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NASA NTRS2015

Center Planning and Development: Multi-User Spaceport Initiatives

The Vehicle Assembly building at NASAs Kennedy Space Center has been used since 1966 to vertically assemble every launch vehicle, since the Apollo Program, launched from Launch Complex 39 (LC-39). After the cancellation of the Constellation Program in 2010 and the retirement of the Space Shuttle Program in 2011, the VAB faced an uncertain future. As the Space Launch System (SLS) gained a foothold as the future of American spaceflight to deep space, NASA was only using a portion of the VABs initial potential. With three high bays connected to the Crawler Way transportation system, the potential exists for up to three rockets to be simultaneously processed for launch. The Kennedy Space Center (KSC) Master plan, supported by the Center Planning and Development (CPD) Directorate, is guiding Kennedy toward a 21st century multi-user spaceport. This concept will maintain Kennedy as the United States premier gateway to space and provide multi-user operations through partnerships with the commercial aerospace industry. Commercial aerospace companies, now tasked with transporting cargo and, in the future, astronauts to the International Space Station (ISS) via the Commercial Resupply Service (CRS) and Commercial Crew Program (CCP), are a rapidly growing industry with increasing capabilities to make launch operations more economical for both private companies and the government. Commercial operations to Low Earth Orbit allow the government to focus on travel to farther destinations through the SLS Program. With LC-39B designated as a multi-use launch pad, companies seeking to use it will require an integration facility to assemble, integrate, and test their launch vehicle. An Announcement for Proposals (AFP) was released in June, beginning the process of finding a non-NASA user for High Bay 2 (HB2) and the Mobile Launcher Platforms (MLPs). An Industry Day, a business meeting and tour for interested companies and organizations, was also arranged to identify and answer any additional questions posed by potential proposers. After amending the AFP and posting additional material for potential users to consider, proposals are being accepted until July 31, at which point they will be evaluated to determine the proposer which best meets the objectives of the government. By identifying VAB HB2 as available and seeking proposals from the commercial sector for VAB HB2 and MLP use, Center Planning and Development is ensuring Kennedy Space Centers relevance in the evolving launch industry of the 21st century.

AFP↗

NASA NTRS2016

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

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

Gilbert, Michael G.↗

NASA NTRS2016

Flat H Redundant Frangible Joint Development

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

Brown, Chris↗

NASA NTRS2016

Commercial Crew Launch America

This presentation is intended to discuss NASA's long term human exploration goals of our solar system. The emphasis will be on how our CCP (Commercial Crew Program) supports our space bound human exploration goals by encouraging commercial entities to perform missions to LEO (Low Earth Orbit), thus allowing NASA to focus on beyond LEO human exploration missions.

Thon, Jeffrey S.↗

NASA NTRS2018

Implementation of J-A Methodology Elastic-Plastic Crack Instability Analysis Capability into the WARP-3D Code

Characterization of the near crack-tip stress/strain fields is the foundation of fracture mechanics. The description of the near tip stress field and the prediction of when fracture occurs is well established for brittle materials that exhibit linear elastic behavior. However, in ductile materials or conditions that violate linear elastic assumptions (Aluminum alloys, Al 2024-T3, Al 2024- T351 etc.), the elastic-plastic crack-tip stress fields are characterized by the Hutchison-Rice-Rosengren (HRR) field. The J-integral is commonly used to characterize amplitude of the HRR field under elastic-plastic conditions. The J-integral has been demonstrated for crack-tip fields that are under high constraint conditions (i.e., small-scale plasticity where the J-dominance is maintained). However, as the external load increases, yielding changes from small- to largescale plasticity and usually a loss of constraint (i.e., reduction in the triaxial stress field along the crack front). The loss of constraint leads to the deviation of the crack-tip stress fields from that given by the HRR field. Hence, the J-dominance will be gradually lost and additional parameter(s) are required to quantify the crack-tip stress fields and predict fracture behavior. The assessment objectives were to: 1) implement a two-parameter (i.e., J-A) fracture criterion into an elastic-plastic three-dimensional (3D) finite element analysis (FEA), 2) validate the implementation by comparison with the A parameter from literature data, 3) conduct material characterization tests to quantify the material behavior and provide fracture data for validation of the J-A fracture criteria, and (4) perform evaluations to establish if the J-A criteria can be used to predict fracture in a ductile metallic material (e.g., aluminum alloys). The A parameter in these criteria is the second parameter in a three-term elastic-plastic asymptotic expansion of the neartip stress behavior. A series of extensive FEAs were performed using WARP3D software package to obtain solutions for the A parameter for different specimen configurations. The methodology needed for the estimation of the A parameter in the asymptotic expansion was developed and implemented using Matlab®. A user material (UMAT) routine was used to model the material stress-strain response using a Ramberg-Osgood power law with a hardening exponent (n) and a material coefficient (alpha). This UMAT routine was successfully implemented in WARP3D software and validated through comparison with the experimental data. Three configurations were extracted from published results: 1) center cracked plate (CCP), 2) single edge-cracked plate (SECP), and 3) double edge-cracked plate (DECP). These configurations and four other configurations (three-hole tension (THT)), three-point bend (3PTB), three-hole compact tension (3PCT), and compact tension (CT)) were analyzed to verify the methodology that was developed and implemented into WARP3D. Solutions of the A parameter were obtained for remote tension loading conditions that started with small-scale yielding and continued into the large-scale plasticity regime. The results indicate that the methodology developed can be used to calculate the elastic-plastic J-A parameters for test specimens with a range of crack geometries, material strain hardening behaviors, and loading conditions. The J-A parameters were implemented as fracture criteria and used to predict the test results. For comparison, other fracture criteria were used to predict the same test results. Major findings include: The A constraint parameter A varies with specimen type and applied load thus accurate determination is crucial in predicting the failure load, and the A parameter is asymptotic as the failure load is approached, making an accurate determination difficult (i.e., small differences in the A parameter can cause large variations in failure load) for materials exhibiting elastic-plastic behavior. The failure predictions from J-A methodology were more accurate than the traditionally used KC and J methods, and have comparable scatter to that observed when using the crack-tip opening angle (CTOA) method. However, the J-A methodology requires considerable effort (expertise level and labor) to implement and to evaluate the A parameter for different specimen types and materials, or to apply this methodology to part-through crack (e.g., 3D problems) structural applications.

Hamm, Kenneth R., Jr.↗

NASA NTRSDate not supplied

TPSAS-NF1676L-30470-DND

Outside NASA: Single Agency document that can be referenced in NASA contracts (e.g. CCP) and used in NASA-ESA-JAXA Mutual Recognition of SMA Standards Within NASA: - Lists requirements from Center documents that must be addressed by Programs and Projects in their EEE Parts Management and Control Plan (EPMCP) - Tailor-able by Center/Project Technical Authority - Standardize requirements for “Low Risk” projects -not to overburden “Higher Risk” projects with excessive requirements

Peter J Majewicz↗

NASA NTRSDate not supplied

Concept for a Far-infrared Outgoing Radiation Closure Experiment – Antarctica (FORCE-A)

The next decade promises to be an incredibly exciting time in climate science. There are two new space flight missions, PREFIRE and FORUM, that will open the far-infrared spectrum to direct, accurate observations for the first time. PREFIRE is planned to operate between 2022 and 2024 and FORUM will launch in late 2025 or early 2026. The TICFIRE instrument is also a candidate for the NASA A-CCP mission to be launched in the 2028 timeframe. A key focus of these missions and instruments is improved understanding of polar climates. In support of these missions we present a concept for a radiative closure experiment to be conducted in Antarctica during the PREFIRE mission lifetime and then again during the operational FORUM and TICFIRE/A-CCP missions. The main component of the campaigns would be a long-duration balloon flight launched from McMurdo Station with the potential of 1-2 months aloft. Candidate balloon flight instrumentation includes a far-IR Fourier transform spectrometer and far-IR radiometers. Ground based instrumentation includes zenith viewing infrared and far-infrared spectrometers, lidars, and microwave radiometers. The objective of the FORCE-A campaign is to demonstrate radiative closure in the infrared with the multiple campaign instruments combined with the numerous relevant satellite instruments that pass overhead every 30 minutes (AIRS, CrIS, IASI, MODIS, VIIRS, CERES, BBR, Libera). The campaign will serve to advance radiation sciences as well as to provide the means for validation of the new far-infrared observations.

Martin G Mlynczak↗

NASA NTRSDate not supplied

The Aerosol Component of the ACCP Designated Observable Study

The 2017 Earth Science Decadal Survey (DS) recommended science and applications priorities to be pursued by NASA during the 2017-2027 timeframe. Aerosols (A) and clouds, convection, and precipitation (CCP) were identified as essential “designated observables” requiring additional capabilities beyond those planned in the current Program of Record. The DS recommended NASA develop a medium-to-large mission to address these observables, which would represent foundational elements of the future global observing system. In response, NASA initiated a 3-year study, to conclude in 2021, of a combined ACCP architecture, including identification of science and application goals and objectives, desired geophysical variables, and observing system capabilities. The goal of the study is to develop and explore a variety of concepts and develop several recommendations. ACCP science objectives include improving characterization of the distribution and properties of aerosols, the direct and indirect impacts of aerosol on the radiation budget, and improving understanding of aerosol processes related to air quality. The study is currently exploring satellite architecture concepts and suborbital measurements to provide desired observational capabilities, within the context of the planned international Earth observation program. This presentation will summarize ACCP science objectives and the potential suite of aerosol-oriented observing system capabilities.

David M Winker↗

NASA NTRSDate not supplied

Science Performance Comparison Between a Spaceborne HSRL and CALIOP

NASA operates airborne and spaceborne lidar systems to answer aerosol and cloud related science questions. NASA Langley Research Center has extensive experience operating lidar systems in both regimes. These include High Spectral Resolution Lidar (HSRL) systems, which have been operating on airborne systems,and CALIOP, the spaceborne elastic backscatter lidar system on board CALIPSO. In support of NASA’s ACCP Study Plan to address the Aerosol (A) and Cloud, Convection, and Precipitation (CCP) Designated Observables called out in the 2017 Earth Science Decadal Survey, LaRC is using lidar simulation tools to evaluate the performance of spaceborne systems using both the HSRL and elastic backscatter techniques. The LaRC high-fidelity simulator tool models both HSRL and elastic backscatter lidar systems by modeling the effects of the instrument specifications and producing backscatter signals generated from molecules, aerosols, clouds, ocean surface, and ocean subsurface. It derives the solar background signals from the scene specific aerosol and cloud characteristics, surface type, and sun elevation. The tool models both random and systematic uncertainties in the retrieved geophysical parameters. In this study, we will present simulated results that compare and contrast the performance of spaceborne HSRL systems to the performance of CALIOP. As recommended by the Decadal Study, ACCP is seeking advances over performance that has been achieved by A-Train. This study will provide a description of the HSRL and elastic backscatter techniques and demonstrate how and why the performance of these HSRL systems exceeds the performance of CALIOP.

Kathleen A Powell↗

NASA NTRSDate not supplied

Thermal Analysis of an In-Space Heat Shield Exposed to a Rocket Plume During Stage Separation

Thermal analyses were conducted to evaluate the thermal response of various individual materials and multi-layer configurations for an in-space heat shield exposed to a rocket plume during stage separation. Frequently used, readily available thermal protection materials consisting of cork, carbon cloth phenolic (CCP), and silica cloth phenolic (SCP) were selected for an initial screening analysis. SCP was chosen as the primary material for further evaluation using an updated thermal environment calculated using computational fluid dynamics (CFD) results. A multi-layer configuration consisting of SCP providing erosion resistance and a Nomex honeycomb providing thermal protection was then evaluated as a solution for more mass-efficient performance. Pyrolysis depth, bondline temperature, back-side temperature, and a thermal factor of safety were used to define the necessary material thickness profile. Adhesives were included in the analyses with considerations for maximum temperature and application method. One dimensional thermal analyses at several stations along the heat shield surface were performed for the initial screening and follow-on analyses. The methodology used standard processes and computer programs applicable to solid rocket motor internal insulation and nozzle thermal analysis such as Chemical Equilibrium and Applications (CEA), Aerotherm Chemical Equilibrium (ACE), Momentum/Energy Integral Technique (MEIT), and Insulation Thermal Response and Ablation Code (ITRAC). The baseline SCP/Nomex honeycomb multi-layer configuration thermal performance predictions satisfied the objectives with an acceptable mass estimate for the design maturity. The EA9673 film adhesive and SCP resin were the best performing bonding agents considered for the SCP/Nomex honeycomb and Nomex honeycomb/structural substrate interfaces. The baseline mass estimate was lowest when the resin was the bonding agent due to the higher maximum service temperature. These thermal analyses evaluated typical internal and external nozzle materials using a calculated thermal environment and heat loads that were lower than a typical rocket motor internal environment but greater than standard external aeroheating.

Andrew T Hiatt↗

NASA NTRSDate not supplied

The NASA Aerosols, Clouds, Convection, and Precipitation (ACCP) Observing System

NASA’s new Earth System Observatory (ESO) will provide key information related to understanding climate change processes, mitigating natural hazards, fighting forest fires, and improving real-time agricultural processes. The ACCP observing system will address two of the five major focus areas: aerosols, which determine air quality and affect the global energy balance, a key source of uncertainty in predicting climate change; and clouds, convection, and precipitation, whose processes are also a large source of uncertainty in future projections of climate change as well as predictions of severe weather. ACCP, currently in the concept investigation phase, is made up of two projects, one in an inclined orbit and the other in a polar orbit, with both projects addressing synergistic A and CCP science. Suborbital science is also a significant element of ACCP. This talk will describe the science objectives of ACCP and their relationship to the 2017 NASA Earth Science Decadal Survey as well as summarize the orbital architecture and major science activities during the concept investigation phase.

Scott Braun↗

NASA NTRS2020

A Classification of Ice Crystal Habits Using Combined Lidar and Scanning Polarimeter Observations during the SEAC4RS Campaign

Using collocated NASA Cloud Physics Lidar (CPL) and Research Scanning Polarimeter (RSP) data from the Studies of Emissions and Atmospheric Composition, Clouds and Climate Coupling by Regional Surveys (SEAC4RS) campaign, a new observational-based method was developed which uses a K-means clustering technique to classify ice crystal habit types into seven categories: column, plates, rosettes, spheroids, and three different type of irregulars. Intercompared with the collocated SPEC, Inc., Cloud Particle Imager (CPI) data, the frequency of the detected ice crystal habits from the proposed method presented in the study agrees within 5% with the CPI-reported values for columns, irregulars, rosettes, and spheroids, with more disagreement for plates. This study suggests that a detailed ice crystal habit retrieval could be applied to combined space-based lidar and polarimeter observations such as CALIPSO and POLDER in addition to future missions such as the Aerosols, Clouds, Convection, and Precipitation (A-CCP).

Natalie Midzak↗

NASA NTRSDate not supplied

Orion Main Parachute Asymmetry Testing Revisited

Limited bridle-level asymmetry data were collected on three Orion main parachute cluster tests early in the development program. The results were published contemporaneously using analysis techniques developed by the Ares parachute program. Both programs seemed to indicate that large parachutes could develop line asymmetries far larger than what was assumed in design guides. Unfortunately, no additional asymmetry data were collected during Orion parachute development to corroborate these results. Recent high-fidelity data from Commercial Crew Program parachute system tests reinforce these legacy results. A method was developed to estimate suspension line-level asymmetry by “un-averaging” Orion bridle-level measurements using assumptions gleaned from the recent CCP experience. Efforts were made to improve the visualization of load asymmetry and its relationship with parachute geometric shape deformations.

parachutes↗

NASA NTRSDate not supplied

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

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

parachutes↗

NASA NTRSDate not supplied

Molecular Accumulation during JWST’s Optical Telescope Cryogenic Thermal Vacuum Testing

Maintaining molecular cleanliness during the JWST’s Optical Telescope/Instrument Module (OTIS) Cryogenic Thermal Vacuum (TV) test campaign was critical to the success of its optical mission on orbit. In the thermal vacuum tests leading up to the final cryogenic test to validate the OTIS flight hardware, NASA Johnson Space Center’s (JSC’s) TV Chamber A was fully characterized for molecular contamination. It was found to contain common volatile condensable materials (VCM), including hydrocarbons, plasticizers, and silicones, all of which absorb in JWST’s infrared wavelength region. Due to the risks involved, cleaning molecular contamination from the OTIS mirrors was not an option and heating the Primary Mirror (PM) segments would have also been a risky and expensive endeavor. As a result, a monitoring process was developed and implemented during four different Pathfinder or risk reduction tests that were scheduled to occur prior to the flight hardware test. The goal was to quantify and assess the risk of molecular contamination depositing on the PM resulting from relatively warm chamber shrouds “leading” colder PM mirrors during warmup, by a margin of 10-50 Kelvin (K). This was accomplished using Cryogenic Quartz Crystal Microbalances (CQCMs), held at temperatures slightly cooler than the segments to signal the onset of contamination events. Per the JWST Contamination Control Plan (CCP)1, the total Primary Mirror molecular allocation requirement was 50 angstroms. In all tests, the results showed an average accumulated molecular contamination of <10 angstroms.

optics↗

NASA NTRSDate not supplied

Molecular Accumulation during JWST’s Optical Telescope Cryogenic Thermal Vacuum Testing

molecular, contamination, thermal vacuum, cryogeni↗

NASA NTRS2024

Ensuring Safety of Government Personnel During Suborbital Spaceflight

The NASA Suborbital Crew (SubC) project is focused on enabling flights by NASA civil servants, such as scientists and engineers conducting research, on suborbital vehicles. A broader goal is ensuring that commercial human spaceflight is both viable and safe. Within the Commercial Crew Program (CCP), the SubC project is exploring game-changing methods to perform safety assessments to enable NASA personnel to fly on suborbital missions. Commercial suborbital space flight capabilities are anticipated to be more accessible, affordable, and available than missions to the International Space Station and could provide additional opportunities for testing and qualification of space flight hardware, human-tended microgravity research, and further cutting-edge research enabled by the space environment. Although NASA currently permits human tended suborbital payloads for non-civil servants under auspices of NASA’s Flight Opportunities Program, the SubC effort will enable civil servant scientists, researchers, and even engineers to accompany their experiments and tests into the space microgravity environment. Figure 1 illustrates how the SubC program complements other microgravity experimental platforms. The targeted scope for SubC includes end-to-end suborbital capabilities reaching ~80km with several minutes of sustained microgravity (Table 1). The NASA SubC project office is working with the Federal Aviation Administration’s Office of Commercial Space Transportation (FAA-AST) and the commercial suborbital space transportation industry to develop an efficient and holistic approach to a safety review and eventual government participation in suborbital flight. The current FAA certification process for suborbital launches is congressionally mandated to only consider public safety. NASA is responsible for understanding the risks to its employees should they fly on a commercially available suborbital flight. The SubC project is employing a Safety Case approach, applied to commercial suborbital providers, which is not a traditional certification process as was used for the SpaceX Dragon and Boeing Starliner vehicles. Rather, it is an assessment using elements of NASA’s Risk-Informed Safety Case and the Armstrong Flight Research Center’s Airworthiness Assessment process.

Elizabeth C Blome↗

NASA NTRSDate not supplied

Ensuring Safety of Government Personnel During Suborbital Spaceflight

The NASA Suborbital Crew (SubC) office is focused on enabling flights by NASA civil servants, such as scientists and engineers conducting research, on suborbital vehicles. A broader goal is ensuring that commercial human spaceflight is both viable and safe. Within the Commercial Crew Program (CCP), the SubC office is exploring game-changing methods to perform safety assessments to enable NASA personnel to fly on suborbital missions. Commercial suborbital space flight capabilities are anticipated to be more accessible, affordable, and available than missions to the International Space Station and could provide additional opportunities for testing and qualification of space flight hardware, human-tended microgravity research, and further cutting-edge research enabled by the space environment. Although NASA currently supports human tended suborbital payloads for non-civil servants under auspices of NASA’s Flight Opportunities Program, the SubC effort will enable civil servant scientists, researchers, and engineers to accompany their experiments and tests into the space microgravity environment.

Risk Management↗