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NASA NTRSDate not supplied

Recent Langley Aerothermodynamic Laboratory Testing (2019-2022)

In support of flight programs, multiple wind tunnel entries were conducted on reentry vehicle configurations to investigate blunt body aeroheating environments. Blunt body block thermal protection system (TPS) roughness, the Low-Earth Orbit Flight Test of an Inflatable Decelerator aeroshell scalloping, and a woven TPS all were tested to determine the effects of those parameters on increased surface heating to the vehicle. Commercial Crew Program studies also utilized the speed and ease of testing in the LAL to analyze parametric databases of low-earth reentry configurations, like the Boeing CST-100, and vehicles designed to travel to the moon or Mars, such as the SpaceX Starship. LAL wind tunnel investigations also supported several DoD and AFRL flight projects, such as HIFiRE 6 and BOLT. External customers leveraged the LAL testing capability to advance their research programs, including UPSTAR, RocketLab, and Lawrence Livermore National Laboratory. Academia groups benefitted from the inexpensive cost to test in the tunnels for many university collaborations, such as studies conducted in partnership with the University of Maryland on a flat plate, using a pressure rake and investigating fluid structure interactions. Multiple studies in collaboration with Purdue considered boundary layer transition on various cone configurations. Another study was conducted using a cone with shaped roughness elements borrowed from the Arnold Engineering Development Complex. Internal testing included studies using a phosphor thermography system that can measure higher temperatures than the current LAL phosphor capability and a characterization study of the noise in the wind tunnel flow. The breadth of testing across research and commercial paradigms, both internal and external to NASA, different configurations, a variety of test techniques and aerodynamic and aerothermal environments will be discussed in this overview presentation of the recent work conducted in the LAL.

wind tunnel test↗
NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗
NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗
NASA NTRS2014

Supporting Multiple Programs and Projects at NASA's Kennedy Space Center

With the conclusion of the shuttle program in 2011, the National Aeronautics and Space Administration (NASA) had found itself at a crossroads for finding transportation of United States astronauts and experiments to space. The agency would eventually hand off the taxiing of American astronauts to the International Space Station (ISS) that orbits in Low Earth Orbit (LEO) about 210 miles above the earth under the requirements of the Commercial Crew Program (CCP). By privatizing the round trip journey from Earth to the ISS, the space agency has been given the additional time to focus funding and resources to projects that operate beyond LEO; however, adding even more stress to the agency, the premature cancellation of the program that would succeed the Shuttle Program - The Constellation Program (CxP) -it would inevitably delay the goal to travel beyond LEO for a number of years. Enter the Space Launch System (SLS) and the Orion Multipurpose Crew Vehicle (MPCV). Currently, the SLS is under development at NASA's Marshall Spaceflight Center in Huntsville, Alabama, while the Orion Capsule, built by government contractor Lockheed Martin Corporation, has been assembled and is currently under testing at the Kennedy Space Center (KSC) in Florida. In its current vision, SLS will take Orion and its crew to an asteroid that had been captured in an earlier mission in lunar orbit. Additionally, this vehicle and its configuration is NASA's transportation to Mars. Engineers at the Kennedy Space Center are currently working to test the ground systems that will facilitate the launch of Orion and the SLS within its Ground Services Development and Operations (GSDO) Program. Firing Room 1 in the Launch Control Center (LCC) has been refurbished and outfitted to support the SLS Program. In addition, the Spaceport Command and Control System (SCCS) is the underlying control system for monitoring and launching manned launch vehicles. As NASA finds itself at a junction, so does all of its associated centers across the US. KSC has found itself at the blunt end of change as the entire center has transitioned from an operations mindset to a development mentality. The author of this paper has had the fortunate privilege and opportunity to be part of a transforming NASA during the fall months of 2014. The following is a high level account of projects that he had the chance to work on including the Spaceport Command and Control System, the Advanced Ground System and Maintenance Program Project, Customer Avionics Development & Analysis (CAIDA) Lab and Swamp Works.

Advanced Ground System Maintenance↗
NASA NTRSDate not supplied

Global Rescue Response to a Multivehicle Deorbit from the International Space Station

The U.S. Department of Defense (DoD) has been tasked to support rescue efforts in the event of an off-nominal landing of a Commercial Crew Program vehicle transporting NASA crewmembers to or from the International Space Station. The DoD is further tasked to support returning U.S. and International Partner crewmembers on Russian Soyuz spacecraft missions, specifically to ensure aeromedical evacuation capability in the event of a crewmember injury at the time of launch or landing. This DoD mission is primarily considered during planned launch and landing operations, with forces placed in an alert posture to support if needed. However, overall mission concept of operations encompasses a no-notice rescue capability in the event of an on-orbit emergency. Such contingency scenarios are pre-coordinated and simulated to ensure a ready posture of associated DoD assets and to promote coordination of government, commercial, and military stakeholders. To date, planning and simulations have focused on execution of a single rescue mission; the possibility of a multi-vehicle evacuation and rescue scenario has not been adequately explored. This presentation will examine the process of responding to an emergency onboard the International Space Station that results in the early departure and deorbit of multiple docked vehicles to preserve the health and safety of the crew. We will highlight the complexity of this recovery scenario and discuss potential complications that could arise, as well as identify areas in which deliberate planning and simulation can better ensure successful preparation for such a multifaceted recovery operation.

Travis Levon Houser↗
NASA NTRSDate not supplied

Revisiting the Soyuz-1 Parachute Failure in the Context of Safety in the Modern Era

The Soyuz‑1 accident remains one of the most consequential parachute related failures in human spaceflight history and provides enduring lessons for modern Entry, Descent, and Landing (EDL) system design. Occurring during the height of the Cold War and the Space Race, the mission unfolded under extraordinary political and schedule pressure as the Soviet Union sought to maintain its early leadership in space achievements following the death of chief designer Sergei Korolev. Despite unresolved propulsion, electrical, and parachute system deficiencies, Soyuz‑1 proceeded to launch and immediately encountered critical inflight anomalies, including a failed solar panel deployment, attitude control issues, and communication dropouts. Upon reentry, a malfunction in the parachute system, driven by a primary main canopy that failed to deploy, and subsequent entanglement of the reserve main canopy with the primary drogue parachute, resulted in insufficient deceleration and the fatal crash of cosmonaut Vladimir Komarov. Subsequent investigations revealed deep rooted cultural and organizational issues within the Soviet space program, including inadequate testing, suppression of dissent, undocumented last minute design changes, and the absence of integrated parachute system verification. More than 200 design flaws were identified after the accident, and firsthand accounts, including those from Yuri Gagarin, highlighted widespread concern prior to launch. Over time, the Soviet program implemented substantial reforms: systematic design corrections, rigorous process documentation, and an extensive series of drop tests that ultimately transformed the Soyuz system into one of the world’s most reliable human-rated return vehicles. This paper examines the technical architecture of the Soyuz‑1 parachute system, reconstructs the likely deployment sequence and failure mechanism, and analyzes the cultural contributors that shaped the accident. The study draws parallels to modern spacecraft parachute development, emphasizing the critical importance of integrated system testing, transparent engineering culture, and continuous hardware surveillance. These lessons remain directly relevant to today’s NASA and Commercial Crew Programs (CCP), where the Government continues to refine its understanding of aggregate risk and strengthen overall astronaut safety in the face of increasingly complex parachute systems.

Aaron L Morris↗
NASA NTRS2016

Purpose, Principles, and Challenges of the NASA Engineering and Safety Center

NASA formed the NASA Engineering and Safety Center in 2003 following the Space Shuttle Columbia accident. It is an Agency level, program-independent engineering resource supporting NASA's missions, programs, and projects. It functions to identify, resolve, and communicate engineering issues, risks, and, particularly, alternative technical opinions, to NASA senior management. The goal is to help ensure fully informed, risk-based programmatic and operational decision-making processes. To date, the NASA Engineering and Safety Center (NESC) has conducted or is actively working over 600 technical studies and projects, spread across all NASA Mission Directorates, and for various other U.S. Government and non-governmental agencies and organizations. Since inception, NESC human spaceflight related activities, in particular, have transitioned from Shuttle Return-to-Flight and completion of the International Space Station (ISS) to ISS operations and Orion Multi-purpose Crew Vehicle (MPCV), Space Launch System (SLS), and Commercial Crew Program (CCP) vehicle design, integration, test, and certification. This transition has changed the character of NESC studies. For these development programs, the NESC must operate in a broader, system-level design and certification context as compared to the reactive, time-critical, hardware specific nature of flight operations support.

Gilbert, Michael G.↗
NASA NTRS2011

Development of Space Shuttle Rescue and Recovery Operations

As the first Space Shuttle launch was still in our future, many from NASA, the Department of Defense (DoD) and NASA contractors were busy planning for not only a nominal launch and return, but contingency operations at the launch pad and landing sites. Prior to the first launch, detailed coordination, planning and simulations were conducted at all three locations and internal rescue procedures were taught at Kennedy Space Center (KSC). Later in the Program, the Transoceanic Abort Landing (TAL) sites were added in Europe and Africa. For the 51L mission a new TAL site was brought on line in Morocco. However, upon launch, the Shuttle Program experienced it's first lost. During the following months a complete review of all contingency operations (launch and landing) was completed. Many enhancements were made based on the reviews following. A Mode VIII water rescue was developed for NASA by the DoD before the STS-26 launch. Different concepts were explored and being debated by NASA. Training of the contingency forces was required before final decisions were made forcing the teaching of two different sets of procedures. To assist with training, a video was developed for the fire/crash/rescue personnel. This accompanied the detailed extraction procedures that were developed by a combination of KSC and DoD firemen. Training for the fire/crash/rescue personnel at Vandenberg AFB was also being planned before the accident happen. The fire/crash/rescue mockup that was being built at Chanute AFB was diverted to Edwards AFB. Educational Objectives: With the emphasis on Commercial Crew Programs for Space flight it is important that all involved understand what is required to prepare for contingencies. Cost effective means of being prepared for contingencies are needed. Questions: 1. When should planning for nominal and contingency operations begin? 2. What type of training aids are needed for contingency operations? 3. Who were the major contributors to Shuttle contingency operations?

Chandler, Michael↗
NASA NTRS2015

Test and Inspection Requirements for Frangible Joints Used in Human-Rated Spacecraft Applications

The purpose of this document is to define a series of test and inspection requirements for a specific type of frangible joint assembly used in human-rated spacecraft applications. It is intended to be an enhancement to the Commercial Crew Program JSC 62809D Human Rated Spacecraft Pyrotechnic Specification and lists very specific tests and inspections with accompanying tables. This document does not eliminate any of the requirements stated in JSC 62809D. Many of the test and inspections in this document are standard operating procedure for pyrotechnics suppliers. This document provides detail on the individual items to avoid ambiguity. In particular, this document details the test and inspection requirements for offset notch style frangible joints with aluminum machined plates. It is expected that a user would tailor the contents of this document for their particular vehicle application and provide a certifying organization with rationale for such tailoring. Tailoring to the requirements of this document requires approval of the certifying organization (e.g. NASA for a NASA human spaceflight program). The FJ must perform in accordance with design specifications after subjection to all environments it would encounter in its lifecycle. This document does not cover all possible environments that may exist in unique applications and a user may determine that additional tests are necessary. The user must develop written inspection and test procedures with detailed acceptance criteria.

Sirri Oguz↗
NASA NTRS2015

FJET Database Project: Extract, Transform, and Load

The Data Mining & Knowledge Management team at Kennedy Space Center is providing data management services to the Frangible Joint Empirical Test (FJET) project at Langley Research Center (LARC). FJET is a project under the NASA Engineering and Safety Center (NESC). The purpose of FJET is to conduct an assessment of mild detonating fuse (MDF) frangible joints (FJs) for human spacecraft separation tasks in support of the NASA Commercial Crew Program. The Data Mining & Knowledge Management team has been tasked with creating and managing a database for the efficient storage and retrieval of FJET test data. This paper details the Extract, Transform, and Load (ETL) process as it is related to gathering FJET test data into a Microsoft SQL relational database, and making that data available to the data users. Lessons learned, procedures implemented, and programming code samples are discussed to help detail the learning experienced as the Data Mining & Knowledge Management team adapted to changing requirements and new technology while maintaining flexibility of design in various aspects of the data management project.

excel vba↗
NASA NTRS2016

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

Tylka, Jonathan↗
NASA NTRS2016

Simulation of Mission Phases

This position with the Simulation and Graphics Branch (ER7) at Johnson Space Center (JSC) provided an introduction to vehicle hardware, mission planning, and simulation design. ER7 supports engineering analysis and flight crew training by providing high-fidelity, real-time graphical simulations in the Systems Engineering Simulator (SES) lab. The primary project assigned by NASA mentor and SES lab manager, Meghan Daley, was to develop a graphical simulation of the rendezvous, proximity operations, and docking (RPOD) phases of flight. The simulation is to include a generic crew/cargo transportation vehicle and a target object in low-Earth orbit (LEO). Various capsule, winged, and lifting body vehicles as well as historical RPOD methods were evaluated during the project analysis phase. JSC core mission to support the International Space Station (ISS), Commercial Crew Program (CCP), and Human Space Flight (HSF) influenced the project specifications. The simulation is characterized as a 30 meter +V Bar and/or -R Bar approach to the target object's docking station. The ISS was selected as the target object and the international Low Impact Docking System (iLIDS) was selected as the docking mechanism. The location of the target object's docking station corresponds with the RPOD methods identified. The simulation design focuses on Guidance, Navigation, and Control (GNC) system architecture models with station keeping and telemetry data processing capabilities. The optical and inertial sensors, reaction control system thrusters, and the docking mechanism selected were based on CCP vehicle manufacturer's current and proposed technologies. A significant amount of independent study and tutorial completion was required for this project. Multiple primary source materials were accessed using the NASA Technical Report Server (NTRS) and reference textbooks were borrowed from the JSC Main Library and International Space Station Library. The Trick Simulation Environment and User Training Materials version 2013.0 release was used to complete the Trick tutorial. Multiple network privilege and repository permission requests were required in order to access previous simulation models. The project was also an introduction to computer programming and the Linux operating system. Basic C++ and Python syntax was used during the completion of the Trick tutorial. Trick's engineering analysis and Monte Carlo simulation capabilities were observed and basic space mission planning procedures were applied in the conceptual design phase. Multiple professional development opportunities were completed in addition to project duties during this internship through the System for Administration, Training, and Education Resources for NASA (SATERN). Topics include: JSC Risk Management Workshop, CCP Risk Management, Basic Radiation Safety Training, X-Ray Radiation Safety, Basic Laser Safety, JSC Export Control, ISS RISE Ambassador, Basic SharePoint 2013, Space Nutrition and Biochemistry, and JSC Personal Protective Equipment. Additionally, this internship afforded the opportunity for formal project presentation and public speaking practice. This was my first experience at a NASA center. After completing this internship I have a much clearer understanding of certain aspects of the agency's processes and procedures, as well as a deeper appreciation from spaceflight simulation design and testing. I will continue to improve my technical skills so that I may have another opportunity to return to NASA and Johnson Space Center.

Carlstrom, Nicholas Mercury↗
NASA NTRS2016

Flat H Redundant Frangible Joint Development

Orion and Commercial Crew Program (CCP) Partners have chosen to use frangible joints for certain separation events. The joints currently available are zero failure tolerant and will be used in mission safety applications. The goal is to further develop a NASA designed redundant frangible joint that will lower flight risk and increase reliability. FY16 testing revealed a successful design in subscale straight test specimens that gained efficiency and supports Orion load requirements. Approach / Innovation A design constraint is that the redundant joint must fit within the current Orion architecture, without the need for additional vehicle modification. This limitation required a design that changed the orientation of the expanding tube assemblies (XTAs), by rotating them 90deg from the standard joint configuration. The change is not trivial and affects the fracture mechanism and structural load paths. To address these changes, the design incorporates cantilevered arms on the break plate. The shock transmission and expansion of the XTA applies force to these arms and creates a prying motion to push the plate walls outward to the point of structural failure at the notched section. The 2014 test design revealed that parts could slip during functioning wasting valuable energy needed to separate the structure with only a single XTA functioning. Dual XTA functioning fully separated the assembly showing a discrepancy can be backed up with redundancy. Work on other fully redundant systems outside NASA is limited to a few patents that have not been subjected to functionality testing Design changes to prevent unwanted slippage (with ICA funding in 2015) showed success with a single XTA. The main goal for FY 2016 was to send the new Flat H RFJ to WSTF where single XTA test failures occurred back in 2014. The plan was to gain efficiency in this design by separating the Flat H RFJ with thicker ligaments with dimensions baselined in 2014. Other modifications included geometry changes to better disperse loads paths and to minimize air gaps. The design additionally added more structural strength to enhance the structural limits in static loads testing. The design also implemented a smoother load line through the assembly. Results / Knowledge Gained The new Flat H RFJ successfully fractured at WSTF with thicker ligaments and lower cord size. Where failure to separate occurred earlier, there is now excessive energy available for structural separation. The new challenge to provide some structural support to prevent secondary fracturing of the break plate remains to be completed. This future work is being funded by the JSC Engineering Directorate in 2017 to elevate the TRL on curved Flat H RFJs that configure with the Orion Service Panel Separation. Additional funding from JSC Engineering will provide new design testing to avoid secondary fracturing.

Brown, Chris↗
NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗
NASA NTRS2019

Modular Damage Detection for Expandable and Inflatable Structures

NASA has identified potential damage from micrometeoroid and orbital debris (MMOD) impacts as a primary threat to Commercial Crew Program vehicles. The International Space Station (ISS) and extraterrestrial habitats also exhibit the risk of damage caused by MMODs. Currently no integrated in-situ or real-time health monitoring damage detection system is being used for expandable and inflatable structures. A novel, modular damage detection system design that incorporates interchangeable and replaceable sensory panels in a foldable architecture is described. The design implements technologies that provide for situational awareness, self-configuration, and damage detection and localization. The system is applicable for the new Gateway and surface and ground support infrastructure

Lewis, Mark E.↗
NASA NTRS2019

Large Male Anthropomorphic Test Device (ATD) Finite Element Model (FEM) Correlation Improvement

As part of an activity for the Commercial Crew Program (CCP), a NASA Engineering and Safety Center (NESC) team conducted tests of small female, medium male, and large male Hybrid III anthropomorphic test device (ATD) head-neck complexes. The results were compared to simulation results from ATD finite element model (FEM) predictions to determine the validity and fidelity of ATD models for use in certifying CCP vehicles. The NESC was requested to help improve the large male ATD FEM to better represent physical responses. This report contains the outcome of the NESC assessment.

Kelly, Michael J.↗
NASA NTRSDate not supplied

A Sample/Jitter Monte Carlo Technique for Main Parachute Loads Predictions

Models for Orion parachute performance are based on reconstructions of the Capsule Parachute Assembly System (CPAS) drop test campaign and were documented in the CPAS “Model Memo.” Experience with similar Commercial Crew Program (CCP) parachute systems resulted in some updates to the Orion models in preparation for Artemis missions. The reefing cutter dispersion model for the drogues and mains had been overly-conservative by producing wide timing differences within clusters. A higher-fidelity timing model was generated by separating out in-lot variation and temperature effects. The main parachute inflation model had accounted for some correlations between parameters using complicated 2-D geometric bounding, but the results tended to exaggerate individual peak loads from fast (leading) inflations and under-emphasize actual lagging experience. Several flight tests were reconstructed again with an emphasis on matching peak load magnitudes using a search algorithm. A simpler method for generating inflation parameters uses the 3-D correlated reconstructed “samples” with some random “jitter” applied. Dispersed Monte Carlo inputs are then checked against flight test data to evaluate whether they represent reality.

parachutes↗
NASA NTRSDate not supplied

Chasing Spacecraft

Measurements made during actual flight on a spacecraft represent the holy grail in supporting cutting edge research and providing critical vehicle health information during exposure to the harsh environments of launch and reentry. Remote optical imaging data obtained by the Scientifically Calibrated In-Flight Imagery (SCIFLI) team at NASA Langley Research Center (LaRC) is currently being used by NASA’s Artemis and Commercial Crew Programs to ensure the safety of astronauts. This emerging capability had its genesis during the Space Shuttle Program. A look toward the future will showcase the use of high-altitude long-endurance uncrewed aircraft coupled with novel sensors to support civilian and national flight-testing interests more effectively.

Tom Horvath↗