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NASA NTRS2015

FJET Database Project: Extract, Transform, and Load

The Data Mining & Knowledge Management team at Kennedy Space Center is providing data management services to the Frangible Joint Empirical Test (FJET) project at Langley Research Center (LARC). FJET is a project under the NASA Engineering and Safety Center (NESC). The purpose of FJET is to conduct an assessment of mild detonating fuse (MDF) frangible joints (FJs) for human spacecraft separation tasks in support of the NASA Commercial Crew Program. The Data Mining & Knowledge Management team has been tasked with creating and managing a database for the efficient storage and retrieval of FJET test data. This paper details the Extract, Transform, and Load (ETL) process as it is related to gathering FJET test data into a Microsoft SQL relational database, and making that data available to the data users. Lessons learned, procedures implemented, and programming code samples are discussed to help detail the learning experienced as the Data Mining & Knowledge Management team adapted to changing requirements and new technology while maintaining flexibility of design in various aspects of the data management project.

excel vba↗

NASA NTRS2024

Agency Additive Manufacturing (AM) Certification Support Team (AACT) Risk Reduction – Safe Life Category: Fracture Control Framework for Un-inspectable Fracture Critical AM Parts

The NASA Engineering and Safety Center (NESC) was requested to support the development of a governing philosophy to provide a consistent and systematic approach for fracture control certification of additive manufacturing (AM) hardware that cannot be reliably inspected. The overall goal of the NESC assessment was to make progress toward a framework for general certification of un-inspectable fracture critical AM hardware and toward approaches for evaluating risks associated with these components. This report contains the results of the assessment.

Additive Manufacturing↗

NASA NTRS2012

Materials and Process Activities for NASA's Composite Crew Module

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center (NESC) to design, build, and test a full-scale Composite Crew Module (CCM). The overall goal of the CCM project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project s baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. The materials and process activities were prioritized based on a rapid prototype approach. This approach focused developmental activities on design details with greater risk and uncertainty, such as out-of-autoclave joining, over some of the more traditional lamina and laminate building block levels. While process development and associated building block testing were performed, several anomalies were still observed at the full-scale level due to interactions between process robustness and manufacturing scale-up. This paper describes the process anomalies that were encountered during the CCM development and the subsequent root cause investigations that led to the final design solutions. These investigations highlight the importance of full-scale developmental work early in the schedule of a complex composite design/build project.

Polis, Daniel L.↗

NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This report contains the outcome of the NESC assessment.

Composite Overwrapped Pressure Vessels; Linear Ela↗

NASA NTRS2022

Safe Human Expeditions Beyond Low Earth Orbit (LEO)

The NASA Engineering and Safety Center (NESC) conducted an interdisciplinary study and workshop focusing on capabilities needed for crew health and safety on long-duration deep space expeditions in support of the Artemis Program and missions to Mars. The study focused on integration among four disciplines: 1) space weather monitoring and forecasting, 2) shielding technologies, 3) human health research, and 4) human factors engineering tools. An integrated risk assessment was performed to inform characteristics of mission architecture and capabilities needed for safe, long-duration human expeditions beyond low Earth orbit. This report contains the outcome of the NESC assessment.

Low Earth Orbit↗

NASA NTRS2022

Unique Science from the Moon in the Artemis Era

Since the beginning of the space age, the Moon has been proposed as a platform for astronomy. The Moon provides unique capabilities for astrophysics observations. NASA’s Artemis plan to return humans to the Moon in the mid-2020s in a sustainable manner provides an opportunity to advance synergistic approaches between human and robotic exploration. This NASA Engineering and Safety Center (NESC) workshop assesses the feasibility and value proposition of using the Moon as a location for performing unique science observations, leveraging Artemis-era infrastructure while evaluating risks and key engineering challenges.

NASA Engineering and Safety Center↗

NASA NTRS2018

Demonstration of the Space Launch System Augmenting Adaptive Control Algorithm on Pole-Cart Platform

NASA's baseline Space Launch System (SLS) ight control system (FCS) includes an adaptive augmenting control (AAC) portion in addition to the ight-heritage nominal classical controller. The AAC algorithm is intended to improve the robustness and performance of the classical controller. Over the past several years, the AAC algorithm developed at NASA Marshall Space Flight Center (MSFC) has matured significantly through extensive simulation, rigorous analytical proofs, and a series of successful ight tests on a F18 aircraft. This study was part of a SLS program and NASA Engineering and Safety Center (NESC) joint e ort to further increase the confidence level of the AAC algorithm by demonstrating its key functionalities on a classroom type of example, the pole-cart sys- tem, at the NASA Langley Research Center (LaRC) dynamics and control laboratory. The fundamental dynamics behind balancing an inverted pendulum is similar to controlling an aerodynamically unstable rocket. Both systems are inherently open-loop unstable and requires feedback control for attitude stabilization. The principles behind the AAC algorithm is applicable to a wide range of conditionally stable dynamical systems. Hence, the outcomes from this simple and inexpensive exercise has provided the SLS program with additional confidence into the AAC design, operation, robustness, and application.

Pei, Jing↗

NASA NTRS2024

Trade Space Analyses: Balancing Crew and Mission Design Parameters

In 2020, the Associate Administrator for Human Exploration and Operations and the Agency’s Federated Board requested an assessment to develop a methodology for trade space analysis comparing crew size for Mars missions against mission design parameters. The NASA Engineering and Safety Center (NESC) conducted an assessment to develop a methodology for systematic, repeatable trade space analysis for crew size and developed an initial set of human performance models and a list of candidate crew tasks for NASA’s first mission to Mars. This report contains the results of the NESC assessment.

Humans to Mars↗

NASA NTRS2025

Trade Space Analyses: Balancing Crew and Mission Design Parameters-Candidate Mars Master Task List

Crew Duties and Tasks↗

NASA NTRS2021

Improvements to the Flight Analysis and Simulation Tool (FAST) and Initial Development of the Genesis Flight Mechanics Simulation for Ascent, Aerocapture, Entry, Descent, and Landing (A2EDL) Trajectory Design

The NASA Engineering and Safety Center (NESC) was requested to provide significant enhancements to the Flight Analysis and Simulation Tool (FAST), a generic, variable-degree-of-freedom, multi-body ascent, aerocapture, entry, descent, and landing (A2EDL) flight simulation code and a key Agency analysis tool. This report details the upgrades to FAST that were completed, describes a change to the assessment’s scope that allowed its goals to be exceeded with a new and innovative approach, and discusses the results of the modified approach.

NASA Engineering and Safety Center; Flight Analysi↗

NASA NTRS2009

A Review of the MLAS Parachute Systems

The NASA Engineering and Safety Center (NESC) is developing the Max Launch Abort System (MLAS) as a risk-mitigation design should problems arise with the baseline Orion spacecraft launch abort design. The Max in MLAS is dedicated to Max Faget, the renowned NASA spacecraft designer. The MLAS flight test vehicle consists of boost skirt, coast skirt and the MLAS fairing which houses a full scale boilerplate Orion Crew Module (CM). The objective of the flight test is to prove that the CM can be released from the MLAS fairing during pad abort conditions without detrimental recontact between the CM and fairing, achieving performance similar to the Orion launch abort system. The boost and coast skirts provide the necessary thrust and stability to achieve the flight test conditions and are released prior to the test -- much like the Little Joe booster was used in the Apollo Launch Escape System tests. To achieve the test objective, two parachutes are deployed from the fairing to reorient the CM/fairing to a heatshield first orientation. The parachutes then provide the force necessary to reduce the total angle of attack and body angular rates required for safe release of the CM from the fairing. A secondary test objective after CM release from the fairing is to investigate the removal of the CM forward bay cover (FBC) with CM drogue parachutes for the purpose of attempting to synchronously deploying a set of CM main parachutes. Although multiple parachute deployments are used in the MLAS flight test vehicle to complete its objective, there are only two parachute types employed in the flight test. Five of the nine parachutes used for MLAS are 27.6 ft D(sub 0) ribbon parachutes, and the remaining four are standard G-12 cargo parachutes. This paper presents an overview of the 27.6 ft D(sub 0) ribbon parachute system employed on the MLAS flight test vehicle for coast skirt separation, fairing reorientation, and as drogue parachutes for the CM after separation from the fairing. Discussion will include: the process used to select this design, previously proven as a spin/stall recovery parachute; descriptions of all components of the parachute system; the minor modifications necessary to adapt the parachute to the MLAS program; the techniques used to analyze the parachute for the multiple roles it performs; a discussion of the rigging techniques used to interface the parachute system to the vehicle; and a brief description of how the evolution of the program affected parachute usage and analysis. An overview of the Objective system, rationale for the MLAS approach and the future of the program will also be presented. We hope to have flight test results to report at the time of the Conference Presentation.

Taylor, Anthony P.↗

NASA NTRS2020

Composite Overwrapped Pressure Vessel (COPV) Damage Tolerance Life Analysis Methodology and Test Best Practices: Appendices

The NASA Engineering and Safety Center (NESC) Deputy Director requested an independent assessment to develop data to understand the limitations of linear elastic fracture mechanics (LEFM) computational methods used to predict fatigue crack growth rate (da/dN) behavior of small detectable cracks in thin metal liners for composite overwrapped pressure vessels (COPVs). The NESC assessment team was also requested to demonstrate a test-based methodology for validating damage tolerance requirements for COPVs with elastically responding metal liners where LEFM methods are not appropriate. This document contains the appendices to the main report.

Composite Overwrapped Pressure Vessels; Linear Ela↗

NASA NTRS2015

Check-Cases for Verification of 6-Degree-of-Freedom Flight Vehicle Simulations: Appendices - Volume 2

This NASA Engineering and Safety Center (NESC) assessment was established to develop a set of time histories for the flight behavior of increasingly complex example aerospacecraft that could be used to partially validate various simulation frameworks. The assessment was conducted by representatives from several NASA Centers and an open-source simulation project. This document contains details on models, implementation, and results.

Murri, Daniel G.↗

NASA NTRS2010

NASA Engineering and Safety Center Technical Bulletin No. 10-02: Potential Failure of Dual Simultaneously Initiated Pyrotechnic Operated Valves

The NASA Engineering and Safety Center (NESC) Technical Bulletin No. 09-01 reported an independent investigation of four pyrovalve failures that occurred while using aluminum (Al) pyrovalve primer chamber assemblies (PCAs) during ground testing. The investigation revealed that simultaneous firing (within a few microseconds) of the NASA Standard Initiators (NSIs) was the primary reason why the booster charge failed to ignite and the pyrovalves subsequently failed to operate. A second investigation of a new stainless steel (SS) PCA design with separate flame channels was completed in 2010. The new SS configuration was found to be improved in most respects; however, no improvement was noted in the temperature delivered to ignite the booster during dual simultaneous NSI firings. Simultaneous firings should be avoided when using either the Al or the SS PCA design.

Potential Failure↗

NASA NTRS2011

A Review of the NASA MLAS Flight Demonstration

The NASA Engineering and Safety Center (NESC) has tested the Max Launch Abort System (MLAS) as a risk-mitigation design should problems arise with the baseline Orion spacecraft launch abort design. The Max in MLAS is not Maximum, but rather dedicated to Max Faget, the renowned NASA Spacecraft designer. In July 2009, the mission was flown, with great success, from the NASA Wallops Flight Facility. The MLAS flight test vehicle prototype consists of a boost skirt, coast skirt, and the MLAS fairing itself, which houses an Orion Command Module (CM) boilerplate. The objective of the MLAS flight test is to reorient the fairing with the CM, weighing approximately 29,000 lbs and traveling 290 fps, 180 degrees to an orientation suitable for the release of the CM during a pad abort or low altitude abort. The boost and coast skirts provide the necessary thrust and stability to establish the flight test conditions and are released prior to the reorientation of the fairing. A secondary test objective after successful release of the CM from the fairing is to demonstrate the removal of the CM forward bay cover (FBC) with the CM drogue parachutes, and subsequent deployment of the CM main parachutes attached to the FBC. Although multiple parachute deployments are used in the MLAS flight test vehicle to complete its objective, there are only two parachute types employed in the flight test. Five of the nine parachutes used for MLAS are 27.6 ft DO ribbon parachutes already proven as a spin/stall parachute for military aircraft, and the remaining four are G-12 cargo parachutes modified for increased strength and reefing. This paper presents an overview of the 27.6 ft DO ribbon parachute system employed on the MLAS flight test vehicle for coast skirt separation, fairing reorientation, and as CM drogue parachutes. Discussion will include: the process used to select this design; descriptions of all components of the parachute system; the minor modifications necessary to adapt the parachute to the MLAS program; the techniques used to analyze the parachute for the multiple roles it performs including discussions of how the evolution of the program affected parachute usage and analysis; a summary of the results of the highly successful flight test, including video of the flight test; and an overview of the subsequent post-test analysis.

Taylor, Anthony P.↗

NASA NTRS2014

Evaluation of Agency Non-Code Layered Pressure Vessels (LPVs)

In coordination with the Office of Safety and Mission Assurance and the respective Center Pressure System Managers (PSMs), the NASA Engineering and Safety Center (NESC) was requested to formulate a consensus draft proposal for the development of additional testing and analysis methods to establish the technical validity, and any limitation thereof, for the continued safe operation of facility non-code layered pressure vessels. The PSMs from each NASA Center were asked to participate as part of the assessment team by providing, collecting, and reviewing data regarding current operations of these vessels. This report contains the outcome of the assessment and the findings, observations, and NESC recommendations to the Agency and individual NASA Centers.

Prosser, William H.↗

NASA NTRS2014

Evaluation of Agency Non-Code Layered Pressure Vessels (LPVs) : Appendices - Volume 2

In coordination with the Office of Safety and Mission Assurance and the respective Center Pressure System Managers (PSMs), the NASA Engineering and Safety Center (NESC) was requested to formulate a consensus draft proposal for the development of additional testing and analysis methods to establish the technical validity, and any limitation thereof, for the continued safe operation of facility non-code layered pressure vessels. The PSMs from each NASA Center were asked to participate as part of the assessment team by providing, collecting, and reviewing data regarding current operations of these vessels. This document contains the appendices to the main report.

Prosser, William H.↗

NASA NTRS2014

Evaluation of Agency Non-Code Layered Pressure Vessels (LPVs)

Prosser, William H.↗