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CSP Manufacturing Challenges and Assembly Reliability

Although the expression of CSP is widely used by industry from suppliers to users, its implied definition had evolved as the technology has matured. There are "expert definition"- package that is up to 1.5 time die- or "interim definition". CSPs are miniature new packages that industry is starting to implement and there are many unresolved technical issues associated with their implementation. For example, in early 1997, packages with 1 mm pitch and lower were the dominant CSPs, whereas in early 1998 packages with 0.8 mm and lower became the norm for CSPs. Other changes included the use of flip chip die rather than wire bond in CSP. Nonetheless the emerging CSPs are competing with bare die assemblies and are becoming the package of choice for size reduction applications. These packages provide the benefits of small size and performance of the bare die or flip chip, with the advantage of standard die packages. The JPL-led MicrotypeBGA Consortium of enterprises representing government agencies and private companies have jointed together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects. This talk will cover specifically the experience of our consortium on technology implementation challenges, including design and build of both standard and microvia boards, assembly of two types of test vehicles, and the most current environmental thermal cycling test results.

Ghaffarian, Reza↗

NASA Support for Commercial Crew Launch Capabilities

Since the earliest days of U.S. human spaceflight, NASA’s Marshall Space Flight Center in Huntsville, Alabama, has played a key role in American crew launch capability, from engineering support for the first Mercury-Redstone launches, to the Saturn launches to the Moon, through Shuttle and now Artemis. Today, Marshall brings that expertise gained through decades of crewed space launches to NASA’s Commercial Crew Program (CCP), providing launch vehicle engineering and programmatic support. The team’s responsibilities have included human certification of commercial launch systems for the CCP missions, including Atlas V and Falcon 9, and verifying each launch vehicle complies with flight certification. MSFC provides expertise in nearly all aspects of launch vehicle design and performance including solid motors and liquid engines, stage propulsion, thrust vector control, structural and dynamics, safety and mission assurance. During each commercial crew launch, an engineering support team is on console at Marshall’s Huntsville Operations Support Center, which has provided launch operations support since Apollo, providing real-time oversight to safety standards for the vehicle and verifying data. Launch vehicle support for Commercial Crew has come as a paradigm shift for the MSFC team, inspiring new approaches that leverage expertise and best practices from past NASA-developed launch vehicle missions, while at the same time providing new synergies from work with commercial partners on CCP. This paper will explore the role that the Marshall launch vehicle services team plays in the Commercial Crew Program, as well as lessons learned from the program that will continue to benefit a new era of spaceflight partnerships.

Commercial Crew↗

Human Exploration Science Office (KX) Overview

The Human Exploration Science Office supports human spaceflight, conducts research, and develops technology in the areas of space orbital debris, hypervelocity impact technology, image science and analysis, remote sensing, imagery integration, and human and robotic exploration science. NASA's Orbital Debris Program Office (ODPO) resides in the Human Exploration Science Office. ODPO provides leadership in orbital debris research and the development of national and international space policy on orbital debris. The office is recognized internationally for its measurement and modeling of the debris environment. It takes the lead in developing technical consensus across U.S. agencies and other space agencies on debris mitigation measures to protect users of the orbital environment. The Hypervelocity Impact Technology (HVIT) project evaluates the risks to spacecraft posed by micrometeoroid and orbital debris (MMOD). HVIT facilities at JSC and White Sands Test Facility (WSTF) use light gas guns, diagnostic tools, and high-speed imagery to quantify the response of spacecraft materials to MMOD impacts. Impact tests, with debris environment data provided by ODPO, are used by HVIT to predict risks to NASA and commercial spacecraft. HVIT directly serves NASA crew safety with MMOD risk assessments for each crewed mission and research into advanced shielding design for future missions. The Image Science and Analysis Group (ISAG) supports the International Space Station (ISS) and commercial spaceflight through the design of imagery acquisition schemes (ground- and vehicle-based) and imagery analyses for vehicle performance assessments and mission anomaly resolution. ISAG assists the Multi-Purpose Crew Vehicle (MPCV) Program in the development of camera systems for the Orion spacecraft that will serve as data sources for flight test objectives that lead to crewed missions. The multi-center Imagery Integration Team is led by the Human Exploration Science Office and provides expertise in the application of engineering imagery to spaceflight. The team links NASA programs and private industry with imagery capabilities developed and honed through decades of human spaceflight, including imagery integration, imaging assets, imagery data management, and photogrammetric analysis. The team is currently supporting several NASA programs, including commercial demonstration missions. The Earth Science and Remote Sensing Team is responsible for integrating the scientific use of Earth-observation assets onboard the ISS, which consist of externally mounted sensors and crew photography capabilities. This team facilitates collaboration on remote sensing and participates in research with academic organizations and other Government agencies, not only in conjunction with ISS science, but also for planetary exploration and regional environmental/geological studies. Human exploration science focuses on science strategies for future human exploration missions to the Moon, Mars, asteroids, and beyond. This function provides communication and coordination between the science community and mission planners. ARES scientists support the operation of robotic missions (i.e., Mars Exploration Rovers and the Mars Science Laboratory), contribute to the interpretation of returned mission data, and translate robotic mission technologies and techniques to human spaceflight.

Calhoun, Tracy A.↗

Rocket Propulsion Test Design and Analysis

As the small satellite launch vehicle (SSLV) market grows and NASA continues to prepare for upcoming missions in the Artemis program, John C. Stennis Space Center’s (SSC) testing facilities must adapt to the increasing demand in liquid rocket engine testing. The Rocket Propulsion Test Design and Analysis Project for this rotation focused in both of this areas through two separate subprojects, the creation of a Private Rocket Engine Database and the automatization of the A1-Set Point Prediction Model. To identify the testing requirements of future Stennis Space Center (SSC) costumers, an excel spread sheet was commissioned as a database to collect technical and non-technical features of over one hundred privately developed liquid and hybrid rocket engine. Similarly, The A-1 Set Point Sheet Model is used to satisfy Aerojet Rocketdyne’s testing requirements of Net Positive Suction Pressure (NPSP) for the RS-25 staged combustion cycle engine. To expand the capabilities of this prediction model, a feed back loop was programmed to automate the search of setpoints using Excel Visual Basic for Applications (VBA).

John Paul Ortiz↗

High-Pressure Systems Suppress Fires in Seconds

Much deserved attention is given to the feats of innovation that allow humans to live in space and robotic explorers to beam never-before-seen images back to Earth. In the background of these accomplishments is a technology that makes it all possible the rockets that propel NASA s space exploration efforts skyward. Marshall Space Flight Center has been at the heart of the Agency s rocketry and spacecraft propulsion efforts since its founding in 1960. Located at the Redstone Arsenal near Huntsville, Alabama, the Center has a legacy of success stretching back to the Saturn rockets that carried the Apollo astronauts into space. Even before Marshall was established, Redstone was the site of significant advances in American rocketry under the guidance of famous rocket engineer Werner Von Braun; these included the Juno I rocket that successfully carried the United States first satellite, Explorer 1, into orbit in 1958. And from the first orbital test flight of the Space Shuttle Columbia through the final flights of the shuttle program this year, these vehicles have been enabled by the solid rocket boosters, external tank, and orbiter main engines created at Marshall. Today, Marshall continues to host innovation in rocket and spacecraft propulsion at state-of-the-art facilities such as the Propulsion Research Laboratory. Like many of its past successes, some of the Center s current advancements are being made with the help of private industry partners. The efforts have led not only to new propulsion technologies, but to terrestrial benefits in a seemingly unrelated field in this case, firefighting.

Source record↗

Commercial development of space - A national commitment

The United States is currently in a unique position. It has all the assets required to lead the world in commercial space development. It has the transportation: the Shuttle and a family of expendable launch vehicles. Space Station Freedom is forthcoming. It has the extrepreneurial spirit, coupled with a strong university system and lending institutions with financial capacity necessary for entrepreneurial activities. But, there are a number of actions that the government should take to improve the climate and prospects for greater commercial development of space. This paper outlines some of the steps that NASA is taking to incentivize the private sector to apply its resources and talents to commercial space endeavors.

Rose, James T.↗

Atmospheric Science Field Laboratory - A feasibility study

Plans are underway to transfer the technology represented by the lightning and atmospheric science research facilities and capabilities at the Kennedy Space Center to outside users in other government agencies, private industry, and the academic community. Rocket triggered lightning is being used to demonstrate the feasibility of establishing an Atmospheric Science Field Laboratory as a permanent facility and long-term cost sharing. Results from previous programs and data from a lightning event which occurred during the STS-7 flight are presented to demonstrate the adequacy of the present lightning protection and measuring system to protect personnel, vehicle, and ground equipment, as well as to rapidly assess damage due to a lightning event.

Jafferis, William↗

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C Dempsey↗

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C. Dempsey↗

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C. Dempsey↗

Kennedy Space Center's Partnership with Graftel Incorporated

NASA Kennedy Space Center (KSC) has recently partnered with Graftel Incorporated under an exclusive license agreement for the manufacture and sale of the Smart Current Signature Sensor. The Smart Current Signature Sensor and software were designed and developed to be utilized on any application using solenoid valves. The system monitors the electrical and mechanical health of solenoids by comparing the electrical current profile of each solenoid actuation to a typical current profile and reporting deviation from its learned behavior. The objective of this partnership with Graftel is for them to develop the technology into a hand-held testing device for their customer base in the Nuclear Power Industry. The device will be used to perform diagnostic testing on electromechanical valves used in Nuclear Power plants. Initially, Graftel plans to have working units within the first year of license in order to show customers and allow them to put purchase requests into their next year's budget. The subject technology under discussion was commercialized by the Kennedy Space Center Technology Programs and Partnerships Office, which patented the technology and licensed it to Graftel, Inc., a company providing support, instrumentation, and calibration services to the nuclear community and private sector for over 10 years. For the nuclear power industry, Graftel designs, manufacturers, and calibrates a full line of testing instrumentation. Grafters smart sensors have been in use in the United States since 1993 and have proved to decrease set-up time and test durations. The project was funded by Non-Destructive Engineering, and it is felt that this technology will have more emphasis on future vehicles. Graftel plans to market the Current Signature Sensor to the Electric Utility industry. Graftel currently supplies product and services to the Nuclear Power Industry in the United States as well as internationally. Product and services sold are used in non-destructive testing for valves, penetrations and other applications. Graftel also supplies testing services to an industrial customer base. The customer base includes 90 percent of the U.S. Nuclear plants and plants in Brazil, Europe, and Asia. Graftel works internationally with two representative groups and employees and has ten people at the principle location and a group of contract engineers around the country.

Dunn, Carol Anne↗

NASA's Exploration and In-Space Services (NExIS) Division OSAM-1 Propellant Transfer Subsystem Progress 2020

National Aeronautics and Space Administration (NASA)’s Exploration and In-Space Services (NExIS) Division of Goddard Space Flight Center has been developing technology for the On-orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1) to robotically refuel heritage and new satellites on-orbit. OSAM-1, formerly known as Restore-L, successfully passed an important NASA milestone called Key Decision Point-C (KDP-C), receiving agency-level approval for its implementation. The decision point also establishes the mission’s official schedule and budget. The OSAM-1 spacecraft, Servicing Payload and the Space Infrastructure Dexterous Robot (SPIDER) payload will refuel a satellite in space, assemble a communications antenna and manufacture a beam. By demonstrating these capabilities, the mission is advancing never-before tested technologies for use in future missions (by NASA and other government organizations and private industry). The mission is funded by the Technology Demonstration Missions program within NASA’s Space Technology Mission Directorate. This paper covers a review of servicing extensibility and critical technologies that are being developed within NExIS with a focus on the fluid transfer refueling technology within the framework of the Propellant Transfer Subsystem (PTS). An overview of the planned initial technology demonstration servicing mission via the OSAM-1 Space Vehicle is provided as an extension of the technology development progress reported in 20181, and 20192. The general objectives, challenges, and key technologies are presented as an introduction to the context of the OSAM-1 mission, and a precursor to the OSAM-1 PTS specific development status. Development and progress of the Hose Management Assembly (HMA) and Propellant Transfer Assembly (PTA) are discussed. HMA risk reduction test results including those of thermal vacuum testing are presented. Important analytical results are discussed and progress of drawings and procedures developed for the fabrication and testing phase are shown. A summary of the PTS overall verification status and design activities prepared for the critical design peer review are presented. Procurement progress is shown with status on long, medium, and short term efforts to acquire the hardware required to support the mission objectives. Technology development, challenges, and testing status are discussed with particular regard to the OSAM-1 specific key assemblies including the PTA and HMA along with the overall integrated flight mockup of the spacecraft to client fluid transfer testing conducted in the servicing testbeds. The paper concludes with key milestones leading to the goal of on-orbit refueling to be demonstrated in 2024. The overall mission Launch Readiness Date (LRD) has been realigned to accommodate budget profiles and incorporation of additional on-orbit assembly and manufacturing demonstration efforts.

Propellant transfer, satellite servicing↗

Commercial Hypersonic Transportation Market Study

At the request of NASA, Deloitte conducted an independent market study to provide an independent assessment on the economic viability of hypersonic and supersonic air transportation to inform ongoing strategic planning of research areas within the government and industry and to focus on the areas for technology development and vehicle design requirements. The Study was organized into three primary areas of investigation: Defining the Market appetite for high speed air transport, Defining the business cases; and Assessing Barriers in the environment. The market demand was assessed across a range of Mach numbers from Mach 2 to Mach 6 and ticket price elasticity was determined by surveying potential customers, literature reviews and stakeholder and expert interviews for passenger aircraft, private aircraft and cargo markets. The business case analyses assessed potential business cases across a three-dimensional trade space: flight speed (Mach 2-6), passenger capacity (20-200 passengers) and design range (2500-7500 nmi.). By using the SpaceWorks Rosetta model, we were able to assess each combination in the trade space and to determine the steady state Internal Rate of Return (IRR or profit) was our primary figure of merit and allowed us to rank order the business cases to understand the trends and draw conclusions from the complex trade space. Lastly, we assessed other potential barriers to high speed flight. These were determined through literature review and stakeholder/expert interviews. Once these were compiled, we developed an objective scoring system to allow us to determine overall significance and challenge to aspiring market entrants. The majority of the research was conducted between July and December of 2020 and the results compiled and communicated to NASA in the first quarter of calendar year 2021. This report, along with the companion briefing deck, document the summation of our research and serve as a data repository for use by future researchers in government and industry.

hypersonic aircraft↗

TO36 Hypersonic Study

Commercial Hypersonic Transportation Market Study. At the request of NASA, Deloitte conducted an independent market study to provide an independent assessment on the economic viability of hypersonic and supersonic air transportation to inform ongoing strategic planning of research areas within the government and industry and to focus on the areas for technology development and vehicle design requirements. The Study was organized into three primary areas of investigation: Defining the Market appetite for high speed air transport, Defining the business cases; and Assessing Barriers in the environment. The market demand was assessed across a range of Mach numbers from Mach 2 to Mach 6 and ticket price elasticity was determined by surveying potential customers, literature reviews and stakeholder and expert interviews for passenger aircraft, private aircraft and cargo markets. The business case analyses assessed potential business cases across a three-dimensional trade space: flight speed (Mach 2-6), passenger capacity (20-200 passengers) and design range (2500-7500 nmi.). By using the SpaceWorks Rosetta model, we were able to assess each combination in the trade space and to determine the steady state Internal Rate of Return (IRR or profit) was our primary figure of merit and allowed us to rank order the business cases to understand the trends and draw conclusions from the complex trade space. Lastly, we assessed other potential barriers to high speed flight. These were determined through literature review and stakeholder/expert interviews. Once these were compiled, we developed an objective scoring system to allow us to determine overall significance and challenge to aspiring market entrants. The majority of the research was conducted between July and December of 2020 and the results compiled and communicated to NASA in the first quarter of calendar year 2021. This report, along with the companion briefing deck, document the summation of our research and serve as a data repository for use by future researchers in government and industry.

hypersonic aircraft↗

Understanding Columbia's Reentry Problems

Soon after the Space Shuttle Columbia accident occurred last year, a group of CFD analysts from NASA centers and private industry was organized to help determine the cause of the accident. This group was under the direction of the Applied Aeroscience and CFD Branch of the Aeroscience and Flight Mechanics Division at the Johnson Space Center. For external flow simulations, noncommercial CFD codes that specialize in hypersonic or high Mach number flows were used. These tools were used to determine heating rates, pressures, and temperatures for a large number of vehicle damage scenarios. Lockheed Martin Space Operations was called upon to provide CFD support in the area of internal flows within the shuttle wing cavity, and or these simulations, FLUENT 6.1 was chosen. Two large-scale, simplified models were run to understand the flow patterns once a breach of the internal wing cavity was initiated. The results were primarily used to visualize flow patterns within the wing cavity. The first CFD model included the entire left wing without the wheel. well cavity. The purpose of the first model, which did not include the reinforced carbon-carbon (RCC) cavity along the wing leading edge, was to visualize the flow field within the wing cavity immediately after the leading edge spar breach, This model assumed that the flow coming into the wing cavity was nom1 to the spar. It included all o f the primary vents that allow for flow between the main cavities of the wing. A six-inch diameter hole was modeled in the spar at the approximate location where the spar breach was judged to have occurred, which was between RCC panels 8 and 9. The results of the modeling showed that at this location, the high temperature, high velocity gas stream entering the wing cavity impinged on the outboard wheel well cavity. Instrumentation in the Shuttle wheel well cavity registered abnormal temperatures during reentry, so the FLUENT results helped support the conclusion of the accident investigation team that the spar breach was in the RCC panel 8-9 area, and that the initial spar breach was likely entering the wing cavity normal to the spar. This model also showed that the flow entering the wing cavity tended to swirl within the cavity just outboard of the wheel well, and did not initially penetrate further into the rear cavities of the wing. The second CFD model was a 2-D simulation of the left wing cavity and the RCC cavity. It was used to visualize the flow through the RCC breach, through the wing spar breach, and into the wing cavity directly outboard of the wheel well. The purpose of this model was to verify whether or not it was possible for the flow to come into the wing cavity normal to the leading edge spar. The results from this 2-D model showed that the internal structure behind the RCC panels probably deflected the flow entering the RCC cavity so that it impinged normal to the spar. As in the 3-D model, this deflected flow stream was found to impinge on the wheel well outer wall. This model again supported the conclusions regarding the location of the spar breach and how the flow behaved inside the wing cavity.

Paul, Thomas H.↗

Understanding Columbia's Reentry Problems

Soon after the Space Shuttle Columbia accident occurred last year, a group of CFD analysts from NASA centers and private industry was organized to help determine the cause of the accident. This group was under the direction of the Applied Aeroscience and CFD Branch of the Aeroscience and Flight Mechanics Division at the Johnson Space Center. For external flow simulations, noncommercia2 CFD codes that specialize in hypersonic or high Mach number flows were used. These tools were used to determine heating rates, pressures, and temperatures for a large number of vehicle damage scenarios. Lockheed Martin Space Operations was called upon to provide CFD support in the area of internal flows within the shuttle wing cavity, and for these simulations, FLUENT 6.1 was chosen. Two large-scale, simplified models were m to understand the flow patterns once a breach of the internal wing cavity was initiated. The results were primarily used to visualize flow patterns within the wing cavity. The first CFD model included the entire lee wing without the wheel well cavity. The purpose of the first model, which did not include the reinforced carbon-carbon (RCC) cavity along the wing leading edge, was to visualize the flow field within the wing cavity immediately after the leading edge spar breach, This model assumed that the flow coming into the wing cavity was normal to the spar. It included all of the primary vents that allow for flow between the main cavities of the wing. A six-inch diameter hole was modeled in the spar at the approximate location where the spar breach was judged to have occurred, which was between RCC panels 8 and 9. The results of the modeling showed that at this location, the high temperature, high velocity gas stream entering the wing cavity impinged on the outboard wheel well cavity. Instrumentation in the Shuttle wheel well cavity registered abnormal temperatures during reentry, so the FLUENT results helped support the conclusion of the accident investigation team that the spar breach was in the RCC panel 8-9 area, and that the initial spar breach was likely entering the wing cavity normal to the spar. This model also showed that the flow entering the wing cavity tended to swirl within the cavity just outboard of the wheel well, and did not initially penetrate further into the rear cavities of the wing. The second CFD model was a 2-D simulation of the left wing cavity and the RCC cavity. It was used to visualize the flow through the RCC breach, through the wing spar breach, and into the wing cavity directly outboard of the wheel well. The purpose of this model was to verify whether or not it was possible for the flow to come into the wing cavity normal to the leading edge spar. The results from this 2-D model showed that the internal structure behind the RCC panels probably deflected the flow entering the RCC cavity so that it impinged normal to the spar. As in the 3-D model, this deflected flow stream was Found to impinge on the wheel well outer wall. This model again supported the conclusions regarding the location of the spar breach and how the flow behaved inside the wing cavity.

Paul, Thomas↗

Considerations of a habitat design

Habitats are the cost effective way to house people on the Moon for more than a couple of days. NASA, universities, and private industry have designed habitats to house astronauts for their lunar tour of duty. Designs range from 'campsites' to permanent 'cities' for human development of the Moon. Considering the high cost per round of equipment delivered to the Moon, each pound is questioned and minimized. Beyond the changing, mission-dependent requirements, such as duration, crew size, reusability, mission objectives, many general requirements are semi-constant for the lunar habitat design. Launch vehicle payload envelope, environment, operations, degree of commonality/optimization, radiation protection and support systems (thermal, environmental control, data handling, communications, power structures) affect the habitat design. Habitat design requirements with an emphasis on the semi-constant elements are explored in this paper.

Elrod, Molly↗

The Opportunity in Commercial Approaches for Future NASA Deep Space Exploration Elements

In 2011, NASA released a report assessing the market for commercial crew and cargo services to low Earth orbit (LEO). The report stated that NASA had spent a few hundred million dollars in the Commercial Orbital Transportation Services (COTS) program on the portion related to the development of the Falcon 9 launch vehicle. Yet a NASA cost model predicted the cost would have been significantly more with a non-commercial cost-plus contracting approach. By 2016 a NASA request for information stated it must "maximize the efficiency and sustainability of the Exploration Systems development programs", as "critical to free resources for reinvestment...such as other required deep space exploration capabilities." This work joins the previous two events, showing the potential for commercial, public private partnerships, modeled on programs like COTS, to reduce the cost to NASA significantly for "...other required deep space exploration capabilities." These other capabilities include landers, stages and more. We mature the concept of "costed baseball cards", adding cost estimates to NASA's space systems "baseball cards." We show some potential costs, including analysis, the basis of estimates, data sources and caveats to address a critical question - based on initial assessment, are significant agency resources justified for more detailed analysis and due diligence to understand and invest in public private partnerships for human deep space exploration systems? The cost analysis spans commercial to cost-plus contracting approaches, for smaller elements vs. larger, with some variation for lunar or Mars. By extension, we delve briefly into the potentially much broader significance of the individual cost estimates if taken together as a NASA investment portfolio where public private partnership are stitched together for deep space exploration. How might multiple improvements in individual systems add up to NASA human deep space exploration achievements, realistically, affordably, sustainably, in a relevant timeframe?

cost modeling estimation↗