Search NASA⌕ Search

SEARCH · Search NASA

Results for “NASA Engineering and Safety Center”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

The HYTHIRM Project: Flight Thermography of the Space Shuttle During the Hypersonic Re-entry

This report describes a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. A background and an overview of several multidisciplinary efforts that culminated in the acquisition of high resolution calibrated infrared imagery of the Space Shuttle during hypervelocity atmospheric entry is presented. The successful collection of thermal data has demonstrated the feasibility of obtaining remote high-resolution infrared imagery during hypersonic flight for the accurate measurement of surface temperature. To maximize science and engineering return, the acquisition of quantitative thermal imagery and capability demonstration was targeted towards three recent Shuttle flights - two of which involved flight experiments flown on Discovery. In coordination with these two Shuttle flight experiments, a US Navy NP-3D aircraft was flown between 26-41 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 (STS-119) and Mach 14.7 (STS-128) using a long-range infrared optical package referred to as Cast Glance. This same Navy aircraft successfully monitored the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission (STS-125). The purpose of this paper is to describe the systematic approach used by the Hypersonic Thermodynamic Infrared Measurements team to develop and implement a set of mission planning tools designed to establish confidence in the ability of an imaging platform to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. The mission planning tools included a pre-flight capability to predict the infrared signature of the Shuttle. Such tools permitted optimization of the hardware configuration to increase signal-to-noise and to maximize the available dynamic range while mitigating the potential for saturation. Post flight, analysis tools were used to assess atmospheric effects and to convert the 2-D intensity images to 3-D temperature maps of the windward surface. Comparison of the spatially resolved global thermal measurements to surface thermocouples and CFD prediction is made. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the Shuttle suggests future applications towards hypersonic flight test programs within NASA, DoD and DARPA along with flight test opportunities supporting NASA's project Constellation.

Horvath, Thomas J.↗
NASA NTRS2010

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗
NASA NTRSDate not supplied

Spacecraft Line-Of-Sight Jitter Mitigation and Management Lessons Learned and Engineering Best Practices

Predicting, managing, controlling, and testing spacecraft line-of-sight (LoS) jitter caused by micro-vibrations due to onboard internal disturbance sources is a formidable multidisciplinary engineering task. It is especially challenging for those missions hosting high-performance, vibration-sensitive optical sensor payloads with stringent pointing stability requirements. Both NASA and ESA are planning technically aggressive spaceflight missions that include ultra-high-performance optical payloads with delicate, highly vibration-sensitive scientific and observational instruments. The GN&C community of practice will need to leverage and build upon their collective experiences and lessons learned to better address future micro-vibration challenges. To identify lessons learned and best engineering practices the NASA Engineering & Safety Center (NESC) sponsored a two-day Spacecraft LoS Jitter Workshop in late 2019. The workshop’s goal was to provide a multidisciplinary forum to elicit deeper understanding of the issues related to solving the spacecraft LoS jitter/micro-vibration problem. A primary objective was to identify and share best practices, rules of thumb, and options for jitter-related activities. Representatives from NASA, JPL, ESA, along with NASA’s industrial partners, independent consultant subject matter experts, and members of academia participated in the workshop. This paper will describe the motivation for the NASA Spacecraft LoS Jitter Workshop and summarize the identified findings, observations, and recommendations.

Lessons Learned;↗
NASA NTRS2021

Spacecraft Line-of-Sight Jitter Management and Mitigation Lessons Learned and Engineering Best Practices

Predicting, managing, controlling, and testing spacecraft line-of-sight (LoS) jitter caused by micro-vibrations due to on-board internal disturbance sources is a formidable multidisciplinary engineering task. It is especially challenging for those missions hosting high-performance (e.g., nano-radian/milli-arcsecond class), vibration-sensitive optical sensor payloads with stringent pointing stability requirements. The Nation Aeronautics and Space Administration (NASA) and the European Space Agency (ESA) are planning technically aggressive spaceflight missions that include ultra-high-performance optical payloads with delicate, highly vibration-sensitive scientific and observational instruments. The guidance, navigation, and control community of practice will need to leverage collective experiences and document their best practices and lessons learned to address future micro-vibration challenges. To identify lessons learned and best practices the NASA Engineering & Safety Center sponsored a 2-day Spacecraft LoS Jitter Workshop in late 2019. The workshop’s goal was to provide a multidisciplinary forum to elicit deeper understanding of the issues related to addressing the spacecraft LoS jitter/micro-vibration problem. The primary objective was to identify, document, and share lessons learned, best practices, and preferred options for jitter-related analysis and test activities. Representatives from NASA, ESA, along with NASA’s industrial partners, independent consultant subject matter experts, and members of academia participated in the workshop. This paper describes the motivation for the workshop and summarize the identified findings and recommendations.

Lessons Learned↗
NASA NTRS2007

Huygens Titan Probe Trajectory Reconstruction Using Traditional Methods and the Program to Optimize Simulated Trajectories II

On January 14, 2005, ESA's Huygens probe separated from NASA's Cassini spacecraft, entered the Titan atmosphere and landed on its surface. As part of NASA Engineering Safety Center Independent Technical Assessment of the Huygens entry, descent, and landing, and an agreement with ESA, NASA provided results of all EDL analyses and associated findings to the Huygens project team prior to probe entry. In return, NASA was provided the flight data from the probe so that trajectory reconstruction could be done and simulation models assessed. Trajectory reconstruction of the Huygens entry probe at Titan was accomplished using two independent approaches: a traditional method and a POST2-based method. Results from both approaches are discussed in this paper.

Striepe, Scott A.↗
NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This pa- per provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗
NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This paper provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗
NASA NTRS2011

Innovative Comparison of Transient Ignition Temperature at the Booster Interface, New Stainless Steel Pyrovalve Primer Chamber Assembly "V" (PCA) Design Versus the Current Aluminum "Y" PCA Design

An assessment of four spacecraft pyrovalve anomalies that occurred during ground testing was conducted by the NASA Engineering & Safety Center (NESC) in 2008. In all four cases, a common aluminum (Al) primer chamber assembly (PCA) was used with dual NASA Standard Initiators (NSIs) and the nearly simultaneous (separated by less than 80 microseconds) firing of both initiators failed to ignite the booster charge. The results of the assessment and associated test program were reported in AIAA Paper AIAA-2008-4798, NESC Independent Assessment of Pyrovalve Ground Test Anomalies. As a result of the four Al PCA anomalies, and the test results and findings of the NESC assessment, the Mars Science Laboratory (MSL) project team decided to make changes to the PCA. The material for the PCA body was changed from aluminum (Al) to stainless steel (SS) to avoid melting, distortion, and potential leakage of the NSI flow passages when the device functioned. The flow passages, which were interconnected in a Y-shaped configuration (Y-PCA) in the original design, were changed to a V-shaped configuration (V-PCA). The V-shape was used to more efficiently transfer energy from the NSIs to the booster. Development and qualification testing of the new design clearly demonstrated faster booster ignition times compared to the legacy AL Y-PCA design. However, the final NESC assessment report recommended that the SS V-PCA be experimentally characterized and quantitatively compared to the Al Y-PCA design. This data was deemed important for properly evaluating the design options for future NASA projects. This test program has successfully quantified the improvement of the SS V-PCA over the Al Y-PCA. A phase B of the project was also conducted and evaluated the effect of firing command skew and enlargement of flame channels to further assist spacecraft applications.

Saulsberry, Regor L.↗
NASA NTRS2016

Infrared Observations of the Orion Capsule During EFT-1 Hypersonic Reentry

High-resolution infrared observations of the Orion capsule during its atmospheric reentry on December 5, 2015 were made from a US Navy NP-3D. This aircraft, equipped with a long-range optical sensor system, tracked the capsule from Mach 10 to 7 from a distance of approximately 60 nmi. Global surface temperatures of the capsule's thermal heatshield were derived from near infrared intensity measurements. The global surface temperature measurements complemented onboard instrumentation and were invaluable to the interpretation of the in-depth thermocouple measurements which rely on inverse heat transfer methods and material response codes to infer the desired surface temperature from the sub-surface measurements. The full paper will address the motivations behind the NASA Engineering Safety Center sponsored observation and highlight premission planning processes with an emphasis on aircraft placement, optimal instrument configuration and sensor calibrations. Critical aspects of mission operations coordinated from the NASA Johnson Spaceflight Center and integration with the JSC Flight Test Management Office will be discussed. A summary of the imagery that was obtained and processed to global surface temperature will be presented. At the capsule's point of closest approach relative to the imaging system, the spatial resolution was estimated to be approximately 15-inches per pixel and was sufficient to identify localized temperature increases associated with compression pad support hardware on the heatshield. The full paper will discuss the synergy of the quantitative imagery derived temperature maps with in-situ thermocouple measurements. Comparison of limited onboard surface thermocouple data to the image derived surface temperature will be presented. The two complimentary measurements serve as an example of the effective leveraging of resources to advance the understanding of high Mach number environments associated with an ablated heatshield and provide unique data for the validation of design tools and numerical flight simulation techniques. Collaborative opportunities and technology investments in support of planned observations of NASA's next Orion flight test in 2018 will be explored in the full manuscript.

Horvath, Thomas J.↗
NASA NTRS2017

Modeling to Mars: a NASA Model Based Systems Engineering Pathfinder Effort

The NASA Engineering Safety Center (NESC) Systems Engineering (SE) Technical Discipline Team (TDT) initiated the Model Based Systems Engineering (MBSE) Pathfinder effort in FY16. The goals and objectives of the MBSE Pathfinder include developing and advancing MBSE capability across NASA, applying MBSE to real NASA issues, and capturing issues and opportunities surrounding MBSE. The Pathfinder effort consisted of four teams, with each team addressing a particular focus area. This paper focuses on Pathfinder team 1 with the focus area of architectures and mission campaigns. These efforts covered the timeframe of February 2016 through September 2016. The team was comprised of eight team members from seven NASA Centers (Glenn Research Center, Langley Research Center, Ames Research Center, Goddard Space Flight Center IV&V Facility, Johnson Space Center, Marshall Space Flight Center, and Stennis Space Center). Collectively, the team had varying levels of knowledge, skills and expertise in systems engineering and MBSE. The team applied their existing and newly acquired system modeling knowledge and expertise to develop modeling products for a campaign (Program) of crew and cargo missions (Projects) to establish a human presence on Mars utilizing In-Situ Resource Utilization (ISRU). Pathfinder team 1 developed a subset of modeling products that are required for a Program System Requirement Review (SRR)/System Design Review (SDR) and Project Mission Concept Review (MCR)/SRR as defined in NASA Procedural Requirements. Additionally, Team 1 was able to perform and demonstrate some trades and constraint analyses. At the end of these efforts, over twenty lessons learned and recommended next steps have been identified.

Phojanamongkolkij, Nipa↗
NASA NTRS2009

Spacecraft Electrical Connector Selection and Application Processes

This assessment was initiated by the NASA Engineering & Safety Center (NESC) after a number of recent "high profile" connector problems, the most visible and publicized of these being the problem with the Space Shuttle's Engine Cut-Off System cryogenic feed-thru connector. The NESC commissioned a review of NASA's connector selection and application processes for space flight applications, including how lessons learned and past problem records are fed back into the processes to avoid recurring issues. Team members were primarily from the various NASA Centers and included connector and electrical parts specialists. The commissioned study was conducted on spacecraft connector selection and application processes at NASA Centers. The team also compared the NASA spacecraft connector selection and application process to the military process, identified recent high profile connector failures, and analyzed problem report data looking for trends and common occurrences. The team characterized NASA's connector problem experience into a list of top connector issues based on anecdotal evidence of a system's impact and commonality between Centers. These top issues are as follows, in no particular rank order: electrically shorted, bent and/or recessed contact pins, contact pin/socket contamination leading to electrically open or intermittencies, connector plating corrosion or corrosion of connector components, low or inadequate contact pin retention forces, contact crimp failures, unmated connectors and mis-wiring due to workmanship errors during installation or maintenance, loose connectors due to manufacturing defects such as wavy washer and worn bayonet retention, damaged connector elastomeric seals and cryogenic connector failure. A survey was also conducted of SAE Connector AE-8C1 committee members regarding their experience relative to the NASA concerns on connectors. The most common responses in order of occurrence were contact retention, plating issues, worn-out or damaged coupling mechanisms, bent pins, contact crimp barrel cracking and torn seals. In addition to these common themes, responses included issues with markings, dimensional errors on the build, contact/socket damage (handling), manufacturing defects and customer misapplication and mishandling. The NESC team concluded that considering the large quantity and wide variety of connectors successfully flown on human and robotic space applications, the number of failures is quite low. However, "high profile" failures with significant cost, schedule, safety, and/or mission success impacts continue to occur. It was also concluded that connector failures occur throughout a system's life-cycle with the majority of connector issues application related. A number of recommendations were identified for improving NASA connector selection processes and overall space connector reliability and performance.

Iannello, Chris↗
NASA NTRS2010

Design and Analysis of Outer Mold Line Close-outs for the Max Launch Abort System (MLAS) Flight Experiment

In 2007, the NASA Exploration Systems Mission Directorate (ESMD) chartered the NASA Engineering Safety Center (NESC) to demonstrate an alternate launch abort concept as risk mitigation for the Orion project's baseline "tower" design. On July 8, 2009, a full scale, passive aerodynamically stabilized Max Launch Abort System (MLAS) pad abort demonstrator was successfully launched from NASA Goddard Space Flight Center's Wallops Flight Facility. Aerodynamic close-outs were required to cover openings on the MLAS fairing to prevent aerodynamic flow-through and to maintain the MLAS OML surface shape. Two-ply duct tape covers were designed to meet these needs. The duct tape used was a high strength fiber reinforced duct tape with a rubberized adhesive that demonstrated 4.6 lb/in adhesion strength to the unpainted fiberglass fairing. Adhesion strength was observed to increase as a function of time. The covers were analyzed and experimentally tested to demonstrate their ability to maintain integrity under anticipated vehicle ascent pressure loads and to not impede firing of the drogue chute mortars. Testing included vacuum testing and a mortar fire test. Tape covers were layed-up on thin Teflon sheets to facilitate installation on the vehicle. Custom cut foam insulation board was used to fill mortar hole and separation joint cavities and provide support to the applied tape covers. Flight test results showed that the tape covers remained adhered during flight.

Woods-Vedeler, Jessica A.↗
NASA NTRS2021

Spacecraft Line-Of-Sight Jitter Management and Mitigation Lessons Learned And Engineering Best Practices

Predicting, managing, controlling, and testing spacecraft line-of-sight (LoS) jitter caused by micro-vibrations due to on-board internal disturbance sources is a formidable multidisciplinary engineering task. It is especially challenging for those missions hosting high-performance (e.g., nano-radian/milli-arcsecond class), vibration-sensitive optical sensor payloads with stringent pointing stability requirements. The Nation Aeronautics and Space Administration (NASA) and the European Space Agency (ESA) are planning technically aggressive spaceflight missions that include ultra-high-performance optical payloads with delicate, highly vibration-sensitive scientific and observational instruments. The guidance, navigation, and control community of practice will need to leverage collective experiences and document their best practices and lessons learned to address future micro-vibration challenges. To identify lessons learned and best practices the NASA Engineering & Safety Center sponsored a 2-day Spacecraft LoS Jitter Workshop in late 2019. The workshop’s goal was to provide a multidisciplinary forum to elicit deeper understanding of the issues related to addressing the spacecraft LoS jitter/micro-vibration problem. The primary objective was to identify, document, and share lessons learned, best practices, and preferred options for jitter-related analysis and test activities. Representatives from NASA, ESA, along with NASA’s industrial partners, independent consultant subject matter experts, and members of academia participated in the workshop. This paper will describe the motivation for the workshop and summarize the identified findings and recommendations.

Swanson, Davin K.↗
NASA NTRS2011

Grid Fin Stabilization of the Orion Launch Abort Vehicle

Wind tunnel tests were conducted by Nielsen Engineering & Research (NEAR) and Rose Engineering & Research (REAR) in conjunction with the NASA Engineering & Safety Center (NESC) on a 6%-scale model of the Orion launch abort vehicle (LAV) configured with four grid fins mounted near the base of the vehicle. The objectives of these tests were to 1) quantify LAV stability augmentation provided by the grid fins from subsonic through supersonic Mach numbers, 2) assess the benefits of swept grid fins versus unswept grid fins on the LAV, 3) determine the effects of the LAV abort motors on grid fin aerodynamics, and 4) generate an aerodynamic database for use in the future application of grid fins to small length-to-diameter ratio vehicles similar to the LAV. The tests were conducted in NASA Ames Research Center's 11x11-foot transonic wind tunnel from Mach 0.5 through Mach 1.3 and in their 9x7-foot supersonic wind tunnel from Mach 1.6 through Mach 2.5. Force- and moment-coefficient data were collected for the complete vehicle and for each individual grid fin as a function of angle of attack and sideslip angle. Tests were conducted with both swept and unswept grid fins with the simulated abort motors (cold jets) off and on. The swept grid fins were designed with a 22.5deg aft sweep angle for both the frame and the internal lattice so that the frontal projection of the swept fins was the same as for the unswept fins. Data from these tests indicate that both unswept and swept grid fins provide significant improvements in pitch stability as compared to the baseline vehicle over the Mach number range investigated. The swept fins typically provide improved stability as compared to the unswept fins, but the performance gap diminished as Mach number was increased. The aerodynamic performance of the fins was not observed to degrade when the abort motors were turned on. Results from these tests indicate that grid fins can be a robust solution for stabilizing the Orion LAV over a wide range of operating conditions.

Pruzan, Daniel A.↗
NASA NTRS2005

Inspection of the Math Model Tools for On-Orbit Assessment of Impact Damage Report

In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments, and real-time on-orbit assessments. The tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.

Harris, Charles E.↗
NASA NTRS2006

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.

Sutter, James K.↗
NASA NTRS2007

Strain Measurement Using FBG on COPV in Stress Rupture Test

White Sands Test Facility (WSTF) was requested to perform ambient temperature hydrostatic pressurization testing of a Space Transportation System (STS) 40-in. Kevlar Composite Overwrapped Pressure Vessel (COPV). The 40-in. vessel was of the same design and approximate age as the STS Main Propulsion System (MPS) and Orbiter Maneuvering System (OMS) vessels. The NASA Engineering Safety Center (NESC) assembled a team of experts and conducted an assessment that involved a review of national Kevlar COPY data. During the review, the STS COPVs were found to be beyond their original certification of ten years. The team observed that the likelihood of STS COPV Stress rupture, a catastrophic burst before leak failure mode, was greater than previously believed. Consequently, a detailed assessment of remaining stress rupture life became necessary. Prior to STS-114, a certification deviation was written for two flights of OV-103 (Discovery) and OV-104 (Atlantis) per rationale that was based on an extensive review of the Lawrence Livermore National Laboratories, COPV data, and revisions to the STS COPV stress levels. In order to obtain flight rationale to extend the certification deviation through the end of the Program, the Orbiter Project Office has directed an interagency COPV team to conduct further testing and analysis to investigate conservatism in the stress rupture model and evaluate material age degradation. Additional analysis of stress rupture life requires understanding the fiber stresses including stress that occurs due to thru-wall composite compression in COPV components. Data must be obtained at both zero gauge pressure (pre-stress) and at the component operating pressure so that this phenomenon can be properly evaluated. The zero gauge pressure stresses are predominantly a result of the autofrettage process used during vessel manufacture. Determining these pre-stresses and the constitutive behavior of the overwrap at pressure will provide necessary information to better predict the remaining life of the STS COPVs. The primary test objective is obtaining data to verify the hypothesis of a radially oriented thru-thickness stress-riser in the COPV composite whose magnitude is a function of the applied pressure and the load history. The anticipated load dependent response follows from the constitutive behavior of the composite overwrap so data to quantify its nonlinear and time dependent response will be sought. The objective of the Fiber Braggs Gratings (FBGs) were to advance the state-of-the-art by developing techniques using FBG sensors that are capable of assessing stress-rupture degradation in Kevlar COPVs in a health monitoring mode (1). Moreover, they sought to answer questions of how embedded sensors affect overall integrity of the structure. And lastly, they sought to provide an important link in the overall stress rupture study that will help close the loop on the COPV fabrication process. NDE inspection methods will be used from start to finish and FBG will be an integral link within the overall chain.

Banks, Curtis↗
NASA NTRS2007

Astronaut Risk Levels During Crew Module (CM) Land Landing

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

Lawrence, Charles↗