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Fault Detection, Isolation and Recovery (FDIR) Portable Liquid Oxygen Hardware Demonstrator

The Fault Detection, Isolation and Recovery (FDIR) hardware demonstration will highlight the effort being conducted by Constellation's Ground Operations (GO) to provide the Launch Control System (LCS) with system-level health management during vehicle processing and countdown activities. A proof-of-concept demonstration of the FDIR prototype established the capability of the software to provide real-time fault detection and isolation using generated Liquid Hydrogen data. The FDIR portable testbed unit (presented here) aims to enhance FDIR by providing a dynamic simulation of Constellation subsystems that feed the FDIR software live data based on Liquid Oxygen system properties. The LO2 cryogenic ground system has key properties that are analogous to the properties of an electronic circuit. The LO2 system is modeled using electrical components and an equivalent circuit is designed on a printed circuit board to simulate the live data. The portable testbed is also be equipped with data acquisition and communication hardware to relay the measurements to the FDIR application running on a PC. This portable testbed is an ideal capability to perform FDIR software testing, troubleshooting, training among others.

Oostdyk, Rebecca L.↗

Forecasting Evaluation of WindSat in the Coastal Environment

WindSat has demonstrated that measurements from polarimetric space-based microwave radiometers can be used to retrieve global ocean surface vector winds. Since the date of launch in 2003, substantial incremental improvements have been made to WindSat data processing, calibration, and retrieval algorithms. The retrievals now have higher resolution, improved wind vector ambiguity removal, and enhanced capability to represent high winds. Utilization of WindSat retrievals (wind vectors, total precipitable water, rainrate and sea surface temperature) will be demonstrated in the context of operational weather forecasting applications, especially the monitoring of topographically-forced winds. Examples will be presented from various parts of the world, including inland seas, midlatitude oceans, the tropics, and the United States. We will illustrate retrievals in extreme high- and extreme low-wind regimes, both of which can be problematic. Rain contamination will be addressed. We will include a comparison of WindSat vector maps to corresponding maps from the QuikScat scatterometer. We will discuss how near-realtime data from WindSat is being transitioned to specific offices within the National Weather Service.

Lee, Thomas F.↗

Microbiological Validation of the IVGEN System

The principal purpose of this report is to describe a validation process that can be performed in part on the ground prior to launch, and in space for the IVGEN system. The general approach taken is derived from standard pharmaceutical industry validation schemes modified to fit the special requirements of in-space usage.

Porter, David A.↗

Evolution of Software-Only-Simulation at NASA IV and V

Software-Only-Simulations have been an emerging but quickly developing field of study throughout NASA. The NASA Independent Verification Validation (IVV) Independent Test Capability (ITC) team has been rapidly building a collection of simulators for a wide range of NASA missions. ITC specializes in full end-to-end simulations that enable developers, VV personnel, and operators to test-as-you-fly. In four years, the team has delivered a wide variety of spacecraft simulations that have ranged from low complexity science missions such as the Global Precipitation Management (GPM) satellite and the Deep Space Climate Observatory (DSCOVR), to the extremely complex missions such as the James Webb Space Telescope (JWST) and Space Launch System (SLS).This paper describes the evolution of ITCs technologies and processes that have been utilized to design, implement, and deploy end-to-end simulation environments for various NASA missions. A comparison of mission simulators are discussed with focus on technology and lessons learned in complexity, hardware modeling, and continuous integration. The paper also describes the methods for executing the missions unmodified flight software binaries (not cross-compiled) for verification and validation activities.

Embedded↗

Supercomputing in the Age of Discovering Superearths, Earths and Exoplanet Systems

NASA's Kepler Mission was launched in March 2009 as NASA's first mission capable of finding Earth-size planets orbiting in the habitable zone of Sun-like stars, that range of distances for which liquid water would pool on the surface of a rocky planet. Kepler has discovered over 1000 planets and over 4600 candidates, many of them as small as the Earth. Today, Kepler's amazing success seems to be a fait accompli to those unfamiliar with her history. But twenty years ago, there were no planets known outside our solar system, and few people believed it was possible to detect tiny Earth-size planets orbiting other stars. Motivating NASA to select Kepler for launch required a confluence of the right detector technology, advances in signal processing and algorithms, and the power of supercomputing.

exoplanet↗

Chasing Exoplanets

NASA's Kepler Mission was launched in March 2009 as NASA's first mission capable of finding Earth-size planets orbiting in the habitable zone of Sun-like stars, that range of distances for which liquid water would pool on the surface of a rocky planet. Kepler has discovered over 1000 planets and over 4600 candidates, many of them as small as the Earth. Today, Kepler's amazing success seems to be a fait accompli to those unfamiliar with her history. But twenty years ago, there were no planets known outside our solar system, and few people believed it was possible to detect tiny Earth-size planets orbiting other stars. Motivating NASA to select Kepler for launch required a confluence of the right detector technology, advances in signal processing and algorithms, and the power of supercomputing.

Kepler Mission↗

Prospecting for Habitable Worlds

NASAs Kepler Mission was launched in March 2009 as NASAs first mission capable of finding Earth-size planets orbiting in the habitable zone of Sun-like stars, that range of distances for which liquid water would pool on the surface of a rocky planet. Kepler has discovered over 2200 planets and over 2200 candidate planets, many of them as small as the Earth. Forty nine of these are less than twice the size of Earth and orbit in the habitable zone of their stars, all of which are cooler and significantly smaller than the Sun.Today, Keplers amazing success seems to be a fait accompli to those unfamiliar with her history. But twenty years ago, there were no planets known outside our solar system, and few people believed it was possible to detect tiny Earth-size planets orbiting other stars. Indeed, demonstrating that the science was feasible took four proposals to NASAs Discovery Program and extensive research and laboratory demonstrations. Motivating NASA to select Kepler for launch required a confluence of the right detector technology, advances in signal processing and algorithms, and the power of supercomputing. On August 23 2015 we reported the discovery of Kepler-452b, the first small, possibly rocky planet in the habitable zone of a G2 star very similar to our own. Kepler-452b orbits its star once every 385 days in an orbit just 5 larger than that of Earth. This discovery represents an important step towards finding and characterizing small habitable worlds orbiting Sun-like stars.

Jenkins, Jon M.↗

The Earth Observing System (EOS)

The Earth Observing System is a US National Aeronautics and Space Administration (NASA) program consisting of a science segment, a data system, and a space segment made up of a series of polar-orbiting and mid-inclination satellites for long-term monitoring of the Earth as an integrated system, including observations of the land surface, biosphere, atmosphere, cryosphere, and oceans. Initially conceived in the mid-late 1980s, it was implemented as a series of large "flagship" missions and smaller focused satellites, often in partnership with instruments and sometimes spacecraft from other nations. In 1984 NASA formed several instrument panels to develop concepts for “facility instruments” that would provide comprehensive support to the scientific and applications’ communities, each with a supporting science team competitively selected via peer-review. An Announcement of Opportunity was released in 1988 and proposals were solicited for three types of proposals: (i) instrument investigations that would include the provision of instrumentation for flight on a polar platform, including non-Earth science payloads requiring polar orbits (PI instruments), (ii) research facility instrument team member and team leader investigations for facility instruments, and (iii) interdisciplinary science investigations to provide data analysis and modeling, preparing to use data acquired from the space platforms. The initial selections made in 1989 included support for 24 instrument investigations, 6 research facility instrument investigations, and 28 interdisciplinary investigations. Although considerable changes were made over the years in the structure and orbital configuration of the various instruments and platforms, a total of 10 different missions were eventually flown, as shown in Fig. 1. These included three multiinstrument flagship platforms known as Terra (launched in 1999), Aqua (launched in 2002), and Aura (launched in 2004), where the Terra mission emphasis was primarily on land processes, Aqua on the hydrological cycle, and Aura on atmospheric chemistry. In addition to these flagship missions the EOS missions included Landsat 7 (land cover classification and change), QuikScat (wind speed and direction over the oceans), Jason-1 (ocean surface topography and sea level), ACRIMSAT (total solar irradiance (TSI)), SAGE III (stratospheric aerosol and ozone levels), ICESat (ice, cloud, and land elevation), and SORCE (Solar Radiation and Climate Experiment; total and spectral solar irradiance). In addition EOS supported CERES (an Earth radiation budget sensor) and LIS (a lightning sensor), that flew as part of the NASA/JAXA Tropical Rainfall Measuring Mission (1997), and SeaWinds (wind speed and direction), that flew as part of the short-lived ADEOS II (Midori II, 2002) mission of JAXA (Japan Aerospace Exploration Agency). The EOS contributions are too numerous to present in detail in this article, but can be viewed for convenience as a means of obtaining global measurements (with appropriate characteristics) of the 24 variables and variable groups listed in Table 1. This table was created by the EOS community in the late 1990s as a way to succinctly indicate which instruments on the various EOS platforms were expected to contribute to each of the specified variables in primary (bold), secondary (bold italics), or contributing (roman) roles. All of the science data products produced by these space missions are available without charge throughout the world, and are thus highly valued for their many contributions to applications such as air quality, fires, land cover change, and the state of the oceans, as well as for science and monitoring of the state of the Earth system and its changes over time. These and other international satellites have played a crucial role in understanding and documenting global change, including (i) global surface temperature and atmospheric temperature and water vapor profiles, (ii) glacial retreat, (iii) sea ice extent and change, (iv) solar radiation into and out of the Earth-atmosphere system, (v) atmospheric aerosol and cloud properties, (vi) sources and sinks of

ICESat↗

Prospecting for Habitable Planets

NASA's Kepler Mission was launched in March 2009 as NASA's first mission capable of finding Earth-size planets orbiting in the habitable zone of Sun-like stars, that range of distances for which liquid water would pool on the surface of a rocky planet. Kepler has discovered over 1000 planets and over 4600 candidates, many of them as small as the Earth. Today, Kepler's amazing success seems to be a fait accompli to those unfamiliar with her history. But twenty years ago, there were no planets known outside our solar system, and few people believed it was possible to detect tiny Earth-size planets orbiting other stars. Motivating NASA to select Kepler for launch required a confluence of the right detector technology, advances in signal processing and algorithms, and the power of supercomputing.

Kepler Mission↗

Assessing Flow Formability of Aerospace Aluminum Alloys via DIC Tensile Testing

Over the past decade, NASA Langley Research Center (LaRC) has championed integrally stiffened cylinder (ISC) technology for single-piece, cryogenic tank barrels on launch vehicles. The current investigation aims to extend the hybrid spin/shear/flow forming process to aircraft fuselage structures, a damage tolerance critical application. The WF Maschinenbau VUD-600® vertical spin/flow forming facility recently established at LaRC represents a reasonable sub-scale facsimile of the ISC deformation process for research and development (R&D) purposes. The objective of this study is to explore whether tensile testing with digital image correlation (DIC) is an effective way to rank the formability of candidate aerospace Al alloys and expedite empirical forming trials. Specific tensile data, such as reduction of area, strain hardening exponent, and modulus of resilience, are used as formability metrics for a variety of alloy/temper/product form combinations. Results from high-strength aluminum alloys AA 2139, AA 2050, AA 2043 and AA 2219 are compared with the medium-strength, highly formable AA 6061 benchmark. Rolled, forged and cast preform materials in both the -O temper (fully annealed) and -T4 temper (solution-treated, quenched, and naturally aged) conditions are evaluated. AA 2139 plate in the -T4 temper emerges as the top-ranked material, based on the criteria selected. Starting with preforms in the -T4 temper will result in flow-formed material exhibiting mechanical properties closer to aircraft fuselage requirements. The optimum balance between strength and damage tolerance may also be achieved via post-forming procedures that avoid quenching and stretching.

Aluminum alloys↗

Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Mission Overview and Science Return

The Low-Earth Orbit (LEO) Flight Test of an Inflatable Decelerator (LOFTID) mission was the culmination of two decades of research and development led by NASA Langley Research Center for Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. A HIAD aeroshell can be hard packed into a small volume for launch and then deployed prior to atmospheric entry for stable aerodynamic deceleration through the atmosphere. Much larger than traditional fixed diameter aeroshells that are constrained by the size of launch vehicle shrouds, inflatable decelerators create more drag and start the deceleration process in the upper reaches of the atmosphere with greater efficiency and stability. Large deployable heatshields enable spacecraft to carry bigger, heavier payloads, including scientific instruments and human support systems for planetary landing and exploration. The success of the LOFTID mission could enable new NASA missions to Mars (including access to higher altitudes than currently possible), Venus, and most solar system destinations with atmospheres, as well as cost-effective payload returns to Earth. With its unique 6m diameter inflatable heatshield, LOFTID was the first-of-a-kind orbital reentry flight, and the largest blunt body atmospheric entry of any kind. On November 10, 2022, the LOFTID aeroshell endured the harsh environments of atmospheric reentry while exhibiting stable aerodynamics through the entire spectrum of hypersonic, supersonic, transonic, and subsonic flight. The demonstration confirmed the HIAD technology structural and thermal performance as the aeroshell protected the 1100 kg Reentry Vehicle (RV) entering Earth’s atmosphere at 8 km/s, reaching Mach 30, and experiencing 9.5 g deceleration before deploying parachutes and gently splashing down in the Pacific Ocean, where it was recovered in excellent condition. The LOFTID aeroshell was exposed to an aeroheating environment representative of many Mars and LEO HIAD applications, and successfully demonstrated the ability of the heat-affected inflatable structure to withstand aerodynamic forces that exceeded those expected at Mars. This mission further demonstrated the viability of HIAD technology to deliver large payloads safely and accurately through an atmosphere via a controlled entry, descent, and landing. Whereas LOFTID was indeed a first-of-a-kind flight for an inflatable heatshield, its remarkable performance assured that it will not be the last of its kind.

J M Dinonno↗

Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) Mission Overview and Science Return

The Low-Earth Orbit (LEO) Flight Test of an Inflatable Decelerator (LOFTID) mission was the culmination of two decades of research and development led by NASA Langley Research Center for Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. A HIAD aeroshell can be hard packed into a small volume for launch and then deployed prior to atmospheric entry for stable aerodynamic deceleration through the atmosphere. Much larger than traditional fixed diameter aeroshells that are constrained by the size of launch vehicle shrouds, inflatable decelerators create more drag and start the deceleration process in the upper reaches of the atmosphere with greater efficiency and stability. Large deployable heatshields enable spacecraft to carry bigger, heavier payloads, including scientific instruments and human support systems for planetary landing and exploration. The success of the LOFTID mission could enable new NASA missions to Mars (including access to higher altitudes than currently possible), Venus, and most solar system destinations with atmospheres, as well as cost-effective payload returns to Earth. With its unique 6m diameter inflatable heatshield, LOFTID was the first-of-a-kind orbital reentry flight, and the largest blunt body atmospheric entry of any kind. On November 10, 2022, the LOFTID aeroshell endured the harsh environments of atmospheric reentry while exhibiting stable aerodynamics through the entire spectrum of hypersonic, supersonic, transonic, and subsonic flight. The demonstration confirmed the HIAD technology structural and thermal performance as the aeroshell protected the 1100 kg Reentry Vehicle (RV) entering Earth’s atmosphere at 8 km/s, reaching Mach 30, and experiencing 9.5 g deceleration before deploying parachutes and gently splashing down in the Pacific Ocean, where it was recovered in excellent condition. The LOFTID aeroshell was exposed to an aeroheating environment representative of many Mars and LEO HIAD applications, and successfully demonstrated the ability of the heat-affected inflatable structure to withstand aerodynamic forces that exceeded those expected at Mars. This mission further demonstrated the viability of HIAD technology to deliver large payloads safely and accurately through an atmosphere via a controlled entry, descent, and landing. Whereas LOFTID was indeed a first-of-a-kind flight for an inflatable heatshield, its remarkable performance assured that it will not be the last of its kind.

John M DiNonno↗

Enhanced Simulation Techniques in Predicting Sonic Boom Loudness Using CFD

This paper outlines advancements in predicting sonic boom loudness within the Launch, Ascent, and Vehicle Aerodynamics (LAVA) computational framework. Traditionally, a two step process consisting of a steady state computational fluid dynamics problem for near-field analysis and a far-field propagation solver for calculation of loudness metrics has been used. Improvements to this process made in this work include utilizing a high-order space marching method for mid-field computations, developing a novel output-based mesh adaptation method targeting error in near-field pressure sig-natures, and developing a robust scripting system using curvilinear grids to increase robustness and simplify the process of running large databases of simulation cases. These advancements are detailed and applied to the simulation of the X-59, presenting comparative cost and timing analyses between the prior two step workflow and the current three step procedure. We achieve increased accuracy and robustness for loudness predictions with at least a50%computational cost reduction.

CST↗

The Alaska synthetic aperture radar (SAR) facility project

A receiving station for the acquisition and processing of spaceborne synthetic aperture radar (SAR) data is being established by the National Aeronautics and Space Administration (NASA) at the University of Alaska, Fairbanks. The data that will be received from a number of SAR satellites that are to be launched starting in 1990 will allow U.S. researchers to study sea ice, oceanographic and geological features, hydrological processes, glaciers, and vegetation cover in Alaska and its surrounding seas.

Carsey, F.↗

Solid Rocket Booster (SRB) Flight System Integration at Its Best

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Wood, T. David↗

Tri-Gas Pressurization System Testing and Modeling for Cryogenic Applications

The use of Tri‐gas in rocket propulsion systems is somewhat of a new technology. This paper defines Tri‐gas as a mixture of gases composed largely of helium with a small percentage of a stoichiometric mixture of hydrogen and oxygen. When exposed to a catalyst the hydrogen and oxygen in the mixture combusts, significantly raising the temperature of the mixture. The increase in enthalpy resulting from the combustion process significantly decreases the required quantity of gas needed to pressurize the ullage of the vehicle propellant tanks. The objective of this effort was to better understand the operating characteristics of Tri‐gas in a pressurization system with low temperature applications. In conjunction with ongoing programs at NASA Marshall Space Flight Center, an effort has been undertaken to evaluate the operating characteristics of Tri‐gas through modeling and bench testing. Through improved understanding of the operating characteristics, the risk of using this new technology in a launch vehicle propulsion system was reduced. Bench testing of Tri‐gas was a multistep process that targeted gas characteristics and performance aspects that pose a risk to application in a pressurization system. Pressurization systems are vital to propulsion system performance. Keeping a target ullage pressure in propulsions tanks is necessary to supply propellant at the conditions and flow rates required to maintain desired engine functionality. The first component of testing consisted of sampling Tri‐gas sources that had been stagnant for various lengths of time in order to determine the rate at which stratification takes place. Second, a bench test was set up in which Tri‐gas was sent through a catalyst bed. This test was designed to evaluate the performance characteristics of Tri‐gas, under low temperature inlet temperatures, in a flight‐like catalyst bed reactor. The third, most complex, test examined the performance characteristics of Tri‐gas at low temperature temperatures in a test configuration built to more closely resemble a vehicle pressurization system. The results of these bench tests address various risks that all relate to underperformance of Tri‐gas pressurization systems.

Taylor, B.↗

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

Systems design analysis applied to launch vehicle configuration

As emphasis shifts from optimum-performance aerospace systems to least lift-cycle costs, systems designs must seek, adapt, and innovate cost improvement techniques in design through operations. The systems design process of concept, definition, and design was assessed for the types and flow of total quality management techniques that may be applicable in a launch vehicle systems design analysis. Techniques discussed are task ordering, quality leverage, concurrent engineering, Pareto's principle, robustness, quality function deployment, criteria, and others. These cost oriented techniques are as applicable to aerospace systems design analysis as to any large commercial system.

Ryan, R.↗