Results for “lessons learned process” — Page 4

NASA NTRS2018

Capture Latch Assembly for the NASA Docking System

Final Paper and not the abstract is attached. a summary of the Design, Development, and Qualification of the Capture Latch Assembly (CLA) for the NASA Docking System Block 1 (NDSB1). The CLA is an integral part of the Soft Capture System (SCS) of the NDSB1, serving the purpose of connecting the mating SCS Rings of two docking vehicles. The paper will present an overview of the function of the CLA and its basic concept of operations, including a summary of the major components of the CLA. The development, qualification, and production of the CLA will then be described. Particular focus will be provided on two major issues that occurred during production and qualification of the CLA. The first issue was failures of the CLA Motor (CLM) during acceptance testing (AT). The failures of the CLM were ultimately determined to be due to design defects and manufacturing errors in the motor commutation sensor assembly. The second issue was failure of the secondary release mechanism, or Contingency Capture Latch Release (CCLR) mechanism during development and qualification testing. The CCLR failures were found to be a result of excess free play in the release mechanism, resulting in wear leading to galling inside the release mechanism. An overview of each failure will be provided, along with a summary of the failure investigation and recovery process. Finally, Lessons Learned from each of the major issues and the overall development of the Capture Latch will be presented.

Capture Latch↗

NASA NTRS2018

Fractographic Analysis of 60-Nitinol Bearing Races

Fracture surfaces on a failed bearing race made from 60-Nitinol (60 wt% Ni - 40 wt% Ti) were analyzed. The bearing had experienced excessive localized heat due to an issue during machining that may have resulted in dimensional distortion. However, the classical fracture features that were identified by scanning electron microscopy and the fracture origins coincided with high concentrations of TiC-based contamination. Lessons learned for processing and quality control are discussed. An attempt to use x-ray diffraction to directly measure residual stresses imparted from the required heat treatment is also discussed.

intermetallics↗

NASA NTRS2018

Design, Fabrication, and Critical Current Testing of No-Insulation Superconducting Rotor Coils for NASA's High-Efficiency Megawatt Motor

NASA Glenn Research Center is developing a 1.4~MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper discusses the fabrication of the no-insulation high temperature superconducting (HTS) coils and presents the lessons learned. The process is compared to the fabrication of conventionally insulated HTS coils. Testing of the coils' critical current at liquid nitrogen temperature is also presented. The influence of thermal cycling on the critical current and n-value is studied.

Scheidler, Justin J.↗

NASA NTRS2018

LADEE Simulation for Mission Operations

The Lunar Atmosphere Dust Environment Explorer (LADEE) model-based spacecraft simulator has been discussed previously at the Workshop on Spacecraft Flight Software including the verification and validation of the flight software, hardware integration of payloads, and multi-domain simulation. In addition to flight software development and testing the LADEE simulator was used by Mission Operations to develop and test spacecraft command scripts, train operators during mission simulations, verification of all tactical command sequence files uploaded to spacecraft during flight.This presentation will discuss the experience of the LADEE operations team using the spacecraft simulator including implementation, processes and lessons learned. We will also discuss a specific instance where the simulator was used in operations to debug and design a software fix for a spacecraft anomaly experienced with the star tracker.

Operations↗

NASA NTRS2014

Development of a Route Crossing Tool for Shared Airspace Environments

In current-day Terminal Radar Approach Control (TRACON) operations, departure and arrival controllers maintain separate and dedicated airspace for their respective traffic flows. Although this practice has obvious safety features, it also leads to inefficiencies; for example, departure aircraft may be routinely capped beneath arrival airspace. With the right decision-support and coordination tools, departures could continue to climb through arrival airspace when sufficient gaps exist. Previous studies of ‘shared airspace’ have examined pre-arranged coordination procedures, as well as tools that gave feedback to the controllers on where gaps between arrivals were located and whether the departure aircraft could be scheduled to fly through those gaps [1, 2, 3, 4]. Since then, the Route Crossing Tool (RCT) has been developed to allow controllers to assess multiple pre-defined route options at points where the arrivals and departures cross, thereby increasing the possibility of climbing a departure through an arrival gap.The RCT aids in ensuring lateral separation between departure and arrival aircraft that pass through the same altitude. Since the RCT can be applied tactically, it can enable aircraft to fly through arrival flows even if these aircraft depart outside scheduled times. The RCT makes use of a set of predefined parallel departure routes crossing the arrival flow at equidistant intersecting points on the arrival route. The RCT uses the Estimated Time of Arrival (ETA) of the departure aircraft at each intersecting point to calculate the lateral separation with the neighboring arrivals when it crosses that point; this information is graphically displayed to the controller. Additionally, the RCT incorporates forecast winds in its ETA predictions.Multiple prototypes of the RCT have been iteratively developed with feedback from Subject Matter Experts (SMEs). This paper presents the final design, the design process, and lessons learned. Initial results from a simulation suggest that the tool was successful in helping controllers to safely climb more aircraft. Controller feedback on the tool was also positive.

shared airspace↗

NASA NTRSDate not supplied

Dashboards to Explore Effects of COVID-19 Using Earth Observations

People are reeling from the impacts of the COVID-19 pandemic in every part of the world. As a result,changes in human activity have made visible impacts on ourplanet. To understand these impacts, NASA, ESA (European Space Agency), and JAXA (Japan Aerospace Exploration Agency) joined forces to develop a trilateral dashboard—a situational awareness tool backed by Earth observation derived indicators. An unprecedented collaboration followed for the next two months between the three agencies in which data, science, and technology experts addressed several challenges including indicator development, infrastructure, data management, content development, and communication. “COVID-19 Earth Observation Dashboard” was successfully released offering user-friendly tracking of changes in indicators that include air and water quality, climate, economic activity, and agriculture. This presentation will highlight the outcomes, coordination, technical approaches, collaboration, processes, and lessons learned from the dashboard development.

Manil Maskey↗

NASA NTRS2019

Low-thrust trajectory Bacon plots for Mars mission design

The best way to understand a mission design trade space is by creating a good map of all the possibilities, and by knowing how to read it. Bacon plots, which are low-thrust analogs to porkchop plots, give insight into key parameters and sensitivities of possible transfers to Mars (or other destinations). They are mission and parameter specific, and can be created to represent single or multiple legs. This paper outlines the creation process and lessons learned in interpreting the results. An example is given on how bacon plots have been employed for complex mission-level optimization.

Olikara, Zubin↗

NASA NTRSDate not supplied

Habitability Assessments And Lessons-learned From 3-day And 11-day Enriched Oxygen Hypobaric Chamber Tests At NASA Johnson Space Center

INTRODUCTION: Decompression sickness (DCS) is a risk to the health and performance of astronauts and high-altitude aircrew. Tolerance to flammability, hypoxia, prebreathe duration, and DCS risk varies across different organizations, vehicles, suits, and destinations, necessitating a variety of DCS risk mitigation approaches. Existing models of altitude DCS risk are often insufficient to enable accurate risk-informed decisions during hardware development, mission planning, and flight operations. METHODS: NASA completed outfitting of a dedicated facility at Johnson Space Center to support testing of up to eight human subjects for multiple days in hypobaric and enriched oxygen atmospheres. The primary purpose of the testing capability is validation of DCS risk mitigation protocols for Artemis missions to the Moon; however, it will also support development and validation of a generalizable altitude DCS risk estimation tool. A 3-day and an 11-day prebreathe validation test were completed in 2022, each with 8 human subjects living at 56.5 kPa (8.2 psia), 34% O2, 66% N2, with 5 simulated EVAs performed on masks at 29.6 kPa (4.3 psi), 85% O2, 15% N2. Facility and organizational lessons-learned and process improvements were recorded during and following the tests, and subjective habitability ratings were recorded daily during the 11-day test. Hypoxia and DCS-related physiological and cognitive outcome measures were recorded during both tests and are reported in companion presentations. RESULTS & DISCUSSION: All subjects completed each of the tests. Primary habitability issues related to mask discomfort during simulated EVAs and poor sleep quality due to thin mattresses. Polybenzimidazole (PBI) clothing was worn by all subjects due to the increased fire risk and may be required for Artemis missions; clothing was found to be acceptable overall with the worst ratings being due to poor fit and inelasticity. Chamber O2 and CO2 sensor inconsistency was observed that did not result in test termination but required post-test follow-up. Forward plans include additional hypobaric testing and integration of existing and future physiological outcome data into an open-source Aerospace Estimation Tool for Hypobaric Exposure Risk (AETHER). NASA is also working to make the testing capability available to commercial companies.

Andrew F J Abercromby↗

NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Composite manufacturing↗

NASA NTRSDate not supplied

Manufacturing Trials of Integrally Stiffened Composite Panels Using Automated Fiber Placement

Commercial aircraft structures are frequently manufactured from carbon-epoxy materials because of their weight and stiffness advantages compared to metallic materials. Wing cover panels are regularly manufactured using an automated fiber placement (AFP) process, but current design and manufacturing methodologies do not fully take advantage of the opportunities afforded by AFP. Design and manufacturing studies were undertaken at the NASA Langley Research Center at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to quantify manufacturing benefits and limitations associated with AFP to create structurally efficient integral stiffeners as an alternative to bonded or mechanically fastened stiffeners. This methodology could save weight and remove failure mechanisms by reducing the need for rivets and bonding materials since the stiffener plies are interleaved within the skin plies. The use of AFP with integral stiffeners can open the design space, but a fundamental, systematic evaluation of manufacturing limitations is necessary. Manufacturing trials are described herein, where considered manufacturing variables included stiffener location, stiffener course staggering, stiffener widths, stiffener intersections, and material thicknesses for both the skin and stiffener plies. The manufacturing process and lessons learned from each trial are described, including the most successful current design which contains staggered stiffeners, non-traditional laminate angles, and a combination of multiple material thicknesses within the same laminate.

Automated Fiber Placement↗

NASA NTRSDate not supplied

Habitability Assessments And Lessons-learned From 3-day And 11-day Enriched Oxygen Hypobaric Chamber Tests At NASA Johnson Space Center

INTRODUCTION: Decompression sickness (DCS) is a risk to the health and performance of astronauts and high-altitude aircrew. Tolerance to flammability, hypoxia, prebreathe duration, and DCS risk varies across different organizations, vehicles, suits, and destinations, necessitating a variety of DCS risk mitigation approaches. Existing models of altitude DCS risk are often insufficient to enable accurate risk-informed decisions during hardware development, mission planning, and flight operations. METHODS: NASA completed outfitting of a dedicated facility at Johnson Space Center to support testing of up to eight human subjects for multiple days in hypobaric and enriched oxygen atmospheres. The primary purpose of the testing capability is validation of DCS risk mitigation protocols for Artemis missions to the Moon; however, it will also support development and validation of a generalizable altitude DCS risk estimation tool. A 3-day and an 11-day prebreathe validation test were completed in 2022, each with 8 human subjects living at 56.5 kPa (8.2 psia), 34% O2, 66% N2, with 5 simulated EVAs performed on masks at 29.6 kPa (4.3 psi), 85% O2, 15% N2. Facility and organizational lessons-learned and process improvements were recorded during and following the tests, and subjective habitability ratings were recorded daily during the 11-day test. Hypoxia and DCS-related physiological and cognitive outcome measures were recorded during both tests and are reported in companion presentations. RESULTS & DISCUSSION: All subjects completed each of the tests. Primary habitability issues related to mask discomfort during simulated EVAs and poor sleep quality due to thin mattresses. Polybenzimidazole (PBI) clothing was worn by all subjects due to the increased fire risk and may be required for Artemis missions; clothing was found to be acceptable overall with the worst ratings being due to poor fit and inelasticity. Chamber O2 and CO2 sensor inconsistency was observed that did not result in test termination but required post-test follow-up. Forward plans include additional hypobaric testing and integration of existing and future physiological outcome data into an open-source Aerospace Estimation Tool for Hypobaric Exposure Risk (AETHER). NASA is also working to make the testing capability available to commercial companies.

Andrew Abercromby↗

NASA NTRSDate not supplied

International Space Station Space Environments Performance and Anomaly Resolution

The International Space Station is the largest and most complex on-orbit platform for space science utilization in low Earth orbit. The Space Environments Team addresses natural and induced environments for the ISS Program including external contamination, ionizing radiation, neutral atmosphere and solar ultraviolet radiation, plasma effects, and acoustics. For the ISS to fulfill its mission as a long-duration science platform, space environments effects are assessed, monitored, and controlled through design or operational mitigation. Interactions of ISS hardware with the natural and induced space environments, and the assessment and mitigation of those effects play a critical role in ISS mission operations. The Space Environments Team has complete system integration responsibility in these area for U.S./International Partner/Russian hardware, visiting vehicles, ISS payloads and operation. Lessons learned and processes developed for ISS are applicable to the design, assembly, and operations of long-duration space systems.

space environments↗

NASA NTRSDate not supplied

Applying Satellite Data to Support Disaster Response and Emergency Management Decision Making

Using the vantage point of space, satellite observations provide information about the Earth that can serve a critical role in building situational awareness and filling in data gaps during disaster response. NASA’s Earth Science Division ( studies the Earth as a system and develops technologies to improve the quality of life here on our home planet. Within NASA ESD, the Disasters Program and its Disasters Response Coordination System (DRCS) aims to advance Earth science data and information to support management decisions that prevent or mitigate the impacts of disasters. Using a whole-of-NASA approach to coordinate and mobilize the Agency’s assets and expertise to provide geospatial information during disasters, this work brings the utility of Earth observation information to emergency management and disaster response and reduces the impacts of disasters on lives and livelihoods .This poster will introduce the utility of satellite and geospatial information to disaster response through examples of recent DRCS incident response activations and highlight the DRCS model that employs a user-centered activation framework beginning with direct requests from responders and ending with after-action assessments that feed lessons learned and process improvements.

Remote Sensing↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

Filament winding a polymer/carbon fiber composite overwrap onto an additively manufactured copper combustion chamber will allow it to act as a light-weight structural jacket, significantly reducing weight for high pressure thrust chamber assemblies and reducing overall cost and fabrication schedules. Chamber assemblies for 2k lb. and 7k lb. of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. The recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

composite overwrap↗

NASA NTRSDate not supplied

Lightweight Thrust Chamber Composite Overwrap Lessons Learned

The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.

Allison Clark↗

NASA NTRS2011

Human Spaceflight Conjunction Assessment: Lessons Learned

This viewgraph presentation reviews the process of a human space flight conjunction assessment and lessons learned from the more than twelve years of International Space Station (ISS) operations. Also, the application of these lessons learned to a recent ISS conjunction assessment with object 84180 on July 16, 2009 is also presented.

Smith, Jason T.↗

NASA NTRS1991

Sounding rocket lessons learned

Programmatic, applicatory, developmental, and operational aspects of sounding rocket utilization for materials processing studies are discussed. Lessons learned through the experience of 10 sounding rocket missions are described. Particular attention is given to missions from the SPAR, Consort, and Joust programs. Successful experiments on Consort include the study of polymer membranes and resins, biological processes, demixing of immiscible liquids, and electrodeposition.

Wessling, Francis C.↗

NASA NTRS2006

Archiving Mars Mission Data Sets with the Planetary Data System

This viewgraph presentation reviews the use of the Planetary Data System (PDS) to archive the datasets that are received from the Mars Missions. It reviews the lessons learned in the actual archiving process, and presents an overview of the actual archiving process. It also reviews the lessons learned from the perspectives of the projects, the data producers and the data users.

Planetary Data System (PDS)↗