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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2013

Effects of the Orion Launch Abort Vehicle Plumes on Aerodynamics and Controllability

Characterization of the launch abort system of the Multi-purpose Crew Vehicle (MPCV) for control design and accurate simulation has provided a significant challenge to aerodynamicists and design engineers. The design space of the launch abort vehicle (LAV) includes operational altitudes from ground level to approximately 300,000 feet, Mach numbers from 0-9, and peak dynamic pressure near 1300psf during transonic flight. Further complicating the characterization of the aerodynamics and the resultant vehicle controllability is the interaction of the vehicle flowfield with the plumes of the two solid propellant motors that provide attitude control and the main propulsive impulse for the LAV. These interactions are a function of flight parameters such as Mach number, altitude, dynamic pressure, vehicle attitude, as well as parameters relating to the operation of the motors themselves - either as a function of time for the AM, or as a result of the flight control system requests for control torque from the ACM. This paper discusses the computational aerodynamic modeling of the aerodynamic interaction caused by main abort motor and the attitude control motor of the MPCV LAV, showing the effects of these interactions on vehicle controllability.

Vicker, Darby↗
NASA NTRS2013

Analysis and Results from a Flush Airdata Sensing System in Close Proximity to Firing Rocket Nozzles

This paper presents information regarding the nosecap Flush Airdata Sensing (FADS) system on Orion’s Pad Abort 1 (PA-1) vehicle. The purpose of the nosecap FADS system was to test whether or not useful data could be obtained from a FADS system if it was placed in close proximity to firing rocket nozzles like the Attitude Control Motor (ACM) nozzles on the PA-1 Launch Abort System. The nosecap FADS system used pressure measurements from a series of pressure ports which were arranged in a cruciform pattern and flush with the surface of the vehicle to estimate values of angle of attack, angle of sideslip, Mach number, impact pressure, and freestream static pressure. This paper will present the algorithms employed by the FADS system along with the development of the calibration datasets and a comparison of the final results to the Best Estimated Trajectory (BET) data for PA-1. Also presented in this paper is a Computational Fluid Dynamics (CFD) study to explore the impact of the ACM on the nosecap FADS system. The comparison of the nosecap FADS system results to the BET and the CFD study showed that more investigation is needed to quantify the impact of the firing rocket motors on the FADS system.

Flush Air Data Sensing System↗
NASA NTRS2013

Analysis and Results from a Flush Airdata Sensing (FADS) System in Close Proximity to Firing Rocket Nozzles

This presentation presents information regarding the nose-cap flush airdata sensing (FADS) system on Orion's Pad Abort 1 (PA-1) vehicle. The purpose of the nose-cap FADS system was to test whether or not useful data could be obtained from a FADS system if it was placed in close proximity to firing rockets nozzles like the attitude control motor (ACM) nozzles on the PA-1 launch abort system (LAS). The nose-cap FADS systems use pressure measurements from a series of pressure ports which are arranged in a cruciform pattern and flush with the surface of the vehicle to estimate values of angle of attack, angle of side-slip, Mach number, impact pressure and free-stream static pressure.

Pad Abort 1↗
NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗
NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗
NASA NTRS2010

Objectives and Progress on Ground Vibration Testing for the Ares Projects

Integrated vehicle ground vibration testing (IVGVT) will be a vital component for ensuring the safety of NASA s next generation of exploration vehicles to send human beings to the Moon and beyond. A ground vibration test (GVT) measures the fundamental dynamic characteristics of launch vehicles during various phases of flight. The Ares Flight & Integrated Test Office (FITO) will be conducting the IVGVT for the Ares I crew launch vehicle at Marshall Space Flight Center (MSFC) from 2012 to 2014 using Test Stand (TS) 4550. MSFC conducted similar GVT for the Saturn V and Space Shuttle vehicles. FITO will perform the IVGVT on the Ares I crew launch vehicle, which will lift the Orion crew exploration vehicle to low Earth orbit, and the Ares V cargo launch vehicle, which can launch the lunar lander into orbit and send the combined Orion/lander vehicles toward the Moon. Ares V consists of a six-engine core stage with two solid rocket boosters and an Earth departure stage (EDS). The same engine will power the EDS and the Ares I second stage. The current plan is to test six configurations in three unique test positions inside TS 4550. Four Ares I second stage test configurations will be tested in Position 3, consisting of the Upper Stage and Orion crew module in four nominal conditions: J-2X engine ignition, post Launch Abort System (LAS) jettison, critical slosh mass, and J-2X burn-out. Position 2 consists of the entire launch stack at first stage burn-out (using empty first stage segments). Position 1 represents the entire launch stack at lift-off (using inert first stage segments). Because of long disuse, TS 4550 is being repaired and modified for reactivation to conduct the Ares I IVGVT. The Shuttle-era platforms have been removed and are being replaced with mast climbers that provide ready access to the test articles and can be moved easily to support different positions within the test stand. Two new cranes will help move test articles at the test stand and at the Redstone Arsenal rail-head where first stage segments will be received in late 2010. The electrical system for TS 4550 also will be upgraded. The Hydraulic Support Systems (HDSs) used for Saturn and Shuttle are being disassembled and evaluated for use during IVGVT. Analyses indicate that the 45-year-old HDSs can be refurbished to support the Ares I IVGT. An alternate concept for a pneumatic suspension system is also being explored. A decision on which suspension system configuration to use for IVGVT will be made in 2010.

Tuma, Margaret L.↗
NASA NTRS2008

Integrated Testing Approaches for the NASA Ares I Crew Launch Vehicle

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

Taylor, James L.↗
NASA NTRS2007

Risk Assessment Challenges in the Ares I Upper Stage

NASA Marshall Space Flight Center (MSFC) is currently at work developing hardware and systems for the Ares I rocket that will send future astronauts into orbit. Built on cutting-edge launch technologies, evolved powerful Apollo and Space Shuttle propulsion elements, and decades of NASA spaceflight experience, Ares I is the essential core of a safe, reliable, cost-effective space transportation system -- one that will carry crewed missions back to the moon, on to Mars and out into the solar system. Ares I is an in-line, two-stage rocket configuration topped by the Orion crew vehicle and its launch abort system. In addition to the vehicle's primary mission -carrying crews of four to six astronauts to Earth orbit --Ares I may also use its 25-ton payload capacity to deliver resources and supplies to the International Space Station, or to "park" payloads in orbit for retrieval by other spacecraft bound for the moon or other destinations. Crew transportation to the International Space Station is planned to begin no later than 2014. The first lunar excursion is scheduled for the 2020 timeframe. This paper presents the challenges in designing the Ares I upper stage for reliability and safety while minimizing weight and maximizing performance.

Stott, James E.↗
NASA NTRSDate not supplied

Orion @ Ames

NASA Ames is a key contributor in Orion heatshield development, aerothermodynamics and aerodynamic and launch abort system modeling of the Artemis generation spacecrafts. This talk will provide an overview and highlights of various present and past activities that ARC staff has been contributing to the program.

heatshield↗
NASA NTRS2008

Technical Progress on the Ares I-X Flight Test

Ares I-X will be NASA's first test flight for a new human-rated launch vehicle since 1981, and the team is well on its way toward completing the vehicle's design and hardware fabrication for an April 2009 launch. This uncrewed suborbital development test flight gives NASA its first opportunities to: gather critical data about the flight dynamics of the integrated launch vehicle; understand how to control its roll during flight; better characterize the stage separation environments during future flight; and demonstrate the first stage recovery system. The Ares I-X Flight Test Vehicle (FTV) incorporates a mix of flight and mockup hardware. It is powered by a four-segment solid rocket booster, and will be modified to include a fifth, spacer segment; the upper stage, Orion crew exploration vehicle, and launch abort system are simulator hardware to make the FTV aerodynamically similar to the same size, shape, and weight of Ares I. The Ares IX first stage includes an existing Shuttle solid rocket motor and thrust vector control system controlled by an Ascent Thrust Vector Controller (ATVC) designed and built by Honeywell International. The avionics system will be tested in a dedicated System Integration Laboratory located at Lockheed Martin Space Systems (LMSS) in Denver, Colorado. The Upper Stage Simulator (USS) is made up of cylindrical segments that will be stacked and integrated at Kennedy Space Center (KSC) for launch. Glenn Research Center is already building these segments, along with their internal access structures. The active Roll Control System (RoCS) includes two thruster units harvested from Peacekeeper missiles. Duty cycle testing for RoCS was conducted, and fuel tanking and detanking tests will occur at KSC in early 2008. This important flight will provide valuable experience for the ground operations team in integrating, stacking, and launching Ares I. Data from Ares I-X will ensure the safety and reliability of America's newest launch vehicle.

Davis, S.R.↗
NASA NTRS2009

Flight and Integrated Vehicle Testing: Laying the Groundwork for the Next Generation of Space Exploration Launch Vehicles

Integrated vehicle testing will be critical to ensuring proper vehicle integration of the Ares I crew launch vehicle and Ares V cargo launch vehicle. The Ares Projects, based at Marshall Space Flight Center in Alabama, created the Flight and Integrated Test Office (FITO) as a separate team to ensure that testing is an integral part of the vehicle development process. As its name indicates, FITO is responsible for managing flight testing for the Ares vehicles. FITO personnel are well on the way toward assembling and flying the first flight test vehicle of Ares I, th Ares I-X. This suborbital development flight will evaluate the performance of Ares I from liftoff to first stage separation, testing flight control algorithms, vehicle roll control, separation and recovery systems, and ground operations. Ares I-X is now scheduled to fly in summer 2009. The follow-on flight, Ares I-Y, will test a full five-segment first stage booster and will include cryogenic propellants in the upper stage, an upper stage engine simulator, and an active launch abort system. The following flight, Orion 1, will be the first flight of an active upper stage and upper stage engine, as well as the first uncrewed flight of an Orion spacecraft into orbit. The Ares Projects are using an incremental buildup of flight capabilities prior to the first operational crewed flight of Ares I and the Orion crew exploration vehicle in 2015. In addition to flight testing, the FITO team will be responsible for conducting hardware, software, and ground vibration tests of the integrated launch vehicle. These efforts will include verifying hardware, software, and grou handling interfaces. Through flight and integrated testing, the Ares Projects will identify and mitigate risks early the United States prepares to take its next giant leaps to the Moon and beyond.

Taylor, Jim↗
NASA NTRS2009

Flight and Integrated Vehicle Testing: Laying the Groundwork for the Next Generation of Space Exploration Launch Vehicles

Integrated vehicle testing will be critical to ensuring proper vehicle integration of the Ares I crew launch vehicle and Ares V cargo launch vehicle. The Ares Projects, based at Marshall Space Flight Center in Alabama, created the Flight and Integrated Test Office (FITO) as a separate team to ensure that testing is an integral part of the vehicle development process. As its name indicates, FITO is responsible for managing flight testing for the Ares vehicles. FITO personnel are well on the way toward assembling and flying the first flight test vehicle of Ares I, the Ares I-X. This suborbital development flight will evaluate the performance of Ares I from liftoff to first stage separation, testing flight control algorithms, vehicle roll control, separation and recovery systems, and ground operations. Ares I-X is now scheduled to fly in summer 2009. The follow-on flight, Ares I-Y, will test a full five-segment first stage booster and will include cryogenic propellants in the upper stage, an upper stage engine simulator, and an active launch abort system. The following flight, Orion 1, will be the first flight of an active upper stage and upper stage engine, as well as the first uncrewed flight of an Orion spacecraft into orbit. The Ares Projects are using an incremental buildup of flight capabilities prior to the first operational crewed flight of Ares I and the Orion crew exploration vehicle in 2015. In addition to flight testing, the FITO team will be responsible for conducting hardware, software, and ground vibration tests of the integrated launch vehicle. These efforts will include verifying hardware, software, and ground handling interfaces. Through flight and integrated testing, the Ares Projects will identify and mitigate risks early as the United States prepares to take its next giant leaps to the Moon and beyond.

Taylor, J. L.↗
NASA NTRS2010

Ares I-X Flight Test Development Challenges and Success Factors

The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.

Askins, Bruce↗
NASA NTRSDate not supplied

Predicting Orion Launch Abort Acoustics

Computational fluid dynamics (CFD) scale-resolving simulations were performed to help assess the Orion launch abort system’s vibro-acoustic environment in collaboration with the Orion Loads and Dynamics team at the Johnson Space Center (JSC). The primary objectives are to establish best practices and to validate CFD predictions for surface fluctuating pressure spectra with ground, wind tunnel, and flight test data. Excellent agreement is obtained between CFD predictions by the Cartesian adaptive mesh refinement (AMR) module of the Launch, Ascent, and Vehicle Aerodynamics (LAVA) solver and measurements from a ground test representative of the start of a pad abort scenario, and with measurements from a wind tunnel test case corresponding to a transonic, high total angle of attack ascent abort scenario. A simplified (static and at rest) simulation of a pad abort flight test shows good agreement with the flight data, whereas a more costly simulation where the vehicle is accelerating relative to the ground from rest to Mach 0.4 shows consistent over-prediction of the spectra. Simulation results for a supersonic ascent abort flight test are in reasonable agreement with the measurements, but show larger excursions in regions where non-linear interactions between the plume turbulence, shocks, and turbulent boundary layer are strongest – likely due to CFD modeling assumptions, the effect of which are discussed. Overall, the CFD results demonstrate that scale-resolving simulation methodologies like the one presented can help characterize full-scale launch abort vehicle near-field noise and can complement wind tunnel, ground and flight tests by providing trends and reducing uncertainty for scenarios that cannot or are not planned to be tested.

Orion↗
NASA NTRSDate not supplied

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Ascent vehicles in the developmental stages of the program are instrumented with Developmental Flight Instrumentation (DFI) sensors. These sensors establish a link between a vehicle and engineers on the ground to communicate conditions experienced during the ascent. These data are then compared to pre-flight predictions used in the design process. The aerodynamic, acoustic, thermal, and structural data are either telemetered to ground stations during the ascent or stored on the vehicle for post-flight recovery and archived at the Huntsville Operations Support Center (HOSC). Following NASA's Artemis I Space Launch System (SLS) launch on November 16, 2020, data from three separate programs are available at the HOSC: Space Shuttle Program (Space Transport System (STS)), Constellation Program (Ares I-X), and Artemis Program (SLS). Availability of these data presents a unique opportunity to examine DFI data from three distinct vehicles and analyze the broad impact of the DFI data on the understanding of transonic aerodynamics. Classical spectrogram and Empirical Mode Decomposition techniques were used to present data in aerodynamically analogous regions on each vehicle. On the SLS and Ares I-X, a region downstream of the Launch Abort System motors was chosen. Comparing SLS and the STS, a region downstream of booster Froward Attach Hardware was selected as analogous flow region. Some other regions of interest were also identified. Although similarities in flow features on three vehicles were identified, some challenges in the comparison were also encountered, especially due to poor temporal and spatial resolution of Shuttle measurements.

Space Shuttle↗
NASA NTRSDate not supplied

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Ascent vehicles in the developmental stages of the program are instrumented with Developmental Flight Instrumentation (DFI) sensors. These sensors establish a link between a vehicle and engineers on the ground to communicate conditions experienced during the ascent. These data are then compared to pre-flight predictions used in the design process. The aerodynamic, acoustic, thermal, and structural data are either telemetered to ground stations during the ascent or stored on the vehicle for post-flight recovery and archived at the Huntsville Operations Support Center (HOSC). Following NASA's Artemis I Space Launch System (SLS) launch on November 16, 2020, data from three separate programs are available at the HOSC: Space Shuttle Program (Space Transport System (STS)), Constellation Program (Ares I-X), and Artemis Program (SLS). Availability of these data presents a unique opportunity to examine DFI data from three distinct vehicles and analyze the broad impact of the DFI data on the understanding of transonic aerodynamics. Classical spectrogram and Empirical Mode Decomposition techniques were used to present data in aerodynamically analogous regions on each vehicle. On the SLS and Ares I-X, a region downstream of the Launch Abort System motors was chosen. Comparing SLS and the STS, a region downstream of booster Froward Attach Hardware was selected as analogous flow region. Some other regions of interest were also identified. Although similarities in flow features on three vehicles were identified, some challenges in the comparison were also encountered, especially due to poor temporal and spatial resolution of Shuttle measurements.

Space Shuttle↗
NASA NTRS2011

Aerodynamic Testing of the Orion Launch Abort Tower Separation with Jettison Motor Jet Interactions

The aerodynamic database for the Orion Launch Abort System (LAS) was developed largely from wind tunnel tests involving powered jet simulations of the rocket exhaust plumes, supported by computational fluid dynamics (CFD) simulations. The LAS contains three solid rocket motors used in various phases of an abort to provide propulsion, steering, and Launch Abort Tower (LAT) jettison from the Crew Module (CM). This paper describes a pair of wind tunnel experiments performed at transonic and supersonic speeds to determine the aerodynamic effects due to proximity and jet interactions during LAT jettison from the CM at the end of an abort. The tests were run using two different scale models at angles of attack from 150deg to 200deg , sideslip angles from -10deg to +10deg , and a range of powered thrust levels from the jettison motors to match various jet simulation parameters with flight values. Separation movements between the CM and LAT included axial and vertical translations as well as relative pitch angle between the two bodies. The paper details aspects of the model design, nozzle scaling methodology, instrumentation, testing procedures, and data reduction. Sample data are shown to highlight trends seen in the results.

Rhode, Matthew N.↗
NASA NTRS2008

Ares First Stage "Systemology" - Combining Advanced Systems Engineering and Planning Tools to Assure Mission Success

Ares is an integral part of NASA s Constellation architecture that will provide crew and cargo access to the International Space Station as well as low earth orbit support for lunar missions. Ares replaces the Space Shuttle in the post 2010 time frame. Ares I is an in-line, two-stage rocket topped by the Orion Crew Exploration Vehicle, its service module, and a launch abort system. The Ares I first stage is a single, five-segment reusable solid rocket booster derived from the Space Shuttle Program's reusable solid rocket motor. The Ares second or upper stage is propelled by a J-2X main engine fueled with liquid oxygen and liquid hydrogen. This paper describes the advanced systems engineering and planning tools being utilized for the design, test, and qualification of the Ares I first stage element. Included are descriptions of the current first stage design, the milestone schedule requirements, and the marriage of systems engineering, detailed planning efforts, and roadmapping employed to achieve these goals.

Seiler, James↗