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NASA NTRS2010

Tracking Data Certification for the Lunar Reconnaissance Orbiter

This paper details the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) Flight Dynamics Facility (FDF) tracking data certification effort of the Lunar Reconnaissance Orbiter (LRO) Space Communications Network (SCN) complement of tracking stations consisting of the NASA White Sands 1 antenna (WS1), and the commercial provider Universal Space Network (USN) antennas at South Point, Hawaii; Dongara Australia; Weilheim, Germany; and Kiruna, Sweden. Certification assessment required the cooperation and coordination of parties not under the control of either the LRO project or ground stations as uplinks on cooperating spacecraft were necessary. The LRO range-tracking requirement of 10m 1 sigma could be satisfactorily demonstrated using any typical spacecraft capable of range tracking. Though typical Low Earth Orbiting (LEO) or Geosynchronous Earth Orbiting (GEO) spacecraft may be adequate for range certification, their measurement dynamics and noise would be unacceptable for proper Doppler certification of 1-3mm/sec 1 sigma. As LRO will orbit the Moon, it was imperative that a suitable target spacecraft be utilized which can closely mimic the expected lunar orbital Doppler dynamics of +/-1.6km/sec and +/-1.5m/sq sec to +/-0.15m/sq sec, is in view of the ground stations, supports coherent S-Band Doppler tracking measurements, and can be modeled by the FDF. In order to meet the LRO metric tracking data specifications, the SCN ground stations employed previously uncertified numerically controlled tracking receivers. Initial certification testing revealed certain characteristics of the units that required resolution before being granted certification.

Morinelli, Patrick J.↗

NASA NTRS1968

Development of acoustic test conditions for Apollo lunar module flight certification

Acoustic test conditions to verify structural and component integrity of Apollo lunar module

Dorland, W. D.↗

NASA NTRS2021

Best Practices Identified Through the Completion of UAS Flight Demonstrations

After several years of research into Detect and Avoid (DAA) and Command and Control (C2) systems for Unmanned Aircraft Systems (UAS), the National Aeronautics and Space Administration’s (NASA) UAS Integration into the National Airspace System project initiated a focused two-year effort along with the Federal Aviation Administration (FAA) and three industry partners to investigate remaining issues in the specification, test, certification and airspace integration to allow UAS operations in non-segregated airspace. The approach taken had the industry partners propose a flight demonstration approximating a commercial operation, while NASA helped, as needed, the partners through design and test phases and NASA observed interactions with the FAA. During this effort NASA collected best practices intended to be of value to similar UAS endeavors. These best practices can be divided into different sets, including practices that describe the relationship between business considerations to UAS design or describe several UAS development challenges. Another set includes best practices focused on navigating the UAS design and type certification processes. A third set includes best practices that relate to the design of the DAA system. Deploying DAA systems in this timeframe posed unique challenges. Commercial off-the-shelf DAA systems do not exist, necessitating custom development and, for two of the partners, the use of low-size, -weight, and -power (SWaP) sensors not completely specified for DAA. A fourth set of best practices relates to lost-link contingency planning. The final set of best practices relates to the design and testing of C2 systems and obtaining spectrum licenses. The UAS demonstrations were piloted remotely, and for all aspects of flight safety, a C2 system was required to communicate DAA and other UAS subsystem data to the remote pilot and to allow the pilot to issue commands to the vehicle. Throughout the course of this effort, the partners integrated prototype DAA and C2 systems into unmanned aircraft, tested those systems, and laid the groundwork for type certification programs that are expected to continue.

NASA↗

NASA NTRS2017

MELDI2 Do No Harm Test Series

Mars 2020 will fly the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) sensor suite consisting of a total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer embedded in the thermal protection system (TPS). Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020's predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12" by 12" test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuum/ cycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation. This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

Heatshield↗

NASA NTRS2017

Mars2020 Entry, Descent, and Landing Instrumentation 2 (MEDLI2) Do No Harm Test Series

A total of seventeen instrumented thermal sensor plugs, eight pressure transducers, two heat flux sensors, and one radiometer are planned to be utilized on the Mars 2020 missions thermal protection system (TPS) as part of the Mars Entry, Descent, and Landing Instrumentation II (MEDLI2) project. Of the MEDLI2 instrumentation, eleven instrumented thermal plugs and seven pressure transducers will be installed on the heatshield of the Mars 2020 vehicle while the rest will be installed on the backshell. The goal of the MEDLI2 instrumentation is to directly inform the large performance uncertainties that contribute to the design and validation of a Mars entry system. A better understanding of the entry environment and TPS performance could lead to reduced design margins enabling a greater payload mass-fraction and smaller landing ellipses. To prove that the MEDLI2 system will not degrade the performance of the Mars 2020 TPS, an Aerothermal Do No Harm (DNH) test series was designed and conducted. Like Mars 2020s predecessor, Mars Science Laboratory (MSL), the heatshield material will be Phenolic Impregnated Carbon Ablator (PICA); the Mars 2020 entry conditions are enveloped by the MSL design environments, therefore the development and qualification testing performed during MEDLI is sufficient to show that the similar MEDLI2 heatshield instrumentation will not degrade PICA performance. However, given that MEDLI did not include any backshell instrumentation, the MEDLI2 team was required to design and execute a DNH test series utilizing the backshell TPS material (SLA-561V) with the intended flight sensor suite. To meet the requirements handed down from Mars 2020, the MEDLI2 DNH test series emphasized the interaction between the MEDLI2 sensors and sensing locations with the surrounding backshell TPS and substrucutre. These interactions were characterized by performing environmental testing of four 12 by 12 test panels, which mimicked the construction of the backshell TPS and the integration of the MEDLI2 sensors as seen in Figure 1. The testing included thermal vacuumcycling, random vibration, shock, and arc jet testing. The test panels were fabricated by Lockheed Martin, establishing techniques that will be utilized during the Mars 2020 vehicle installation. Each test panel included one thermal sensor plug (two embedded thermocouples), one heat flux sensor, and multiple pressure port holes for evaluation.This presentation will discuss the planning and execution of the MEDLI2 DNH test series. Selected highlights and results of each environmental test will be presented, and lessons learned will be addressed that will feed forward into the planning for the MEDLI2 flight system certification testing.

backshell↗

NASA NTRS1995

Acoustic flight tests of rotorcraft noise-abatement approaches using local differential GPS guidance

This paper presents the test design, instrumentation set-up, data acquisition, and the results of an acoustic flight experiment to study how noise due to blade-vortex interaction (BVI) may be alleviated. The flight experiment was conducted using the NASA/Army Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) research helicopter. A Local Differential Global Positioning System (LDGPS) was used for precision navigation and cockpit display guidance. A laser-based rotor state measurement system on board the aircraft was used to measure the main rotor tip-path-plane angle-of-attack. Tests were performed at Crows Landing Airfield in northern California with an array of microphones similar to that used in the standard ICAO/FAA noise certification test. The methodology used in the design of a RASCAL-specific, multi-segment, decelerating approach profile for BVI noise abatement is described, and the flight data pertaining to the flight technical errors and the acoustic data for assessing the noise reduction effectiveness are reported.

Chen, Robert T. N.↗

NASA NTRS2011

Design, Development and Test Challenges: Separation Mechanisms for the Orion Pad Abort-1 Flight Test

On May 6, 2010, NASA launched the first successful integrated flight test, Pad Abort-1, of the Orion Project from the White Sands Missile Range in Las Cruces, New Mexico. This test demonstrated the ability to perform an emergency pad abort of a full-scale 4.8 m diameter, 8200 kg crew capsule. During development of the critical separation mechanisms for this flight test, various challenges were overcome related to environments definition, installation complications, separation joint retraction speed, thruster ordnance development issues, load path validation and significant design loads increases. The Launch Abort System retention and release (LAS R&R) mechanism consisted of 6 discrete structural connections between the LAS and the crew module (CM) simulator, each of which had a preloaded tension tie, Superbolt torque-nut and frangible nut. During the flight test, the frangible nuts were pyrotechnically split, permitting the CM to separate from the LAS. The LAS separation event was the driving case in the shock environment for many co-located hardware items. During development testing, it was necessary to measure the source shock during the separation event so the predicted shock environment could be validated and used for certification testing of multiple hardware items. The Lockheed Martin test team measured the source separation shock due to the LAS R&R function, which dramatically decreased the predicted environment by 90% at 100 Hz. During development testing a hydraulic tensioner was used to preload the joint; however, the joint relaxation with the tensioner proved unsatisfactory so the design was modified to include a Superbolt torque-nut. The observed preload creep during lab testing was 4% after 30 days, with 2.5% occurring in the first 24 hours. The conversion of strain energy (preload) to kinetic energy (retraction) was measured to be 50-75%. Design features and careful monitoring of multiple strain gauges on each tension tie allowed a pure tensile load to be applied after stacking at the launch pad. Following installation, preload in each joint was monitored for 24 hours. Due to unforeseen complications and the influence of temperature on the portable data acquisition system, the team encountered difficulty in tracking the joint relaxation. In some cases, bond-line failure of the strain gauges occurred.

Dinsel, Alison↗

NASA NTRS1999

Successful Solutions to SSME/AT Development Turbine Blade Distress

As part of the High-Pressure Fuel Turbopump/Alternate Turbopump (HPFTP/AT) turbine blade development program, unique turbine blade design features were implemented to address 2nd stage turbine blade high cycle fatigue distress and improve turbine robustness. Features included the addition of platform featherseal dampers, asymmetric blade tip seal segments, gold plating of the blade attachments, and airfoil tip trailing edge modifications. Development testing shows these features have eliminated turbine blade high cycle fatigue distress and consequently these features are currently planned for incorporation to the flight configuration. Certification testing will begin in 1999. This presentation summarizes these features.

Montgomery, Stuart K.↗

NASA NTRS2024

Hopkinson Bar Impact Force Measurement for Application to Development of an Artificial Bird

A test method has been published for measuring forces from bird cadavers and artificial birds to demonstrate equivalency to support the use of artificial birds in aircraft certification testing. The test method involves a large diameter Hopkinson bar as the technique for measuring and comparing forces. The method involves the assumption that a force on one end of the bar results in a one-dimensional plane wave that travels down the bar. To avoid reflected waves from the end of the bar overlapping the input pulse, and due to practical limitations on the length of the bar, strain transducers are located relatively close to the impacted face of the bar, raising questions about the validity of the assumption of one-dimensional wave propagation. In addition, the large diameter of the bar can introduce dispersion effects in the propagated pulse. These must be assessed to determine the impact on the accuracy of impact force measurements and, if significant, dispersion correction techniques must be used. In this study analytical, experimental, and computational methods are used to analyze the wave propagation characteristics for impact forces expected from realistic bird impacts. While wave dispersion and effects of non-concentric impacts are present, the resulting errors are relatively small. For the response we expect to see in bird impacts up to velocities of approximately 300 m/sec the large diameter Hopkinson bar test appears to be an acceptable method for measuring the impact forces and comparing the response of real and proposed artificial birds.

Birdstrike↗

NASA NTRS1979

Development and testing of a hot-air solar collector

Summarized report on development and testing of hot-air flat-plate solar collector includes structural details, coating selection, and spacing between coating and glass plate. Report gives complete performance specifications and extensive certifications test report.

Caudle, J. M.↗

NASA NTRS1990

Summary of JAYGO mixing and FSM-1 application of castable inhibitor and liner

Two JAYGO planetary mixers (12 and 42 gallon) are being qualified to mix STW5-3224 liner and STW5-3223 castable inhibitor. These mixers are an integral part of a mix process which allows for safe addition of the asbestos component. An essential part of the engineering evaluation (ETP-0347) of these mixers is the generation of static test fire data. Ultimately, these results will help confirm the adequacy of these mixers for production mixing of liner and inhibitor. (These data are not required for qualification of the Certification Test Plan CTP-0125). The details on the mixing, inhibiting, and sling-lining of JAYGO-mixed castable inhibitor and liner which were applied to the FSM-1 segments are presented. The objectives are the following: (1) to document processing events surrounding the JAYO mixing of castable inhibitor and liner, and the subsequent inhibiting and sling lining onto the FSM-1 segments; and (2) to substantiate the measured properties of these JAYGO-mixed materials (rheological and mechanical) and compare these properties to existing production database.

Evans, Kurt B.↗

NASA NTRS2002

Human Factors Process Task Analysis Liquid Oxygen Pump Acceptance Test Procedure for the Advanced Technology Development Center

A process task analysis effort was undertaken by Dynacs Inc. commencing in June 2002 under contract from NASA YA-D6. Funding was provided through NASA's Ames Research Center (ARC), Code M/HQ, and Industrial Engineering and Safety (IES). The John F. Kennedy Space Center (KSC) Engineering Development Contract (EDC) Task Order was 5SMA768. The scope of the effort was to conduct a Human Factors Process Failure Modes and Effects Analysis (HF PFMEA) of a hazardous activity and provide recommendations to eliminate or reduce the effects of errors caused by human factors. The Liquid Oxygen (LOX) Pump Acceptance Test Procedure (ATP) was selected for this analysis. The HF PFMEA table (see appendix A) provides an analysis of six major categories evaluated for this study. These categories include Personnel Certification, Test Procedure Format, Test Procedure Safety Controls, Test Article Data, Instrumentation, and Voice Communication. For each specific requirement listed in appendix A, the following topics were addressed: Requirement, Potential Human Error, Performance-Shaping Factors, Potential Effects of the Error, Barriers and Controls, Risk Priority Numbers, and Recommended Actions. This report summarizes findings and gives recommendations as determined by the data contained in appendix A. It also includes a discussion of technology barriers and challenges to performing task analyses, as well as lessons learned. The HF PFMEA table in appendix A recommends the use of accepted and required safety criteria in order to reduce the risk of human error. The items with the highest risk priority numbers should receive the greatest amount of consideration. Implementation of the recommendations will result in a safer operation for all personnel.

Diorio, Kimberly A.↗

NASA NTRS2013

Active Matrix OLED Test Report

This report focuses on the limited environmental testing of the AMOLED display performed as an engineering evaluation by The NASA Johnson Space Center (JSC)-specifically. EMI. Thermal Vac, and radiation tests. The AMOLED display is an active-matrix Organic Light Emitting Diode (OLED) technology. The testing provided an initial understanding of the technology and its suitability for space applications. Relative to light emitting diode (LED) displays or liquid crystal displays (LCDs), AMOLED displays provide a superior viewing experience even though they are much lighter and smaller, produce higher contrast ratio and richer colors, and require less power to operate than LCDs. However, AMOLED technology has not been demonstrated in a space environment. Therefore, some risks with the technology must be addressed before they can be seriously considered for human spaceflight. The environmental tests provided preliminary performance data on the ability of the display technology to handle some of the simulated induced space/spacecraft environments that an AMOLED display will see during a spacecraft certification test program. This engineering evaluation is part of a Space Act Agreement (SM) between The NASA/JSC and Honeywell International (HI) as a collaborative effort to evaluate the potential use of AMOLED technology for future human spaceflight missions- both government-led and commercial. Under this SM, HI is responsible for doing optical performance evaluation, as well as temperature and touch screen studies. The NASA/JSC is responsible for performing environmental testing comprised of EMI, Thermal Vac, and radiation tests. Additionally, as part of the testing, limited optical data was acquired to assess performance as the display was subjected to the induced environments. The NASA will benefit from this engineering evaluation by understanding AMOLED suitability for future use in space as well as becoming a smarter buyer (or developer) of the technology. HI benefits from the environmental testing results by understanding its performance limitations/shortcomings to improve subsequent generations of AMOLED technology. Note that the AMOLED used in this test was not deSigned for the space environment but rather for commercial/industrial terrestrial applications.

Salazar, George↗

NASA NTRS2013

Active Matrix Organic Light Emitting Diode (AMOLED) Environmental Test Report

Salazar, George A.↗

NASA NTRS2009

Synergistic Development, Test, and Qualification Approaches for the Ares I and V Launch Vehicles

The U.S. National Aeronautics and Space Administration is designing and developing the Ares I and Ares V launch vehicles for access to the International Space Station (ISS) and human exploration of the Moon. The Ares I consists of a first stage reusable five-segment solid rocket booster, a upper stage using a J-2X engine derived from heritage experience (Saturn and Space Shuttle External Tank programs), and the Orion crew exploration vehicle (CEV). The Ares V is designed to minimize the development and overall life-cycle costs by leveraging off of the Ares I design. The Ares V consists of two boosters, a core stage, an earth departure stage (EDS), and a shroud. The core stage and EDS use LH2/LO2 propellants, metallic propellant tanks, and composite dry structures. The core stage has six RS-68B upgraded Delta IV engines while the EDS uses a J-2X engine for second stage ascent and trans-lunar injection (TLI) burn. System and propulsion tests and qualification approaches for Ares V elements are being considered as follow-on extensions of the Ares I development program. Following Ares I IOC, testing will be conducted to verify the J-2X engine's orbital restart and TLI burn capability. The Ares I upper stage operation will be demonstrated through integrated stage development and acceptance testing. The EDS will undergo similar development and acceptance testing with additional testing to verify aspects of cryogenic propellant management, operation of sub-systems in a space simulation environment, and orbital re-start of the main propulsion system. RS-68B certification testing will be conducted along with integrated core stage development and acceptance testing. Structural testing of the Ares V EDS and core stage propellant tanks will be conducted similar to the Ares I upper stage. The structural qualification testing may be accomplished with separate propellant tank test articles. Structural development and qualification testing of the dry structure will be pursued as part of the design and development process. Especially critical is the development test program for the composite structures. The Ares V payload shroud will undergo acoustic, vibration, structural qualification, and deployment testing in a space simulation environment. Similar to Ares I, requirements for full-scale structural dynamic testing are being studied. Both Ares I and Ares V include validation flight testing as part of the qualification programs.

Cockrell, Charles E.↗

NASA NTRS2007

Integrated System Test Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew access to the International Space Station (ISS) and, together with the Ares V Cargo Launch Vehicle (CaLV), serves as one component of a future launch capability for human exploration of the Moon. During the system requirements definition process and early design cycles, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements: the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine, will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle dynamic test (IVDT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, and a highaltitude actuation of the launch abort system (LAS) following separation. The Orion-1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Cockrell, Charles E., Jr.↗

NASA NTRS1974

United States manned spacecraft reliability experience

Attention is given to the reliability controls in manned spacecraft programs, taking into account the project Mercury, the Gemini program, the Apollo program, the Skylab program, and the Apollo-Soyuz test project. Reliability controls used in these programs are related to reliability management, parts and materials control, failure mode and effects analysis, reliability quantitative analysis, problem reporting and corrective action control, test control, limited-life control, and milestone reviews. A summary is presented of the major reliability tasks and innovations being used on the Space Shuttle program. Examples of these innovations include improved management techniques and an early identification of specific certification tests.

Kleinknecht, K. S.↗

NASA NTRS2008

Integrated Testing Approaches for the NASA Ares I Crew Launch Vehicle

The Ares I crew launch vehicle is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew and cargo access to the International Space Station (ISS) and, together with the Ares V cargo launch vehicle, serves as a critical component of NASA's future human exploration of the Moon. During the preliminary design phase, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements - including the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine - will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the upper stage Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle ground vibration test (IVGVT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, validate the ability of the upper stage to manage cryogenic propellants to achieve upper stage engine start conditions, and a high-altitude demonstration of the launch abort system (LAS) following stage separation. The Orion 1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.

Taylor, James L.↗