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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 NTRS2010

Performance Support Tools for Space Medical Operations

Early Constellation space missions are expected to have medical capabilities similar to those currently on board the Space Shuttle and International Space Station (ISS). Flight surgeons on the ground in Mission Control will direct the Crew Medical Officer (CMO) during medical situations. If the crew is unable to communicate with the ground, the CMO will carry out medical procedures without the aid of a flight surgeon. In these situations, use of performance support tools can reduce errors and time to perform emergency medical tasks. The research presented here is part of the Human Factors in Training Directed Research Project of the Space Human Factors Engineering Project under the Space Human Factors and Habitability Element of the Human Research Program. This is a joint project consisting of human factors teams from the Johnson Space Center (JSC) and the Ames Research Center (ARC). Work on medical training has been conducted in collaboration with the Medical Training Group at JSC and with Wyle that provides medical training to crew members, biomedical engineers (BMEs), and flight surgeons under the Bioastronautics contract. Human factors personnel at Johnson Space Center have investigated medical performance support tools for CMOs and flight surgeons.

Byrne, Vicky↗
NASA NTRS2010

Launch Pad Flame Trench Refractory Materials

The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.

Calle, Luz M.↗
NASA NTRS1983

Tethers open new space options

Several examples of possible applications of the tethering concept in space are examined. In particular, attention is given to a practical design of a 500-kg satellite system to be tethered at a distance of 100 km from the Space Shuttle. The satellite body has the form of a sphere, aerodynamically stabilized and fitted with a dockline adapter that mates with a capture mechanism at the tip of an extendable boom; the tether is a very flexible synthetic line 1-2 mm in diameter. Other applications include a wholly passive stable platform created by tethering two rows of empty Shuttle External Tanks or similar masses 10-20 km apart, a remote docking port for a space station, and constellations of space objects, with tethers used to tie them together and constrain their relative motions.

Bekey, I.↗
NASA NTRS2007

Testing of the Multi-Fluid Evaporator Engineering Development Unit

Hamilton Sundstrand is under contract with the NASA Johnson Space Center to develop a scalable, evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It is being designed to support the Orion Crew Module and to support future Constellation missions. The MFE would be used from Earth sea level conditions to the vacuum of space. The current Shuttle configuration utilizes an ammonia boiler and flash evaporator system to achieve cooling at all altitudes. The MFE system combines both functions into a single compact package with significant weight reduction and improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing surface area to keep the back pressure low. The multiple layer construction of the core allows for efficient scale up to the desired heat rejection rate. The full scale MFE prototype will be constructed with four core sections that, combined with a novel control scheme, manage the risk of freezing the heat exchanger cores. A sub-scale MFE engineering development unit (EDU) has been built, and is identical to one of the four sections of a full scale prototype. The EDU has completed testing at Hamilton Sundstrand. The overall test objective was to determine the thermal performance of the EDU. The first set of tests simulated how each of the four sections of the prototype would perform by varying the chamber pressure, evaporant flow rate, coolant flow rate and coolant temperature. A second set of tests was conducted with an outlet steam header in place to verify that the outlet steam orifices prevent freeze-up in the core while also allowing the desired thermal turn-down ratio. This paper discusses the EDU tests and results.

Quinn, Gregory↗
NASA NTRS2008

Environment Challenges for Exploration of the Moon

NASA's Constellation Program is designing a new generation of human rated launch and space transportation vehicles to first replace the Space Shuttle fleet, then support develop of a permanent human habitat on the Moon, and ultimately prepare for human exploration of Mars. The ambitious first step beyond low Earth orbit is to develop the infrastructure required for conducting missions to a variety of locations on the lunar surface for periods of a week and establishment of a permanent settlement at one of the lunar poles where crews will serve for periods on the order of approx.200 days. We present an overview of the most challenging aspects of the lunar environment that will need to be addressed when developing transport and habitat infrastructure for long term human presence on the Moon including low temperatures and dusty regolith surfaces, radiation environments due to galactic cosmic rays and solar energetic particles, charging of lunar infrastructure when exposed to lunar plasma environments, and secondary meteor environments generated by primary impacts on the lunar surface.

Minow, Joseph I.↗
NASA NTRS2002

University Nanosatellite Program ION-F Constellation

The Space Engineering program at Utah State University has developed a small satellite, known as USUSat, under funding from AFOSR, AFRL, NASA and Utah State University's Space Dynamics Laboratory. This satellite was designed and significantly manufactured by students in the Mechanical and Aerospace Engineering and the Electrical and Computer Engineering Departments within the College of Engineering. USUSat is one of three spacecraft being designed for the Ionospheric Observation Nanosatellite Formation (ION- F). This formation comprises three 15 kg. spacecraft designed and built in cooperation by Utah State University, University of Washington, and Virginia Polytechnic Institute. The ION-F satellites are being designed and built by students at the three universities, with close coordination to insure compatibility for launch, deployment, and the formation flying mission. The JON-F mission is part of the U.S. Air Force Research Laboratory (AFRL) University Nanosatellite Program, which provides technology development and demonstrations for the TechSat2l Program. The University Nanosatellite Program involves 10 universities building nanosatellites for a launch in 2004 on two separate space shuttle missions. Additional support for the formation flying demonstration has been provided by NASA's Goddard Space Flight Center.

NANOSATS (NANOSATELLITES)↗
NASA NTRS2007

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗
NASA NTRS2007

A Case Study Using Modeling and Simulation to Predict Logistics Supply Chain Issues

Optimization of critical supply chains to deliver thousands of parts, materials, sub-assemblies, and vehicle structures as needed is vital to the success of the Constellation Program. Thorough analysis needs to be performed on the integrated supply chain processes to plan, source, make, deliver, and return critical items efficiently. Process modeling provides simulation technology-based, predictive solutions for supply chain problems which enable decision makers to reduce costs, accelerate cycle time and improve business performance. For example, United Space Alliance, LLC utilized this approach in late 2006 to build simulation models that recreated shuttle orbiter thruster failures and predicted the potential impact of thruster removals on logistics spare assets. The main objective was the early identification of possible problems in providing thruster spares for the remainder of the Shuttle Flight Manifest. After extensive analysis the model results were used to quantify potential problems and led to improvement actions in the supply chain. Similarly the proper modeling and analysis of Constellation parts, materials, operations, and information flows will help ensure the efficiency of the critical logistics supply chains and the overall success of the program.

Tucker, David A.↗
NASA NTRS2010

Constellation Program DOLILU Operational Concepts

Day of launch I-load uplink (DOLILU) and a corresponding day of launch trajectory and loads evaluation are being considered for the Constellation Program. Abort effectiveness, controllability, and ascent structural loads all improve with some of the flight software I-loads designed using current measured atmospheric conditions. While a generalized DOLILU framework has been assumed, specific implementation details have not yet been discussed in depth nor documented. Operational improvements can be leveraged from Space Shuttle experience to create a more cost-effective and streamlined process while maintaining the integrity of the results. A preliminary discussion of DOLILU design methodology is presented followed by some suggestions and implementation details for Constellation Program DOLILU operations

Puperi, Daniel S.↗
NASA NTRS1985

Tethers Open New Space Options

The fundamentals of tether action are discussed with focus on the forces acting on tethered masses and a tethered satellite system being developed for deployment from the space shuttle is examined. The static, dynamic, and electric properties of the tether can be exploited for use in the long term observation of phenomena of the lower troposphere; as a space based wind tunnel; to generate high electrodynamic power; to provide desirable gravity for the space station; to dock orbit transfer vehicles with the space station; and to form a constellation of space platforms tied to the space station. Italy is responsible for building and integrating the satellite. NASA is involved in building the deployer and integrating the tethered satellite system with the space shuttle.

Bekey, I.↗
NASA NTRS2012

Friction Pull Plug Welding in Aluminum Alloys

NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗
NASA NTRS2010

The HYTHIRM Project: Flight Thermography of the Space Shuttle During the Hypersonic Re-entry

This report describes a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. A background and an overview of several multidisciplinary efforts that culminated in the acquisition of high resolution calibrated infrared imagery of the Space Shuttle during hypervelocity atmospheric entry is presented. The successful collection of thermal data has demonstrated the feasibility of obtaining remote high-resolution infrared imagery during hypersonic flight for the accurate measurement of surface temperature. To maximize science and engineering return, the acquisition of quantitative thermal imagery and capability demonstration was targeted towards three recent Shuttle flights - two of which involved flight experiments flown on Discovery. In coordination with these two Shuttle flight experiments, a US Navy NP-3D aircraft was flown between 26-41 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 (STS-119) and Mach 14.7 (STS-128) using a long-range infrared optical package referred to as Cast Glance. This same Navy aircraft successfully monitored the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission (STS-125). The purpose of this paper is to describe the systematic approach used by the Hypersonic Thermodynamic Infrared Measurements team to develop and implement a set of mission planning tools designed to establish confidence in the ability of an imaging platform to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. The mission planning tools included a pre-flight capability to predict the infrared signature of the Shuttle. Such tools permitted optimization of the hardware configuration to increase signal-to-noise and to maximize the available dynamic range while mitigating the potential for saturation. Post flight, analysis tools were used to assess atmospheric effects and to convert the 2-D intensity images to 3-D temperature maps of the windward surface. Comparison of the spatially resolved global thermal measurements to surface thermocouples and CFD prediction is made. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the Shuttle suggests future applications towards hypersonic flight test programs within NASA, DoD and DARPA along with flight test opportunities supporting NASA's project Constellation.

Horvath, Thomas J.↗
NASA NTRS2010

The J-2X Upper Stage Engine: From Design to Hardware

NASA is well on its way toward developing a new generation of launch vehicles to support of national space policy to retire the Space Shuttle fleet, complete the International Space Station, and return to the Moon as the first step in resuming this nation s exploration of deep space. The Constellation Program is developing the launch vehicles, spacecraft, surface systems, and ground systems to support those plans. Two launch vehicles will support those ambitious plans the Ares I and Ares V. (Figure 1) The J-2X Upper Stage Engine is a critical element of both of these new launchers. This paper will provide an overview of the J-2X design background, progress to date in design, testing, and manufacturing. The Ares I crew launch vehicle will lift the Orion crew exploration vehicle and up to four astronauts into low Earth orbit (LEO) to rendezvous with the space station or the first leg of mission to the Moon. The Ares V cargo launch vehicle is designed to lift a lunar lander into Earth orbit where it will be docked with the Orion spacecraft, and provide the thrust for the trans-lunar journey. While these vehicles bear some visual resemblance to the 1960s-era Saturn vehicles that carried astronauts to the Moon, the Ares vehicles are designed to carry more crew and more cargo to more places to carry out more ambitious tasks than the vehicles they succeed. The government/industry team designing the Ares rockets is mining a rich history of technology and expertise from the Shuttle, Saturn and other programs and seeking commonality where feasible between the Ares crew and cargo rockets as a way to minimize risk, shorten development times, and live within the budget constraints of its original guidance.

Byrd, Thomas↗
NASA NTRS2011

Application of the Life Safety Code to a Historic Test Stand

NASA has conducted a study to assess alternatives to refurbishing existing launch vehicle modal test facilities as opposed to developing new test facilities to meet the demands of a very fiscally constrained test and evaluation environment. The results of this study showed that Marshall Space Flight Center (MSFC) Test Stand (TS) 4550 could be made compliant, within reasonable cost and schedule impacts, if safety processes and operational limitations were put in place to meet the safety codes and concerns of the Fire Marshall. Trades were performed with key selection criteria to ensure that appropriate levels of occupant safety are incorporated into test facility design modifications. In preparation for the ground vibration tests that were to be performed on the Ares I launch vehicle, the Ares Flight and Integrated Test Office (FITO) organization evaluated the available test facility options, which included the existing mothballed structural dynamic TS4550 used by Apollo and Shuttle, alternative ground vibration test facilities at other locations, and construction of a new dynamic test stand. After an exhaustive assessment of the alternatives, the results favored modifying the TS4550 because it was the lowest cost option and presented the least schedule risk to the NASA Constellation Program for Ares Integrated Vehicle Ground Vibration Test (IVGVT). As the renovation design plans and drawings were being developed for TS4550, a safety concern was discovered the original design for the construction of the test stand, originally built for the Apollo Program and renovated for the Shuttle Program, was completed before NASA s adoption of the currently imposed safety and building codes per National Fire Protection Association Life Safety Code [NFPA 101] and International Building Codes. The initial FITO assessment of the design changes, required to make TS4550 compliant with current safety and building standards, identified a significant cost increase and schedule impact. An effort was launched to thoroughly evaluate the applicable life safety requirements, examine the context in which they were derived, and determine a means by which the TS4550 modifications could be made within budget and on schedule, while still providing the occupants with appropriate levels of safety.

Askins, Bruce↗
NASA NTRS2008

Semi-Automated Diagnosis, Repair, and Rework of Spacecraft Electronics

NASA's Constellation Program for Exploration of the Moon and Mars places human crews in extreme isolation in resource scarce environments. Near Earth, the discontinuation of Space Shuttle flights after 2010 will alter the up- and down-mass capacity for the International Space Station (ISS). NASA is considering new options for logistics support strategies for future missions. Aerospace systems are often composed of replaceable modular blocks that minimize the need for complex service operations in the field. Such a strategy however, implies a robust and responsive logistics infrastructure with relatively low transportation costs. The modular Orbital Replacement Units (ORU) used for ISS requires relatively large blocks of replacement hardware even though the actual failed component may really be three orders of magnitude smaller. The ability to perform in-situ repair of electronics circuits at the component level can dramatically reduce the scale of spares and related logistics cost. This ability also reduces mission risk, increases crew independence and improves the overall supportability of the program. The Component-Level Electronics Assembly Repair (CLEAR) task under the NASA Supportability program was established to demonstrate the practicality of repair by first investigating widely used soldering materials and processes (M&P) performed by modest manual means. The work will result in program guidelines for performing manual repairs along with design guidance for circuit reparability. The next phase of CLEAR recognizes that manual repair has its limitations and some highly integrated devices are extremely difficult to handle and demand semi-automated equipment. Further, electronics repairs require a broad range of diagnostic capability to isolate the faulty components. Finally repairs must pass functional tests to determine that the repairs are successful and the circuit can be returned to service. To prevent equipment demands from exceeding spacecraft volume capacity and skill demands from exceeding crew time and training limits, the CLEAR project is examining options provided by non-real time tele-operations, robotics, and a new generation of diagnostic equipment. This paper outlines a strategy to create an effective repair environment where, with the support of ground based engineers, crewmembers can diagnose, repair and test flight electronics in-situ. This paper also discusses the implications of successful tele-robotic repairs when expanded to rework and reconfiguration of used flight assets for building Constellation infrastructure elements.

Struk, Peter M.↗
NASA NTRS2007

Managing External Relations: The Lifeblood of Mission Success

The slide presentation examines the role of customer and stakeholder relations in the success of space missions. Topics include agency transformation; an overview of project and program experience with a discussion of positions, technical accomplishments, and management lessons learned; and approaches to project success with emphasis on communication. Projects and programs discussed include the Space Shuttle Main Engine System, DC-XA Flight Demonstrator, X-33 Flight Demonstrator, Space Launch Initiative/2nd Generation Reusable Launch Vehicle, X-37 Flight Demonstrator, Constellation (pre Dr. Griffin), Safety and Mission Assurance, and Exploration Launch Projects.

Dumbacher, Daniel L.↗
NASA NTRS2010

Overview of the Orion Thermal Protection System

The Orion spacecraft is being developed as part of the Constellation Exploration Program and will serve as the United States crewed transportation system to the International Space Station after the retirement of the Space Shuttle in 2010 and as the eventual means to return U.S. astronauts to the Moon. Therefore, Orion is being designed for reentry missions from both low Earth orbit and from Lunar-return trajectories. This presentation will provide an overview of the development of the Orion TPS, a critical component in the development of the spacecraft. The thermal protection system (TPS) that protects the crew module from the extreme environments associated with Earth atmospheric reentry consists of a forward heatshield and an aft backshell. The requirements that drive the design of the TPS will be discussed, including several key requirements that establish a precedent for U.S. human-rated spacecraft. For the first time in U.S. human spaceflight, a vehicle s TPS is being designed with a specific, derived requirement for reliability. Also, due to the increased presence of spacecraft in Earth s orbit in recent decades, requirements for micro-meteoroid/orbital debris damage tolerance are also a driving requirement that has affected the selection of portions of the TPS. The efforts to select materials and to define a preliminary design for both the heatshield and the backshell will be described. This will include a discussion of the design challenges presented by the numerous penetrations on both the backshell and the heatshield. Finally, the verification and validation plan which is currently under development to certify the TPS for human-rated missions will be outlined. To support the execution of this plan, a ground test campaign for both thermal and structural performance is being designed. This test campaign will directly support thermal and thermal/structural analyses that also are fundamental to the certification effort.

Kowal, T. John↗
NASA NTRS2011

Ares I-X Ascent Base Environments

Plume induced base heating environments were measured during the flight of the NASA Constellation Ares I-X developmental launch vehicle, successfully flown on October 28, 2009. The Ares IX first stage is a four segment Space Shuttle derived booster with base consisting of a flared aft skirt, deceleration and tumble motors, and a thermal curtain surrounding the first stage 7.2 area ratio nozzle. Developmental Flight Instrumentation (DFI) consisted of radiometers, calorimeters, pressure transducers and gas temperature probes installed on the aft skirt and nozzle to measure the base environments. In addition, thermocouples were also installed between the layers of the flexible thermal curtain to provide insight into the curtain response to the base environments and to assist in understanding curtain failure during reentry. Plume radiation environment predictions were generated by the Reverse Monte Carlo (RMC) code and the convective base heating predictions utilized heritage MSFC empirical methods. These predictions were compared to the DFI data and results from the flight videography. Radiation predictions agreed with the flight measured data early in flight but gauge failures prevented high altitude comparisons. The convective environment comparisons demonstrated the need to improve the prediction methodology; particularly for low altitude, local plume recirculation. The convective comparisons showed relatively good agreement at altitudes greater than 50,000 feet.

Mobley, B. L.↗