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Commercial Crew Development Environmental Control and Life Support System Status: 2011-2012

The National Aeronautics and Space Administration (NASA) Commercial Crew Development (CCDev) - 2 Program is managed within the new Commercial Crew Program Office (CCPO) to help develop a commercial crew transportation system to low earth orbit (LEO). It is intended to foster entrepreneurial activities with a few selected companies. The entrepreneurial activities were encouraged with these few selected companies by NASA providing only part of the total funding to complete specific tasks that were jointly agreed to by NASA and the company. These joint agreements were documented in a Space Act Agreement (SAA) that was signed jointly by NASA and the selected company. This paper will provide an overview of the CCDev - 2 Program and also it will discuss in a high level the Active Thermal Control System (ATCS) / Environmental Control and Life Support (ECLS) System tasks that were performed under CCDev - 2 from the start of CCDev - 2 to March 2012. It will also discuss the extension of the CCDev - 2 Program being proposed for the near future. 1

Williams, David E.

Air Revitalization System Enables Excursions to the Stratosphere

Paragon Space Development Corporation, based in Tucson, Arizona has had a long history of collaboration with NASA, including developing a modular air purification system under the Commercial Crew Development Program, designed to support the commercial space sector. Using that device and other NASA technology, startup company World View is now gearing up to take customers on helium balloon rides to the stratosphere.

Source record

Flight Crew Health Maintenance

The health maintenance program for commercial flight crew personnel includes diet, weight control, and exercise to prevent heart disease development and disability grounding. The very high correlation between hypertension and overweight in cardiovascular diseases significantly influences the prognosis for a coronary prone individual and results in a high rejection rate of active military pilots applying for civilian jobs. In addition to physical fitness the major items stressed in pilot selection are: emotional maturity, glucose tolerance, and family health history.

Gullett, C. C.

An Affordability Comparison Tool (ACT) for Space Transportation

NASA bas recently emphasized the importance of affordability for Commercial Crew Development Program (CCDP), Space Launch Systems (SLS) and Multi-Purpose Crew Vehicle (MPCV). System architects and designers are challenged to come up with architectures and designs that do not bust the budget. This paper describes the Affordability Comparison Tool (ACT) analyzes different systems or architecture configurations for affordability that allows for a comparison of: total life cycle cost; annual recurring costs, affordability figures-of-merit, such as cost per pound, cost per seat, and cost per flight, as well as productivity measures, such as payload throughput. Although ACT is not a deterministic model, the paper develops algorithms and parametric factors that use characteristics of the architectures or systems being compared to produce important system outcomes (figures-of-merit). Example applications of outcome figures-of-merit are also documented to provide the designer with information on the relative affordability and productivity of different space transportation applications.

McCleskey, C. M.

Crew Transportation Technical Standards and Design Evaluation Criteria

Crew Transportation Technical Standards and Design Evaluation Criteria contains descriptions of technical, safety, and crew health medical processes and specifications, and the criteria which will be used to evaluate the acceptability of the Commercial Providers' proposed processes and specifications.

Design Evaluation Criteria

Crew Transportation Technical Management Processes

Under the guidance of processes provided by Crew Transportation Plan (CCT-PLN-1100), this document, with its sister documents, International Space Station (ISS) Crew Transportation and Services Requirements Document (CCT-REQ-1130), Crew Transportation Technical Standards and Design Evaluation Criteria (CCT-STD-1140), Crew Transportation Operations Standards (CCT STD-1150), and ISS to Commercial Orbital Transportation Services Interface Requirements Document (SSP 50808), provides the basis for a National Aeronautics and Space Administration (NASA) certification for services to the ISS for the Commercial Provider. When NASA Crew Transportation System (CTS) certification is achieved for ISS transportation, the Commercial Provider will be eligible to provide services to and from the ISS during the services phase.

Summary of the technical management process

Crew Transportation Operations Standards

The Crew Transportation Operations Standards contains descriptions of ground and flight operations processes and specifications and the criteria which will be used to evaluate the acceptability of Commercial Providers' proposed processes and specifications.

specifications

ISS Crew Transportation and Services Requirements Document

The ISS Crew Transportation and Services Requirements Document (CCT-REQ-1130) contains all technical, safety, and crew health medical requirements that are mandatory for achieving a Crew Transportation System Certification that will allow for International Space Station delivery and return of NASA crew and limited cargo. Previously approved on TN23183.

CCT-REQ-1130

ISS Crew Transportation and Services Requirements Document

The ISS Crew Transportation and Services Requirements Document (CCT-REQ-1130) contains all technical, safety, and crew health medical requirements that are mandatory for achieving a Crew Transportation System Certification that will allow for International Space Station delivery and return of NASA crew and limited cargo. Previously approved on TN38792.

Commercial Crew Program

Determination of Autogenous Ignition Temperature for Isopropyl Alcohol and Ethanol

As part of a recent liquid rocket engine shutdown investigation, a commercial partner requested that NASA provide the autogenous ignition (or autoignition) temperature (AIT) of isopropyl alcohol (IPA). NASA provided the available data, but the data were somewhat scattered, likely due to test configuration and test technique differences. NASA Engineering and Safety Center (NESC) support was requested to experimentally determine the AIT of IPA and ethanol, both of which are extensively applied to propulsion systems. This report contains the outcome of the NESC assessment.

Autoignition Temperature; Isopropyl Alcohol; Comme

NASA Crew Transportation System Certification Plan

NASA Crew Transportation System (CTS) Certification is the authorization granted by the Agency that allows the use of a Commercial Provider’s CTS to transport NASA Crew to and from the ISS. The CTS Certification decision is made by the NASA Associate Administrator based on the comprehensive assessment of the Certification Review Board and recommendations from the CCP and ISS Program Managers and the NASA Associate Administrator of Space Operations Mission Directorate. The Commercial Provider is responsible for developing and executing its plan for certifying the CTS. The Commercial Crew Program (CCP) with the International Space Station (ISS) Program must substantiate the Commercial Provider’s certification assertion of compliance with NASA requirements and NASA Crew safety.

CCP

COTS/CRS: KSC Evolving Host Initiatives with Commercial Space Partners

NASA's Commercial Crew and Cargo Program Office (C3PO) leads the agency's commercial efforts to stimulate United States private companies as the shuttle program comes to a close. Through the Commercial Orbital Transportation Services (COTS) program, two companies, SpaceX and Orbital, were selected to demonstrate their ability to perform flights to the International Space Station. The Commercial Resupply Services (CRS) Project leverages off the COTS experience, and awarded these two private companies contracts to resupply the International Space Station after shuttle fly out. As a 2010 summer intern, I supported the COTS/CRS team in their team meetings, attended and contributed to project discussions and planning, and assisted in developing visual representations for the variety of processes and organizational endeavors required for the program to run smoothly. One aspect of the COTS/CRS program gives the involved private companies the opportunity to request available services from Kennedy Space Center (KSC); one of my projects included assisting in the development of a related Task Order Request (TOR) process. In addition, an integral part of the project was to maintain and enhance the team database for processing the variety of TORS. My experience in the project gave me great insight into the growing field of commercial space activities. The development of the TOR process involved coordinating representatives from a variety of backgrounds at KSC. A clear and concise visual representation of the TOR process in the form of a flow chart was necessary to successfully implement a task order request from one of NASA's commercial partners. The goals of the process charts were to communicate the team's ideas and foster a common thought process while at the same time allow the process to grow and evolve. It was critical that the requests from the private companies were addressed quickly and thoroughly as the process developed this summer is expected to have extensive future use.

Yohpe, Megan

Commercial Crew Development Environmental Control and Life Support System Status

The National Aeronautics and Space Administration (NASA) Commercial Crew Development (CCDev) Project was a short term Project that was managed within the Commercial Crew and Cargo Program Office (C3PO) to help develop and demonstrate a small number of key human spaceflight capabilities in support of moving towards a possible commercial crew transportation system to low earth orbit (LEO). It was intended to foster entrepreneurial activities with a few selected companies. The other purpose of the Project was to try to reduce some of the possible risk with a commercial crew transportation system to LEO. The entrepreneurial activities were encouraged with these few selected companies by NASA providing only part of the total funding to complete specific tasks that were jointly agreed to by NASA and the company. These joint agreements were documented in a Space Act Agreement (SAA) that was signed by NASA and the company. This paper will provide an overview of the CCDev Project and it will also discuss in detail the Environmental Control and Life Support (ECLS) tasks that were performed under CCDev.

Williams, David E.

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Peter Edward Marshall

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Thermal Protection Systems

Process Optimization of Bismaleimide (BMI) Resin Infused Carbon Fiber Composite

Engineers today are presented with the opportunity to design and build the next generation of space vehicles out of the lightest, strongest, and most durable materials available. Composites offer excellent structural characteristics and outstanding reliability in many forms that will be utilized in future aerospace applications including the Commercial Crew and Cargo Program and the Orion space capsule. NASA's Composites for Exploration (CoEx) project researches the various methods of manufacturing composite materials of different fiber characteristics while using proven infusion methods of different resin compositions. Development and testing on these different material combinations will provide engineers the opportunity to produce optimal material compounds for multidisciplinary applications. Through the CoEx project, engineers pursue the opportunity to research and develop repair patch procedures for damaged spacecraft. Working in conjunction with Raptor Resins Inc., NASA engineers are utilizing high flow liquid infusion molding practices to manufacture high-temperature composite parts comprised of intermediate modulus 7 (IM7) carbon fiber material. IM7 is a continuous, high-tensile strength composite with outstanding structural qualities such as high shear strength, tensile strength and modulus as well as excellent corrosion, creep, and fatigue resistance. IM7 carbon fiber, combined with existing thermoset and thermoplastic resin systems, can provide improvements in material strength reinforcement and deformation-resistant properties for high-temperature applications. Void analysis of the different layups of the IM7 material discovered the largest total void composition within the [ +45 , 90 , 90 , -45 ] composite panel. Tensile and compressional testing proved the highest mechanical strength was found in the [0 4] layup. This paper further investigates the infusion procedure of a low-cost/high-performance BMI resin into an IM7 carbon fiber material and the optical, chemical, and mechanical analyses performed.

Ehrlich, Joshua W.

Technology Development and Infusion by NASA's Entry Systems Modeling Project

This paper describes recent development of modeling and simulation technologies for entry systems and their infusion into NASA's exploration missions. Technology development is organized and prioritized using a system-level perspective, resulting in four broad technical areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. The paper will highlight key contributions from each of these areas, their impacts from a spacecraft and mission design perspective, and discuss planned future investment. Aspects of each technical area are only briefly summarized here. Thermal protection material modeling is geared toward high-fidelity, predictive models capable of optimizing design performance, post-flight reconstruction, and quantifying thermal protection system reliability. New computational tools and experimental techniques have been applied to Orion, MSL/Mars 2020, Mars InSight, and Mars Sample Return missions. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. In both cases, substantial improvements in model uncertainty have directly impacted the development of mission margin policies, flight instrumentation design and analysis (Orion and Mars 2020), and have even revealed the importance of neglected phenomena like mid-wave infrared radiation of CO2. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics affecting Orion, Commercial Crew, and Mars programs; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate augmentation of aerothermal environments at Mars during dust storms; and studies of roughness-induced heating augmentation relevant to tiled (Orion, Mars 2020) and woven (Mars Sample Return) thermal protection systems. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent, with precision landing requirements driven by Mars human exploration goals.

Barnhardt, Michael D.