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NASA NTRS2011

Aerodynamic and Aeroacoustic Wind Tunnel Testing of the Orion Spacecraft

The Orion aerodynamic testing team has completed more than 40 tests as part of developing the aerodynamic and loads databases for the vehicle. These databases are key to achieving good mechanical design for the vehicle and to ensure controllable flight during all potential atmospheric phases of a mission, including launch aborts. A wide variety of wind tunnels have been used by the team to document not only the aerodynamics but the aeroacoustic environment that the Orion might experience both during nominal ascents and launch aborts. During potential abort scenarios the effects of the various rocket motor plumes on the vehicle must be accurately understood. The Abort Motor (AM) is a high-thrust, short duration motor that rapidly separates Orion from its launch vehicle. The Attitude Control Motor (ACM), located in the nose of the Orion Launch Abort Vehicle, is used for control during a potential abort. The 8 plumes from the ACM interact in a nonlinear manner with the four AM plumes which required a carefully controlled test to define the interactions and their effect on the control authority provided by the ACM. Techniques for measuring dynamic stability and for simulating rocket plume aerodynamics and acoustics were improved or developed in the course of building the aerodynamic and loads databases for Orion.

Ross, James C.↗

NASA NTRS2011

Overview of Orion Crew Module and Launch Abort Vehicle Dynamic Stability

With the retirement of the Space Shuttle, NASA is designing a new spacecraft, called Orion, to fly astronauts to low earth orbit and beyond. Characterization of the dynamic stability of the Orion spacecraft is important for the design of the spacecraft and trajectory construction. Dynamic stability affects the stability and control of the Orion Crew Module during re-entry, especially below Mach = 2.0 and including flight under the drogues. The Launch Abort Vehicle is affected by dynamic stability as well, especially during the re-orientation and heatshield forward segments of the flight. The dynamic stability was assessed using the forced oscillation technique, free-to-oscillate, ballistic range, and sub-scale free-flight tests. All of the test techniques demonstrated that in heatshield-forward flight the Crew Module and Launch Abort Vehicle are dynamically unstable in a significant portion of their flight trajectory. This paper will provide a brief overview of the Orion dynamic aero program and a high-level summary of the dynamic stability characteristics of the Orion spacecraft.

D. Bruce Owens↗

NASA NTRS2012

Use of Heritage Hardware on Orion MPCV Exploration Flight Test One

Due to an aggressive schedule for the first space flight of an unmanned Orion capsule, currently known as Exploration Flight Test One (EFT1), combined with severe programmatic funding constraints, an effort was made within the Orion Program to identify heritage hardware, i.e., already existing, flight-certified components from previous manned space programs, which might be available for use on EFT1. With the end of the Space Shuttle Program, no current means exists to launch Multi-Purpose Logistics Modules (MPLMs) to the International Space Station (ISS), and so the inventory of many flight-certified Shuttle and MPLM components are available for other purposes. Two of these items are the MPLM cabin Positive Pressure Relief Assembly (PPRA), and the Shuttle Ground Support Equipment Heat Exchanger (GSE HX). In preparation for the utilization of these components by the Orion Program, analyses and testing of the hardware were performed. The PPRA had to be analyzed to determine its susceptibility to pyrotechnic shock, and vibration testing had to be performed, since those environments are predicted to be more severe during an Orion mission than those the hardware was originally designed to accommodate. The GSE HX had to be tested for performance with the Orion thermal working fluids, which are different from those used by the Space Shuttle. This paper summarizes the activities required in order to utilize heritage hardware for EFT1.

Rains, George Edward↗

NASA NTRS2010

Kinetic Temperatures of the Dense Gas Clumps in the Orion KL Molecular Core

High angular-resolution images of the J = 18(sub K)-17(sub K) emission of CH3CN in the Orion KL molecular core were observed with the Submillimeter Array (SMA). Our high-resolution observations clearly reveal that CH3CN emission originates mainly from the Orion Hot Core and the Compact Ridge, both within approximately 15 inches of the warm and dense part of Orion KL. The clumpy nature of the molecular gas in Orion KL can also be readily seen from our high-resolution SMA images. In addition, a semi-open cavity-like kinematic structure is evident at the location between the Hot Core and the Compact Ridge. We performed excitation analysis with the "population diagram" method toward the Hot Core, IRc7, and the northern part of the Compact Ridge. Our results disclose a non-uniform temperature structure on small scales in Orion KL, with a range of temperatures from 190-620 K in the Hot Core. Near the Compact Ridge, the temperatures are found to be 170-280 K. Comparable CH3CN fractional abundances of 10(exp -8) to 10(exp -7) are found around both in the Hot Core and the Compact Ridge. Such high abundances require that a hot gas phase chemistry, probably involving ammonia released from grain mantles, plays an important role in forming these CH3CN molecules.

Wang, Kuo-Song↗

NASA NTRS2012

Gamma-Ray Observations of the Orion Molecular Clouds with the Fermi Large Area Telescope

We report on the gamma-ray observations of giant molecular clouds Orion A and B with the Large Area Telescope (LAT) on board the Fermi Gamma-ray Space Telescope. The gamma-ray emission in the energy band between approx 100 MeV and approx 100 GeV is predicted to trace the gas mass distribution in the clouds through nuclear interactions between the Galactic cosmic rays (CRs) and interstellar gas. The gamma-ray production cross-section for the nuclear interaction is known to approx 10% precision which makes the LAT a powerful tool to measure the gas mass column density distribution of molecular clouds for a known CR intensity. We present here such distributions for Orion A and B, and correlate them with those of the velocity-integrated CO intensity (W(sub CO)) at a 1 deg 1 deg pixel level. The correlation is found to be linear over a W(sub CO) range of approx 10-fold when divided in three regions, suggesting penetration of nuclear CRs to most of the cloud volumes. The W(sub CO)-to-mass conversion factor, X(sub CO), is found to be approx 2.3 10(exp 20) / sq cm (K km/s)(exp -1) for the high-longitude part of Orion A (l > 212 deg), approx 1.7 times higher than approx 1.3 10(exp 20) found for the rest of Orion A and B. We interpret the apparent high X(sub CO) in the high-longitude region of Orion A in the light of recent works proposing a nonlinear relation between H2 and CO densities in the diffuse molecular gas.W(sub CO) decreases faster than the H2 column density in the region making the gas "darker" to W(sub CO).

Ackermann, M.↗

NASA NTRS2012

Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

The NASA Orion Flight Test Office was tasked with conducting a series of flight tests in several launch abort scenarios to certify that the Orion Launch Abort System is capable of delivering astronauts aboard the Orion Crew Module to a safe environment, away from a failed booster. The first of this series was the Orion Pad Abort 1 Flight-Test Vehicle, which was successfully flown on May 6, 2010 at the White Sands Missile Range in New Mexico. This paper provides a brief overview of the three propulsive subsystems used on the Pad Abort 1 Flight-Test Vehicle. An overview of the propulsive systems originally planned for future flight-test vehicles is also provided, which also includes the cold gas Reaction Control System within the Crew Module, and the Peacekeeper first stage rocket motor encased within the Abort Test Booster aeroshell. Although the Constellation program has been cancelled and the operational role of the Orion spacecraft has significantly evolved, lessons learned from Pad Abort 1 and the other flight-test vehicles could certainly contribute to the vehicle architecture of many future human-rated space launch vehicles.

Jones, Daniel S.↗

NASA NTRS2012

Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

Jones, Daniel S.↗

NASA NTRS2012

Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

The National Aeronautics and Space Administration Orion Flight Test Office was tasked with conducting a series of flight tests in several launch abort scenarios to certify that the Orion Launch Abort System is capable of delivering astronauts aboard the Orion Crew Module to a safe environment, away from a failed booster. The first of this series was the Orion Pad Abort 1 Flight-Test Vehicle, which was successfully flown on May 6, 2010 at the White Sands Missile Range in New Mexico. This report provides a brief overview of the three propulsive subsystems used on the Pad Abort 1 Flight-Test Vehicle. An overview of the propulsive systems originally planned for future flight-test vehicles is also provided, which also includes the cold gas Reaction Control System within the Crew Module, and the Peacekeeper first stage rocket motor encased within the Abort Test Booster aeroshell. Although the Constellation program has been cancelled and the operational role of the Orion spacecraft has significantly evolved, lessons learned from Pad Abort 1 and the other flight-test vehicles could certainly contribute to the vehicle architecture of many future human-rated space launch vehicles

Jones, Daniel S.↗

NASA NTRS2013

Development of the Orion Crew-Service Module Umbilical Retention and Release Mechanism

The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.

Separation↗

NASA NTRS2016

Evolution of Orion Mission Design for Exploration Mission 1 and 2

The evolving mission design and concepts of NASA’s next steps have shaped Orion into the spacecraft that it is today. Since the initial inception of Orion, through the Constellation Program, and now in the Exploration Mission frame-work with the Space Launch System (SLS), each mission design concept and pro-gram goal have left Orion with a set of capabilities that can be utilized in many different mission types. Exploration Missions 1 and 2 (EM-1 and EM-2) have now been at the forefront of the mission design focus for the last several years. During that time, different Design Reference Missions (DRMs) were built, analyzed, and modified to solve or mitigate enterprise level design trades to ensure a viable mission from launch to landing. The resulting DRMs for EM-1 and EM-2 were then expanded into multi-year trajectory scans to characterize vehicle performance as affected by variations in Earth-Moon geometry. This provides Orion’s subsystems with stressing reference trajectories to help design their system. Now that Orion has progressed through the Preliminary and Critical Design Reviews (PDR and CDR), there is a general shift in the focus of mission design from aiding the vehicle design to providing mission specific products needed for pre-flight and real time operations. Some of the mission specific products needed include, large quantities of nominal trajectories for multiple monthly launch periods and abort options at any point in the mission for each valid trajectory in the launch window.

Gutkowski, Jeffrey P.↗

NASA NTRS2013

Propulsion Overview of the Orion Pad Abort 1 (PA-1) Flight-Test Vehicle

The NASA Orion Flight Test Office was tasked with conducting a series of flight tests in several launch abort scenarios to certify that the Orion Launch Abort System is capable of delivering astronauts aboard the Orion Crew Module to a safe environment, away from a failed booster. The first of this series was the Orion Pad Abort 1 Flight-Test Vehicle, which was successfully flown on May 6, 2010 at the White Sands Missile Range in New Mexico. This presentation provides a concise overview of the three propulsive subsystems used on the Pad Abort 1 Flight-Test Vehicle. Although the Constellation program has been cancelled and the operational role of the Orion spacecraft has significantly evolved, lessons learned from Pad Abort 1 could certainly contribute to the vehicle architecture of many future human-rated space launch vehicles

Jones, Daniel S.↗

NASA NTRS2019

Optimizing a Coupled Solution for the Orion MPCV Using DPLR and NEQAIR

The goal of this project is to study the convective and radiative heat flux predictions using computational fluid dynamics (CFD) on a smooth body representation of the NASA Orion Multi-Purpose Crew Vehicle (MPCV). The Orion MPCV is designed for long duration missions in space and will play a crucial role in transporting astronauts in the upcoming Artemis missions. With Orion's aim for cost-effective reusability comes a need to study its Thermal Protection System (TPS), which allows for safe entry into the atmospheres of the Earth, Moon, and Mars. In order to study the effects of the TPS on test flights and better understand the aerothermal environment, CFD is a necessary tool used to create simulations of entry vehicles and calculate the heat load and heat flux. However, solutions are often performed using an uncoupled approach between the flow and the radiation solver. This leads to an overestimation of the overall heating effects because they do not consider radiative cooling. Furthermore, the effects of radiation on the aft-body is an area of research with significant uncertainty. Through the use of codes developed at NASA Ames, DPLR and NEQAIR, a coupled solution can be attained for the Orion capsule which will more accurately solve for the effects of radiation in both the fore and aft-body regions. This yields more accurate design margins for the TPS, which produces a better estimate of the thickness required. By developing an accurate coupled solution of the TPS on the Orion MPCV, planners will have greater flexibility in carrying out future missions to the Moon and beyond.

Design↗

NASA NTRSDate not supplied

Ground Segment Operations Concept for the Orion Artemis-2 Optical Communications System

The ACCESS Project (formerly Space Network) will implement an optical communications ground segment to support the Orion Artemis II Optical Communications (O2O) demonstration as part of the next manned human spaceflight mission to the moon, Artemis II. O2O implements laser communication (lasercomm) technology for operational use on the Orion series of spacecraft, as a development test objective (DTO), in order to demonstrate the feasibility and operational utility of lasercomm for human spaceflight missions. O2O consists of three segments: Space Segment, Ground Segment, and Operations Segment. The Space Segment consists of the Space Terminal Element and the Orion spacecraft. The Space Terminal Element effort is managed by the GSFC Laser-Enhanced Mission Communications Navigation and Operational Services (LEMNOS) project in collaboration with MIT Lincoln Laboratory. The Ground Segment consists of an optical ground terminal (GT) at the White Sands Complex (WSC), which is being developed in collaboration with MIT Lincoln Laboratory, the Ground Segment Operations and Analysis (GSOA) element and Ground Data Element (GDE), and a second optical GT in the Optical Communications Telescope Laboratory (OCTL) at the JPL Table Mountain Facility. The Operations Segment consists of the Artemis II Mission Control Center (MCC), the Lasercomm Space Terminal Console (LSTC), and the Lasercomm Link Planning & Analysis Center (LPAC), all located at the Johnson Space Center (JSC). O2O utilizes pulse-position modulation (PPM) direct-to-earth services resulting in an 80 Mbps downlink data rate from lunar orbit. The O2O concept of operations is to provide optical services for a minimum of 1 hour per day for each day of the Artemis II mission. O2O will utilize a 10-20 Mbps uplink data rate and 40-260 Mbps downlink data rate, depending on the Artemis II mission phase. The ACCESS project will also provide a centralized mission data interface for user data distribution and storage to the MCC and perform planning and scheduling of services in coordination with the Operations Segment for the O2O Ground Segment. The O2O Ground Segment will support the following O2O mission phases: Pre-Mission Planning; Daily Operations Planning; Event Execution; and Post-Pass Reporting. O2O will be used to exchange data files between Orion and the MCC and to distribute real-time video through the optical downlink service to the MCC; which would not be possible without the high-bandwidth link that O2O will provide to Orion. In this paper, I will discuss the O2O Ground Segment development approach and how it will support these critical O2O functions: plan and schedule the contact; acquire and track the optical link; flow information bidirectionally; distribute information; and control and accommodate the system.

optical communications↗

NASA NTRS2021

Orion Meteoroid and Debris Analysis with a Single Kevlar® Layer Enhancement to the Propulsion Tank Multi-Layer Insulation: Comparison of the Observed Data and the Adjusted Ballistic Models

In a continual mass optimization effort for the Orion vehicle by NASA and its prime contractor Lockheed Martin Space, along with the European Space Agency (ESA) and its contractors Airbus and Thales Alenia Space-Italy (TAS-I), a series of shield characterization shots have been performed to quantify the ballistic enhancement of a single-layer of Kevlar® in multi-layer insulation (MLI). This enhanced MLI is part of Orion’s propulsion subsystem, and it is planned to replace a double-layer Kevlar® configuration starting at the Artemis IV mission. This effort has included fifty-two shield characterization shots for five different shield configurations over the four Orion propellant storage vessels. These storage vessels are located in the European Service Module (ESM). This shield characterization has been managed by the Hypervelocity Impact Technology (HVIT) group in NASA Astromaterials Research and Exploration Sciences at Johnson Space Center (JSC) for the NASA Engineering and Safety Center (NESC) and the Multi-Purpose Crew Vehicle (MPCV) program office in coordination with Lockheed Martin Space and Thales Alenia Space-Italy (TAS-I). The shield characterization has used the two-stage, light-gas-gun at the Remote Hypervelocity Test Laboratory (RHTL) of NASA JSC White Sands Test Facility (WSTF) for acceleration of projectiles to representative orbital impact speeds. From this shield characterization effort, a revised ballistic limiting equation (BLE) has been developed for each of the five representative shielding configurations of the ESM pressure vessels. This document provides a brief description of the shield configurations considered for the Orion program and the shield characterization findings. These results are compared to the assumed BLE for each configuration going into the Artemis missions that utilize this version of ballistic enhanced MLI. The models are integrated into a fourteen day High Lunar Orbit (HLO) mission as a representative reliability prediction impact for Orion, and it has been found that the predicted risk of a loss-of-crew (LOC) event is actually a little less than half of the assumed value that launched this design modification opportunity.

Joshua E Miller↗

NASA NTRS2022

Turning Limitations into Opportunities in the Development of the Orion Medical System: Incorporation of mHealth Devices

INTRODUCTION: Selection of medical devices for the Orion medical system is a complex task which is dependent on the current state of terrestrial technology. In this work we review the interplay between NASA requirements, constraints, and opportunities for synergy during the development of the Orion medical system. METHODS: The “plan to treat” list of conditions, and subsequently the medical resource list for the Orion Artemis II lunar flyby mission was completed using semi-quantitative methods. During this process, some medical resources were excluded to comply with mass and volume limits, while other resources applicable to multiple medical requirements were prioritized for inclusion. Choices were also examined considering NASA level of care standards for the Artemis design reference missions. As a means to optimize capabilities in spite of mass and volume constraints, ideas for integration of multiple devices into a single platform were explored, including a ‘hackathon’ challenge which was conducted to generate and evaluate concepts for combining medical devices into a single app-based mobile device (ultrasound, ECG, etc.). RESULTS: The Orion team identified 128 medical conditions that we “plan to treat”, with 139 unique medical resources to address these conditions, including 5 digital diagnostic devices (ECG, otoscope, stethoscope, pulse oximeter, and blood pressure monitor). During selection of these digital devices the team noted that miniaturized medical devices often use mobile device platforms (mHealth), some displaying and transmitting data exclusively via mobile device. Of the 5 initially selected devices, all are capable of mobile connection, one which cannot function without a mobile device (ECG). Furthermore, only one of these devices connects natively to a Windows platform, which is currently the only operating system available on Orion. DISCUSSION: Significant savings in mass and volume as well as training and usability improvements can be achieved by leveraging mHealth technologies. However, the platform presents significant challenges for deployment within the Artemis Program including lack of internet connectivity, incompatible operating systems, and radiation concerns. Each of these drawbacks are surmountable with investment in the supporting vehicle architecture, which may become necessary to support the technology trends seen in commercially available medical devices today. Objective: Learn about the opportunities and challenges of leveraging mHealth devices in the development of medical capabilities for austere environments. Learn about the constraints of the NASA spaceflight environment with regards to digital medical device integration.

Douglas Ebert↗

NASA NTRSDate not supplied

Artemis II Mission Performance of the Orion Active Thermal Control System

The Orion spacecraft has recently completed Artemis II, the first crewed mission around the moon in 54 years. This test flight demonstrated vehicle capability as the foundation for all future missions under the Artemis program. As a major system of Orion, the Active Thermal Control System (ATCS) successfully managed crew and vehicle heat loads to provide adequate cooling and thermal comfort for the duration of the Artemis II mission. Thermal control on the Orion vehicle is managed through two redundant cooling loops in the Crew Module (CM) that absorb heat loads from the cabin and Air Revitalization System (ARS) heat exchangers, the Liquid Cooling Garment (LCG) heat exchanger, and the avionics cold plates, and then transfer those heat loads to the Service Module (SM) radiator loops and/or the Phase Change Material (PCM) and ammonia boilers when required through thermal configuration or mission phase. During Artemis II, Orion did not necessitate any supplemental cooling from ammonia boilers until service module separation, allowing the maximum availability of ammonia cooling prior to entry. This presentation will provide an overview of the Orion ATCS major subsystems, highlight the performance during key mission phases, and comment on the applicability of the observed thermal response to future Artemis missions.

Ellie Thurston↗

NASA NTRS2023

The Mid-Infrared Molecular Inventory Towards Orion IRc2

We present the first high spectral resolution mid-infrared survey in the Orion BN/KL region, covering 7.2 to 28.3μm. With SOFIA/EXES we target the enigmatic source Orion IRc2. While this is in the most prolifically studied massive star-forming region, longer wavelengths and molecular emission lines dominated previous spectral surveys. The mid-infrared observations in this work access different components and molecular species in unprecedented detail. We unambiguously identify two new kinematic components, both chemically rich with multiple molecular absorption lines. The “blue clump” has ν LSR = −7.1 ± 0.7 km s −1 and the “red clump” 1.4 ± 0.5 km s −1 . While the blue and red clump shave similar temperatures and line widths, molecular species in the blue clump have higher column densities. They are both likely linked to pure rotational H 2 emission also covered by this survey. This work provides evidence for the scenario that the blue and red clumps are distinct components unrelated to the classic components in the Orion BN/KL region. Comparison to spectroscopic surveys towards other infrared targets in the region show that the blue clump is clearly extended. We analyze, compare, and present in depth findings on the physical conditions of C 2 H 2 , 13 CCH 2 , CH 4 , CS, H 2 O, HCN, H 13 CN, HNC, NH 3 , and SO 2 absorption lines and an H 2 emission line associated with the blue and red clumps. We also provide limited analysis of H 2 O and SiO molecular emission lines towards Orion IRc2 and the atomic forbidden transitions [FeII], [SI], [SIII], and [NeII].

Atomic spectroscopy↗

NASA NTRSDate not supplied

Orion Backup Flight Software

Orion Backup Flight Software (BFS) is a joint NASA/Lockheed Martin effort designed to prevent the loss of the Orion crew. BFS will only take over in the event the primary flight software (PFSW) fails to operate properly due to either hardware or software failures. Since the PFSW runs identical software on identical hardware, it is conceivable that a single issue could simultaneously bring down all the PFSW. To minimize the likelihood BFS would be affected by the same issue, BFS was specifically designed to be as different as possible from PFSW: BFS runs on different hardware, a separate operating system, a different compiler, does not share software libraries, and is written by a different team of programmers. This presentation will provide a high-level overview of the Artemis missions and the Orion vehicle, as well as provide additional details of the BFS system (including how BFS is different than the PFSW). The overall BFS capability evolution and timeline (milestones reached as well as work remaining) through the Artemis III mission will be discussed. Additionally, the verification and validation plans for BFS will be presented, describing how we ensure that only validated configuration data is loaded onto the flight vehicle. Finally, the presentation will close with lessons learned and future plans for Orion BFS.

Orion↗