belly to earth for 18 hours; (2) nose-to-sun, solar inertial for 79 hours; (3) bay-to-sun for 26 hours; and (4) passive thermal control for 37 hours. During the TTS phase, where most observations are scheduled, the instrument will scan back and forth in elevation at 4 deg/sec while the orbiter moves across the sky at its 4 deg/min orbital rate. The combined orbiter/instrument motion will result in a saw-tooth pattern of observations projected on the sky (between the 14 deg and 120 deg elevation limits) and will enable extensive measurements of the brightness, polarization and color of the background starlight to be made.

Weinberg, J. L.↗

NASA NTRS2005

Lighting the Way for Quicker, Safer Healing

Who's to say that a little light can t go a long way? Tiny light-emitting diode (LED) chips used to grow plants in space are lighting the way for cancer treatment, wound healing, and chronic pain alleviation on Earth. In 1993, Quantum Devices, Inc. (QDI), of Barneveld, Wisconsin, began developing the HEALS (High Emissivity Aluminiferous Light-emitting Substrate) technology to provide high-intensity, solid-state LED lighting systems for NASA Space Shuttle plant growth experiments. The company evolved out of cooperative efforts with the Wisconsin Center for Space Automation and Robotics (WCSAR) at the University of Wisconsin-Madison a NASA center for the Commercial Development of Space. Ronald W. Ignatius, QDI s president and chairman, represented one of WCSAR s industrial partners at the time. WCSAR was conducting research on light sources for promoting food growth within closed environments where humans would be present for a long duration, such as the Space Shuttle and the International Space Station. With the support of WCSAR, Ignatius experimented with LEDs, which provide high-energy efficiency and virtually no heat, despite releasing waves of light 10 times brighter than the Sun. Ignatius admits that some scientists involved in the project were skeptical at first, thinking that the idea of using LEDs to promote plant growth was far-fetched. The experiments, however, demonstrated that red LED wavelengths could boost the energy metabolism of cells to advance plant growth and photosynthesis. This finding prompted Ignatius to develop a line of LED products that emit the exact wavelength of light that plants use in photosynthesis. Our company gives credit to Dr. Ray Bula, the director of WCSAR, for having the foresight to go against the prevailing dogma of the time and design the first plant experiment using monochromatic light to grow lettuce plants, Ignatius proclaims. In 1989, Ignatius formed QDI to bring the salt grain-sized LEDs to market, and in October 1995, the light sources made their Space Shuttle flight debut on the second U.S. Microgravity Laboratory Spacelab mission (STS-73, Columbia)

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NASA NTRS2007

Producing a Live HDTV Program from Space

By the year 2000, NASA had flown HDTV camcorders on three Space Shuttle missions: STS-95, STS-93 and STS-99. All three flights of these camcorders were accomplished with cooperation from the Japanese space agency (then known as NASDA and now known as JAXA). The cameras were large broadcast-standard cameras provided by NASDA and flight certified by both NASA and NASDA. The high-definition video shot during these missions was spectacular. Waiting for the return of the tapes to Earth emphasized the next logical step: finding a way to downlink the HDTV live from space. Both the Space Shuttle and the International Space Station (ISS) programs were interested in live HDTV from space, but neither had the resources to fully fund the technology. Technically, downlinking from the ISS was the most effective approach. Only when the Japanese broadcaster NHK and the Japanese space agency expressed interest in covering a Japanese astronaut's journey to the ISS did the project become possible. Together, JAXA and NHK offered equipment, technology, and funding toward the project. In return, NHK asked for a live HDTV downlink during one of its broadcast programs. NASA and the ISS Program sought a US partner to broadcast a live HDTV program and approached the Discovery Channel. The Discovery Channel had proposed a live HDTV project in response to NASA's previous call for offers. The Discovery Channel agreed to provide addItional resources. With the final partner in place, the project was under way. Engineers in the Avionics Systems Division at NASA's Johnson Space Center (JSC) had already studied the various options for downlinking HDTV from the ISS. They concluded that the easiest way was to compress the HDTV so that the resulting data stream would "look" like a payload data stream. The flight system would consist of a professional HDTV camcorder with live HD-SDI output, an HDTV MPEG-2 encoder, and a packetizer/protocol converter.

Grubbs, Rodney↗

NASA NTRS2011

The Sensor Test for Orion RelNav Risk Mitigation (STORRM) Development Test Objective

The Sensor Test for Orion Relative-Navigation Risk Mitigation (STORRM) Development Test Objective (DTO) flew aboard the Space Shuttle Endeavour on STS-134 in May- June 2011, and was designed to characterize the performance of the flash LIDAR and docking camera being developed for the Orion Multi-Purpose Crew Vehicle. The flash LIDAR, called the Vision Navigation Sensor (VNS), will be the primary navigation instrument used by the Orion vehicle during rendezvous, proximity operations, and docking. The DC will be used by the Orion crew for piloting cues during docking. This paper provides an overview of the STORRM test objectives and the concept of operations. It continues with a description of STORRM's major hardware components, which include the VNS, docking camera, and supporting avionics. Next, an overview of crew and analyst training activities will describe how the STORRM team prepared for flight. Then an overview of in-flight data collection and analysis is presented. Key findings and results from this project are summarized. Finally, the paper concludes with lessons learned from the STORRM DTO.

Christian, John A.↗

NASA NTRS2010

NASA Accelerates SpaceCube Technology into Orbit

On May 11, 2009, STS-125 Space Shuttle Atlantis blasted off from Kennedy Space Center on a historic mission to service the Hubble Space Telescope (HST). In addition to sending up the hardware and tools required to repair the observatory, the servicing team at NASA's Goddard Space Flight Center also sent along a complex experimental payload called Relative Navigation Sensors (RNS). The main objective of the RNS payload was to provide real-time image tracking of HST during rendezvous and docking operations. RNS was a complete success, and was brought to life by four Xilinx FPGAs (Field Programmable Gate Arrays) tightly packed into one integrated computer called SpaceCube. SpaceCube is a compact, reconfigurable, multiprocessor computing platform for space applications demanding extreme processing capabilities based on Xilinx Virtex 4 FX60 FPGAs. In a matter of months, the concept quickly went from the white board to a fully funded flight project. The 4-inch by 4-inch SpaceCube processor card was prototyped by a group of Goddard engineers using internal research funding. Once engineers were able to demonstrate the processing power of SpaceCube to NASA, HST management stood behind the product and invested in a flight qualified version, inserting it into the heart of the RNS system. With the determination of putting Xilinx into space, the team strengthened to a small army and delivered a fully functional, space qualified system to the mission.

Petrick, David↗

NASA NTRS1985

Achieving reliability - The evolution of redundancy in American manned spacecraft computers

The Shuttle is the first launch system deployed by NASA with full redundancy in the on-board computer systems. Fault-tolerance, i.e., restoring to a backup with less capabilities, was the method selected for Apollo. The Gemini capsule was the first to carry a computer, which also served as backup for Titan launch vehicle guidance. Failure of the Gemini computer resulted in manual control of the spacecraft. The Apollo system served vehicle flight control and navigation functions. The redundant computer on Skylab provided attitude control only in support of solar telescope pointing. The STS digital, fly-by-wire avionics system requires 100 percent reliability. The Orbiter carries five general purpose computers, four being fully-redundant and the fifth being soley an ascent-descent tool. The computers are synchronized at input and output points at a rate of about six times a second. The system is projected to cause a loss of an Orbiter only four times in a billion flights.

Tomayko, J. E.↗

NASA NTRS2009

Johnson Space Center's Risk and Reliability Analysis Group 2008 Annual Report

The Johnson Space Center (JSC) Safety & Mission Assurance (S&MA) Directorate s Risk and Reliability Analysis Group provides both mathematical and engineering analysis expertise in the areas of Probabilistic Risk Assessment (PRA), Reliability and Maintainability (R&M) analysis, and data collection and analysis. The fundamental goal of this group is to provide National Aeronautics and Space Administration (NASA) decisionmakers with the necessary information to make informed decisions when evaluating personnel, flight hardware, and public safety concerns associated with current operating systems as well as with any future systems. The Analysis Group includes a staff of statistical and reliability experts with valuable backgrounds in the statistical, reliability, and engineering fields. This group includes JSC S&MA Analysis Branch personnel as well as S&MA support services contractors, such as Science Applications International Corporation (SAIC) and SoHaR. The Analysis Group s experience base includes nuclear power (both commercial and navy), manufacturing, Department of Defense, chemical, and shipping industries, as well as significant aerospace experience specifically in the Shuttle, International Space Station (ISS), and Constellation Programs. The Analysis Group partners with project and program offices, other NASA centers, NASA contractors, and universities to provide additional resources or information to the group when performing various analysis tasks. The JSC S&MA Analysis Group is recognized as a leader in risk and reliability analysis within the NASA community. Therefore, the Analysis Group is in high demand to help the Space Shuttle Program (SSP) continue to fly safely, assist in designing the next generation spacecraft for the Constellation Program (CxP), and promote advanced analytical techniques. The Analysis Section s tasks include teaching classes and instituting personnel qualification processes to enhance the professional abilities of our analysts as well as performing major probabilistic assessments used to support flight rationale and help establish program requirements. During 2008, the Analysis Group performed more than 70 assessments. Although all these assessments were important, some were instrumental in the decisionmaking processes for the Shuttle and Constellation Programs. Two of the more significant tasks were the Space Transportation System (STS)-122 Low Level Cutoff PRA for the SSP and the Orion Pad Abort One (PA-1) PRA for the CxP. These two activities, along with the numerous other tasks the Analysis Group performed in 2008, are summarized in this report. This report also highlights several ongoing and upcoming efforts to provide crucial statistical and probabilistic assessments, such as the Extravehicular Activity (EVA) PRA for the Hubble Space Telescope service mission and the first fully integrated PRAs for the CxP's Lunar Sortie and ISS missions.

Valentine, Mark↗

NASA NTRS2005

STS-114: Discovery Day 5 Post MMT Briefing

Wayne Hill, Space Shuttle Deputy Program Manager, and Chair of the Mission Management Team, reports the following: the testing of the thermal protection system in space, on orbit was successful; the MMT meeting formally approved the mission extension for one day; image analysis from the launch phase has been completed; tile and blankets had been formally cleared by the Engineering team; additional inspection of the reinforced carbon-carbon (RCC); gap filler, heat shield and small black spot phenomenon are carefully inspected and evaluated to prepare the safe return of the Discovery. Bill Gerstenmaier, ISS Program Manager reports on the extra vehicular activities (EVA): replaced the GPS antenna; prepared the airlock to attach the ESP2; re-powered CMG2; transfer of CWCs; and the MISSE packages were wrapped around thru at the end of the air lock. He mentioned the high currents problem seen on CMG3, which they will have to take off line to check and understand the problem. Consumables, engineering performance of the three sensors (LCS, LDRI, ITVC), CMG removal and replacement, EVA2 and EVA3, gap fillers, RCC, hydrogen tank pre-press cycles, thermal protection system, inspection, ISS supply maintenance, and projection of next flight are topics covered with the News Media.

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NASA NTRS1987

Apollo Lightcraft project

The detailed design of a beam-powered transatmospheric vehicle, the Apollo Lightcraft, was selected as the project for the design course. The principal goal is to reduce the LEO payload delivery cost by at least three orders of magnitude below the Space Shuttle Orbiter in the post 2020 era. The completely reusable, single-stage-to-orbit shuttlecraft will take off and land vertically, and have a reentry heat shield integrated with its lower surface. At appropriate points along the launch trajectory, the combined cycle propulsion system will transition through three or four airbreathing modes, and finally use a pure rocket mode for orbital insertion. The objective for the Spring semester propulsion source was to design and perform a detailed theoretical analysis on an advanced combined-cycle engine suitable for the Apollo Lightcraft. The preliminary theoretical analysis of this combined-cycle engine is now completed, and the acceleration performance along representative orbital trajectories was simulated. The total round trip cost is $3430 or $686 per person. This represents a payload delivery cost of $3.11/lb, which is a factor of 1000 below the STS. The Apollo Lightcraft concept is now ready for a more detailed investigation during the Fall semester Transatmosphere Vehicle Design course.

Myrabo, Leik N.↗

NASA NTRS1998

Photogrammetric Assessment of the Hubble Space Telescope Solar Arrays During the Second Servicing Mission

This report documents the photogrammetric assessment of the Hubble Space Telescope (HST) solar arrays conducted by the NASA c Center Image Science and Analysis Group during Second Servicing Mission 2 (SM-2) on STS-82 in February 1997. Two type solar array analyses were conducted during the mission using Space Shuttle payload bay video: (1) measurement of solar array motion due to induced loads, and (2) measurement of the solar array static or geometric twist caused by the cumulative array loading. The report describes pre-mission planning and analysis technique development activities conducted to acquire and analyze solar array imagery data during SM-2. This includes analysis of array motion obtained during SM-1 as a proof-of-concept of the SM-2 measurement techniques. The report documents the results of real-time analysis conducted during the mission and subsequent analysis conducted post-flight. This report also provides a summary of lessons learned on solar array imagery analysis from SM-2 and recommendations for future on-orbit measurements applicable to HST SM-3 and to the International Space Station. This work was performed under the direction of the Goddard Space Flight Center HST Flight Systems and Servicing Project.

Sapp, C. A.↗

NASA NTRS1999

The Starshine Hitchhiker Mission on STS-96

A mirrored, spherical "Starshine" satellite was ejected by NASA into a circular low Earth orbit from a Hitchhiker canister in the cargo bay of Space Shuttle OV-103 Discovery at 07:21 Universal Time on June 5, 1999, near the end of Discovery's STS-96 mission to the International Space Station. Starshine's initial orbital altitude was 218 Nautical Miles (387 km), and its orbital inclination was 51.6 deg. The satellite is expected to orbit Earth until sometime in January 2000, when it will reenter the atmosphere and vaporize. Some 25,030 students in 700 schools around the world participated in the construction of this satellite by polishing 878 small, front-surface aluminum mirrors that stud its outer surface. A small fraction of those students is presently tracking the satellite and measuring its angular position at specific times. The Naval Research Laboratory is combining the students' measurements with Naval Space Command radar tracking data to compute the satellite's orbit on a daily basis. From the rate of decay of the orbit, the students are able to calculate the density of the atmosphere at the satellite's present altitude. The students are also accessing the project's web site to observe ground-based and space-based images of the sun and other indices of solar activity. They are then using these data to make correlations between the intensity of solar storms and fluctuations in the density of the earth's upper atmosphere. The number of students participating in the tracking phase of the project is expected to increase dramatically at the start of the fall school term in the northern hemisphere. At the conclusion of the Starshine mission, the student team will attempt to predict when and where the satellite will re-enter the atmosphere, so they can compete for a cash prize for the best photograph of the satellite's fiery demise.

Moore, Gil↗

NASA NTRS2016

In the Hot Seat: STS-115 Lightning Strike Stand Down Debate - NASA Case Study

There is no way the PIC's could have seen any current' was the gist of Mike Griffin's assessment. Griffin was the NASA Administrator at the time. The buck stopped at his desk. Holding a napkin out to Pat Lampton, Griffin showed Lampton the calculations he'd made over dinner that predicted that the Pyrotechnic Initiator Controllers (PIC's) at the base of the Space Shuttle Solid Rocket Boosters (SRBs) were fine. A lightning strike the day before, the worst ever experienced with a Space Shuttle on the launch pad, caused a halt to the launch count down as technicians, engineers, and managers scrambled identify any damage to the launch system. SRB technicians and engineers assessed the data against their Lightning Strike Re-Test Requirements, determining that all but one of the requirements could be checked if they resumed the countdown. For the one remaining requirement, testing the integrity of the PIC's would require 96 hours to set up, test, and reassemble. The engineers were convinced that there was no way to do calculations to show the PIC's were okay. The only option was to stand down. It was SRB Deputy Project Manager (PM) Pat Lampton's responsibility to decide what the SRB project position needed to be to certify that their hardware was safe to fly. He had to communicate that decision to the Mission Management Team (MMT) as a Go or No Go position to resume the count down. If the answer was Go they could still meet a delayed, but acceptable launch schedule. If the answer was No Go, rescheduling the launch would be a grueling shuffling of hardware, personnel, and mission timelines to accommodate Russian missions to the Space Station, supplies for the launch, and personnel manning launch operations. On top of that, Hurricane Ernesto was spinning off the coast of Florida, threatening the need for the Shuttle to roll back to the hangar if they waited too long.

Kummer, Lizette↗

NASA NTRS1995

Load measurement system with load cell lock-out mechanism

In the frame work of the project Shuttle Plume Impingement Flight Experiment (SPIFEX), a Load Measurement System was developed and fabricated to measure the impingement force of Shuttle Reaction Control System (RCS) jets. The Load Measurement System is a force sensing system that measures any combination of normal and shear forces up to 40 N (9 lbf) in the normal direction and 22 N (5 lbf) in the shear direction with an accuracy of +/- 0.04 N (+/- 0.01 lbf) Since high resolution is required for the force measurement, the Load Measurement System is built with highly sensitive load cells. To protect these fragile load cells in the non-operational mode from being damaged due to flight loads such as launch and landing loads of the Shuttle vehicle, a motor driven device known as the Load Cell Lock-Out Mechanism was built. This Lock-Out Mechanism isolates the load cells from flight loads and re-engages the load cells for the force measurement experiment once in space. With this highly effective protection system, the SPIFEX load measurement experiment was successfully conducted on STS-44 in September 1994 with all load cells operating properly and reading impingement forces as expected.

Le, Thang↗

NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗

NASA NTRS1990

Observations of thermal ion influxes about the space shuttle

Ion mass spectrometer measurements made as part of the University of Iowa's Plasma Diagnostic Package on the STS-3 and Spacelab 2 Space Shuttle missions sampled a variety of ion composition and collected ion current responses to gas emissions from the vehicle. The only other shuttle ion measurements were made by an Air Force Geophysics Laboratory (AFGL) quadrupole spectrometer flown on STS-4. Gas emissions change the distribution of the incoming plasma through scattering and charge transfer processes. A background flux of contaminant ion species (mostly relating to water) always exists in the near vicinity of the shuttle with a magnitude which is dependent on the look direction of the spectrometer but which varies differently with changes in the angle of attack than that of the ambient ions. There is a near shuttle wake cavity in the contaminant ion distributions which has a different spatial configuration than the wake of the ambient ions. Although water dumps produce the most persistent ion perturbations, the sources for ion current modification were best delineated from measurements made when only one or two of the Reaction Control System thrusters fired for a relatively long duration. Contaminant ion perturbations associated with such firings were observed to persist for the order of a second after the cessation of the firings. The dense thruster plumes are efficient collisional, charge exchange barriers to the passage of ambient ions. Collected ion current perturbations were more evident for firings of the rear verniers, whose plumes scatter off projecting surfaces, than for the nose thrusters. The effect of the Vernier firings was found to depend not only on the location and attitude of the spectrometer with respect to the shuttle and thruster plume direction, but also on the orientation of the local magnetic field with respect to the shuttle velocity.

Grebowsky, Joe M.↗

NASA NTRS2007

Exploring the Solid Rocket Boosters and Properties of Matter

I worked for the United Space Alliance, LLC (USA) with the Solid Rocket Booster (SRB) Materials and Process engineers (M&P). I was assigned a project in which I needed to research and collect chemical and physical properties information, material safety data sheets (MSDS), and other product information from the vendor's websites and existing "inhouse" files for a select group of materials used in building and refurbishing the SRBs. This information was then compiled in a report that summarized the information collected. My work site was at the Kennedy Space Center (KSC). This allowed for many opportunities to visit and tour sites operated by NASA, by USA, and by the Air Force. This included the vehicle assembly building (VAB), orbital processing facilities (OPF), the crawler with the mobile launch pad (MLP), and the SRB assembly and refurbishment facility (ARF), to name a few. In addition, the launch, of STS- 117 took place within the first week of employment allowing a day by day following of that mission including post flight operations for the SRBs. Two Delta II rockets were also launched during these 7 weeks. The sights were incredible and the operations witnessed were amazing. I learned so many things I never knew about the entire program and the shuttle itself. The entire experience, especially my work with the SRB materials, inspired my plan for implementation into the classroom.

Moffett, Amy↗

NASA NTRS1996

SAMS Acceleration Measurements on Mir from June to November 1995

The NASA Microgravity Science and Applications Division (MSAD) sponsors science experiments on a variety of microgravity carriers, including sounding rockets, drop towers, parabolic aircraft, and Orbiter missions. The MSAD sponsors the Space Acceleration Measurement System (SAMS) to support microgravity science experiments with acceleration measurements to characterize the microgravity environment to which the experiments were exposed. The Principal Investigator Microgravity Services project at the NASA Lewis Research Center supports principal investigators of microgravity experiments as they evaluate the effects of varying acceleration levels on their experiments. In 1993, a cooperative effort was started between the United States and Russia involving science utilization of the Russian Mir space station by scientists from the United States and Russia. MSAD is currently sponsoring science experiments participating in the Shuttle-Mir Science Program in cooperation with the Russians on the Mir space station. Included in the complement of MSAD experiments and equipment is a SAMS unit In a manner similar to Orbiter mission support, the SAMS unit supports science experiments from the U.S. and Russia by measuring the microgravity environment during experiment operations. The initial SAMS supported experiment was a Protein Crystal Growth (PCG) experiment from June to November 1995. SAMS data were obtained during the PCG operations on Mir in accordance with the PCG Principal Investigator's requirements. This report presents an overview of the SAMS data recorded to support this PCG experiment. The report contains plots of the SAMS 100 Hz sensor head data as an overview of the microgravity environment, including the STS-74 Shuttle-Mir docking.

DeLombard, Richard↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗