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NASA NTRS2003

Development of a Flexible Framework of Common Hypersonic Navier-Strokes Meshes for the Space Shuttle Orbiter

A flexible framework for the development of block structured volume grids for hypersonic Navier-Stokes flow simulations was developed for analysis of the Shuttle Orbiter Columbia. The development of the flexible framework, resulted in an ability to quickly generate meshes to directly correlate solutions contributed by participating groups on a common surface mesh, providing confidence for the extension of the envelope of solutions and damage scenarios. The framework draws on the experience of NASA Langely and NASA Ames Research Centers in structured grid generation, and consists of a grid generation process that is implemented through a division of responsibilities. The nominal division of labor consisted of NASA Johnson Space Center coordinating the damage scenarios to be analyzed by the Aerothermodynamics Columbia Accident Investigation (CAI) team, Ames developing the surface grids that described the computational volume about the orbiter, and Langely improving grid quality of Ames generated data and constructing the final volume grids. Distributing the work among the participants in the Aerothermodynamic CIA team resulted in significantly less time required to construct complete meshes than possible by any individual participant. The approach demonstrated that the One-NASA grid generation team could sustain the demand for new meshes to explore new damage scenarios within a aggressive timeline.

Alter, Stephen J.↗

NASA NTRS2003

Effects of Wing Leading Edge Penetration with Venting and Exhaust Flow from Wheel Well at Mach 24 in Flight

A baseline solution for CFD Point 1 (Mach 24) in the STS-107 accident investigation was modified to include effects of: (1) holes through the leading edge into a vented cavity; and (2) a scarfed, conical nozzle directed toward the centerline of the vehicle from the forward, inboard corner of the landing gear door. The simulations were generated relatively quickly and early in the investigation because simplifications were made to the leading edge cavity geometry and an existing utility to merge scarfed nozzle grid domains with structured baseline external domains was implemented. These simplifications in the breach simulations enabled: (1) a very quick grid generation procedure; and (2) high fidelity corroboration of jet physics with internal surface impingements ensuing from a breach through the leading edge, fully coupled to the external shock layer flow at flight conditions. These simulations provided early evidence that the flow through a two-inch diameter (or larger) breach enters the cavity with significant retention of external flow directionality. A normal jet directed into the cavity was not an appropriate model for these conditions at CFD Point 1 (Mach 24). The breach diameters were of the same order or larger than the local, external boundary-layer thickness. High impingement heating and pressures on the downstream lip of the breach were computed. It is likely that hole shape would evolve as a slot cut in the direction of the external streamlines. In the case of the six-inch diameter breach the boundary layer is fully ingested. The intent of externally directed jet simulations in the second scenario was to approximately model aerodynamic effects of a relatively large internal wing pressure, fueled by combusting aluminum, which deforms the corner of the landing gear door and directs a jet across the windside surface. These jet interactions, in and of themselves, were not sufficiently large to explain observed aerodynamic behavior.

Gnoffo, Peter A.↗

NASA NTRS2003

Experimental Hypersonic Aerodynamic Characteristics of the Space Shuttle Orbiter for a Range of Damage Scenarios

Aerodynamic tests in support of the Columbia accident investigation were conducted in two hypersonic wind tunnels at the NASA Langley Research Center, the 20-Inch Mach 6 Air Tunnel and the 20-Inch Mach 6 CF4 Tunnel. The primary purpose of these tests was to measure the forces and moments generated by a variety of outer mold line alterations (damage scenarios) using 0.0075-scale models of the Space Shuttle Orbiter (approximately 10 inches in length). Simultaneously acquired global heat transfer mappings were obtained for a majority of the configurations tested. Test parameters include angles of attack from 38 to 42 deg, unit Reynolds numbers from 0.26 to 3.0 x10^6 per foot, and normal shock density ratios of 5 (Mach 6 air) and 12 (Mach 6 CF4). The damage scenarios evaluated included asymmetric boundary layer transition, gouges in the windward surface acreage thermal protection system tiles, wing leading edge damage (partially and fully missing reinforced carbon-carbon (RCC) panels), holes through the wing from the windward surface to the leeside, deformation of the wing windward surface, and main landing gear door and/or gear deployment. The aerodynamic data were compared to the magnitudes and directions observed in flight, and the heating images were evaluated in terms of the location of the generated disturbances and how these disturbance might relate to the response of discrete gages on the Columbia Orbiter vehicle during entry. The measured aerodynamic increments were generally small in magnitude, as were the flight-derived values during most of the entry. Asymmetric boundary layer transition (ABLT) results were consistent with the flight-derived Shuttle ABLT model, but not with the observed flight trends for STS-107. The partially missing leading edge panel results best matched both the early aerodynamic and heating trends observed in flight. A progressive damage scenario is presented that qualitatively matches the flight observations for the full entry.

Brauckman, Gregory J.↗

NASA NTRS2004

The Vision for Space Exploration

With last year's budget, NASA released a new Strategic Plan outlining a new approach to space exploration using a 'building block' strategy to explore scientifically valuable destinations across our solar system. At the same time that we released the Strategic Plan, our Nation and the NASA family also suffered the loss of the seven brave astronauts aboard the Space Shuttle Columbia. The report of the Columbia Accident Investigation Board emphasized the need for a clearer direction from which to drive NASA's human exploration agenda. On January 14, 2004, the President articulated a new vision for space exploration. You hold in your hands a new, bolder framework for exploring our solar system that builds upon the policy that was announced by the President after months of careful deliberations within the Administration. This plan does not undertake exploration merely for the sake of adventure, however exciting that may be, but seeks answers to profound scientific and philosophical questions, responds to recent discoveries, will put in place revolutionary technologies and capabilities for the future, and will genuinely inspire our Nation, the world, and the next generation. Our aim is to explore in a sustainable, affordable, and flexible manner. We believe the principles and roadmap set down in this document will stand the test of time. Its details will be subject to revision and expansion as new discoveries are made, new technologies are applied, and new challenges are met and overcome. This plan is guided by the Administration's new space exploration policy, 'A Renewed Spirit of Discovery: The President's Vision for U.S. Space Exploration,' a copy of which is provided on the following pages. NASA is releasing this plan simultaneously with NASA's FY 2005 Budget Justification. This plan is fiscally responsible, consistent with the Administration s goal of cutting the budget deficit in half within the next five years. I cannot overstate how much NASA will change in the coming years as this plan is implemented. I also cannot overstate how profound the rewards will be on this new course. With the support of Congress, the science community, the NASA civil and contractor workforce, and most importantly, the American public, we will embark on this very exciting future. When Christopher Columbus made his voyages across the Atlantic in the 15th and 16th centuries, his ships carried the inscription 'Following the light of the sun, we left the Old World.' I look forward to joining you as we follow the light of the planets and the stars into the new worlds of the 21st century.

Source record↗

NASA NTRS2004

Application of Non-Deterministic Methods to Assess Modeling Uncertainties for Reinforced Carbon-Carbon Debris Impacts

The Space Shuttle Columbia Accident Investigation Board (CAIB) made several recommendations for improving the NASA Space Shuttle Program. An extensive experimental and analytical program has been developed to address two recommendations related to structural impact analysis. The objective of the present work is to demonstrate the application of probabilistic analysis to assess the effect of uncertainties on debris impacts on Space Shuttle Reinforced Carbon-Carbon (RCC) panels. The probabilistic analysis is used to identify the material modeling parameters controlling the uncertainty. A comparison of the finite element results with limited experimental data provided confidence that the simulations were adequately representing the global response of the material. Five input parameters were identified as significantly controlling the response.

Lyle, Karen H.↗

NASA NTRS2004

Tethers as Debris: Simulating Impacts of Kevlar Tethers on Shuttle Tiles

In a previous paper I examined the effects of impacts of polymer tethers on aluminum plates using the SPHC hydrodynamic code. In this paper I apply tether models to a new target - models of Space Shuttle tiles developed during the STS 107 accident investigation. In this three-dimensional simulation, a short tether fragment strikes a single tile supported on an aluminum backing plate. A tile of the LI-900 material is modeled. Penetration and damage to the tile and the backwall are characterized for three normal impact velocities. The tether is modeled as a bundle of eight 1-mm strands, with the bundle having dimensions 2-mm x 4-mm x 20-cm. The bulk material properties used are those of Kevlar(TradeMark) 49, for which a Mie-Gruneisen multiphase equation of state (eos) is used. In addition, the strength model is applied in a linear sense, such that tensile loads along the strand length are supported, but there is no strength in the lateral directions. Tile models include the various layers making up the tile structure. The outermost layer is a relatively dense borosilicate glass, known as RCG, 0.5-mm thick. The RCG layer is present on the top and four sides of the tile. Below this coating is the bulk of the tile, 1.8- in thick, made of LI-900, a product consisting of rigidized fiberous silica with a density of 9 lWft3. Below the main insulating layer is a bottom layer of the same material that has been treated to increase its density by approximately 69% to improve its strength. This densified layer is bonded to a Strain Isolation Pad (SIP), modeled as a refractory felt fabric. The SIP is bonded to an aluminum 2024 wall 0.1-in thick. The tile and backwall materials use a Me-Gruneisen multiphase eos, with the exception of the SIP felt, which uses a fabric equation of state. Fabrics must be crushed to the full bulk material density before bulk material properties and a Mie-Gruneisen eos are applied. Tether fragment impact speeds of 3,7, and 10 km/s are simulated, with impact velocities normal to the tile face. Damage results are presented in tabular format.

Evans, Steven W.↗

NASA NTRS2004

Simulation of Flow Through Breach in Leading Edge at Mach 24

A baseline solution for CFD Point 1 (Mach 24) in the STS-107 accident investigation was modified to include effects of holes through the leading edge into a vented cavity. The simulations were generated relatively quickly and early in the investigation by making simplifications to the leading edge cavity geometry. These simplifications in the breach simulations enabled: 1) A very quick grid generation procedure; 2) High fidelity corroboration of jet physics with internal surface impingements ensuing from a breach through the leading edge, fully coupled to the external shock layer flow at flight conditions. These simulations provided early evidence that the flow through a 2 inch diameter (or larger) breach enters the cavity with significant retention of external flow directionality. A normal jet directed into the cavity was not an appropriate model for these conditions at CFD Point 1 (Mach 24). The breach diameters were of the same order or larger than the local, external boundary-layer thickness. High impingement heating and pressures on the downstream lip of the breach were computed. It is likely that hole shape would evolve as a slot cut in the direction of the external streamlines. In the case of the 6 inch diameter breach the boundary layer is fully ingested.

Gnoffo, Peter A.↗

NASA NTRS2004

The Use of SolidEdge as an Engineering Tool to Support NASA Projects

This presentation will cover the use of SolidEdge to facilitate creation of components and component assemblies generated by SOMTC in the support of NASA projects and GSE (e.g., Return To Flight and support components related to a multitude of optical assemblies.) Return To Flight (RTF) Program consist of several projects derived from a Columbia Accident Investigation Board (CAIB) report. One of the recommendations is to increase visual analysis capabilities of the flight vehicle prior to reaching orbit. SolidEdge as the primary 3-D modeler will be utilized by Space Optics Manufacturing Technology Center (SOMTC) at MSFC to generate multiple preliminary design concepts relative to air and ground based viewing platforms with increased fidelity.

Thornton, Gary↗

NASA NTRS2004

Development of a Flexible Framework for Hypersonic Navier-Stoke Space Shuttle Orbiter Meshes

A flexible framework constructing block structured volume grids for hypersonic Navier-Strokes flow simulations was developed for the analysis of the Shuttle Orbiter Columbia. The development of the framework, which was partially basedon the requirements of the primary flow solvers used resulted in an ability to directly correlate solutions contributed by participating groups on a common surface mesh. A foundation was built through the assessment of differences between differnt solvers, which provided confidence for independent assessment of other damage scenarios by team members. The framework draws on the experience of NASA Langley and NASA Ames Research Centers in structured grid generation, and consists of a grid generation, and consist of a grid generation process implemented through a division of responsibilities. The nominal division of labor consisted of NASA Johnson Space Center coordinating the damage scenarios to be analyzed by the Aerothermodynamics Columbia Accident Investigation (ACAI) team, Ames developing the surface grids that described the computational volume about the Orbiter, and Langley improving grid quality of Ames generated data and constructing the final computational volume grids. Distributing the work among the participant in th ACAI team resulted in significantl less time required to construct complete meshes than possible by any individual participant. The approach demonstrated that the One-NASA grid generation team could sustain the demand of for five new meshes to explore new damage scenarios within an aggressive time-line.

Alter, Stephen J.↗

NASA NTRS2004

ASK Talks with Al Diaz

Following the release of the Columbia Accident Investigation Board (CAIB) Report, Alphonso (Al) Diaz, Goddard Center director, was asked by NASA Administrator Sean O'Keefe to head up the Agency's response. The Diaz team, as it came to be known, was changed with making sure the CAIB Report did not become another dusty volume on a shelf of old Agency reviews.

Diaz, Alphonso↗

NASA NTRS2004

Prediction of STS-107 Hypervelocity Flow Fields about the Shuttle Orbiter with Various Wing Leading Edge Damage

Computations were performed for damaged configurations of the Shuttle Orbiter in support of the STS-107 Columbia accident investigation. Two configurations with missing wing leading-edge reinforced carbon-carbon (RCC) panels were evaluated at conditions just prior to the peak heating trajectory point. The initial configuration modeled the Orbiter with an approximate missing RCC panel 6 to determine whether this damage could result in anomalous temperatures measured during the STS-107 reentry. This missing RCC panel 6 computation was found to produce heating augmentation factors of 5 times the nominal heating rates on the side fuselage with lesser heat increases on the front of the OMS pod. This is consistent with the thermocouple and resistance temperature detector sensors from the STS-107 re-entry which observed off nominal high early in the re-entry trajectory. A second damaged configuration modeled the Orbiter with missing RCC panel 9 and included ingestion of the flow into the outboard RCC channel. This computation lowered the level (only 2 times nominal) and moved the location of the heating augmentation on the leeside fuselage relative to the missing RCC panel 6 configuration. The lesser heating augmentation for missing RCC panel 9 was confined near the wing fuselage juncture. Near nominal heating was predicted on the remainder of the side fuselage with some lower than nominal heating on the front surface of the OMS pod. These results for missing RCC panel 9 are consistent with data from the STS-107 re-entry where the heating augmentation was observed to move off the side fuselage and OMS pod sensors at later times in the trajectory. As this solution requires supersonic mass ingestion into the RCC channel, it is probably not an appropriate model prior to penetration of the flow through the spar into the wing structure. It may, however, be representative of the conditions at later times and could account for the movement of the heating signature on the side fuselage.

Pulsonetti, Maria V.↗

NASA NTRS2004

An Inviscid Computational Study of the Space Shuttle Orbiter and Several Damaged Configurations

Inviscid aerodynamic characteristics of the Space Shuttle Orbiter were computed in support of the Columbia Accident Investigation. The unstructured grid software FELISA was used and computations were done using freestream conditions corresponding to those in the NASA Langley 20-Inch Mach 6 CF4 tunnel test section. The angle of attack was held constant at 40 degrees. The baseline (undamaged) configuration and a large number of damaged configurations of the Orbiter were studied. Most of the computations were done on a half model. However, one set of computations was done using the full-model to study the effect of sideslip. The differences in the aerodynamic coefficients for the damaged and the baseline configurations were computed. Simultaneously with the computation reported here, tests were being done on a scale model of the Orbiter in the 20-Inch Mach 6 CF4 tunnel to measure the deltas . The present computations complemented the CF4 tunnel test, and provided aerodynamic coefficients of the Orbiter as well as its components. Further, they also provided details of the flow field.

Prabhu, Ramadas K.↗

NASA NTRS2004

Experimental Hypersonic Aerodynamic Characteristics of the Space Shuttle Orbiter for a Range of Damage Scenarios

Brauckmann, Gregory J.↗

NASA NTRS2005

Characterization of the Space Shuttle Ascent Debris using CFD Methods

After video analysis of space shuttle flight STS-107's ascent showed that an object shed from the bipod-ramp region impacted the left wing, a transport analysis was initiated to determine a credible flight path and impact velocity for the piece of debris. This debris transport analysis was performed both during orbit, and after the subsequent re-entry accident. The analysis provided an accurate prediction of the velocity a large piece of foam bipod ramp would have as it impacted the wing leading edge. This prediction was corroborated by video analysis and fully-coupled CFD/six degree of freedom (DOF) simulations. While the prediction of impact velocity was accurate enough to predict critical damage in this case, one of the recommendations of the Columbia Accident Investigation Board (CAIB) for return-to-flight (RTF) was to analyze the complete debris environment experienced by the shuttle stack on ascent. This includes categorizing all possible debris sources, their probable geometric and aerodynamic characteristics, and their potential for damage. This paper is chiefly concerned with predicting the aerodynamic characteristics of a variety of potential debris sources (insulating foam and cork, nose-cone ablator, ice, ...) for the shuttle ascent configuration using CFD methods. These aerodynamic characteristics are used in the debris transport analysis to predict flight path, impact velocity and angle, and provide statistical variation to perform risk analyses where appropriate. The debris aerodynamic characteristics are difficult to determine using traditional methods, such as static or dynamic test data, due to the scaling requirements of simulating a typical debris event. The use of CFD methods has been a critical element for building confidence in the accuracy of the debris transport code by bridging the gap between existing aerodynamic data and the dynamics of full-scale, in-flight events.

Murman, Scott M.↗

NASA NTRS2004

Lesson Learned

ASA will begin naming "a few hundred" engineers soon who will constitute the Independent. Technical Authority (ITA) recommended by the Columbia Accident Investigation Board to pro- vide an effective check and balance on space programs for safety. Within the next month, the directors of Johnson and Kennedy space centers will name "a couple of dozen at each place" to backstop human spaceflight engineers, according to Theron M. Bradley, Jr., NASA chief engineer. By the time the new fiscal year begins Oct. 1, the ITA should be fully staffed across the agency, with a system of "warrants" delineating who is an expert in what. Overseeing the whole organization

Morring, Frank, Jr.↗

NASA NTRS2004

Agent Architecture for Aviation Data Integration System

This paper describes the proposed agent-based architecture of the Aviation Data Integration System (ADIS). ADIS is a software system that provides integrated heterogeneous data to support aviation problem-solving activities. Examples of aviation problem-solving activities include engineering troubleshooting, incident and accident investigation, routine flight operations monitoring, safety assessment, maintenance procedure debugging, and training assessment. A wide variety of information is typically referenced when engaging in these activities. Some of this information includes flight recorder data, Automatic Terminal Information Service (ATIS) reports, Jeppesen charts, weather data, air traffic control information, safety reports, and runway visual range data. Such wide-ranging information cannot be found in any single unified information source. Therefore, this information must be actively collected, assembled, and presented in a manner that supports the users problem-solving activities. This information integration task is non-trivial and presents a variety of technical challenges. ADIS has been developed to do this task and it permits integration of weather, RVR, radar data, and Jeppesen charts with flight data. ADIS has been implemented and used by several airlines FOQA teams. The initial feedback from airlines is that such a system is very useful in FOQA analysis. Based on the feedback from the initial deployment, we are developing a new version of the system that would make further progress in achieving following goals of our project.

Kulkarni, Deepak↗

NASA NTRS2004

Meshing, Visualization, and Computational Environments

There was probably no higher profile application of meshing, visualization, and computational software this past year than that performed in support of the space shuttle's Return to Flight activities. After heavy use of simulation during the accident investigation, these same tools are now helping address safety and operational issues. In turn, these applications are raising the bar for computational tools in terms of simulation fidelity and turnaround time.

Chawner, John R.↗

NASA NTRS2005

Team Performance and Error Management in Chinese and American Simulated Flight Crews: The Role of Cultural and Individual Differences

This report describes results of a study conducted for NASA-Langley Research Center. This study is part of a program of research conducted for NASA-LARC that has focused on identifying the influence of national culture on the performance of flight crews. We first reviewed the literature devoted to models of teamwork and team performance, crew resource management, error management, and cross-cultural psychology. Davis (1999) reported the results of this review and presented a model that depicted how national culture could influence teamwork and performance in flight crews. The second study in this research program examined accident investigations of foreign airlines in the United States conducted by the National Transportation Safety Board (NTSB). The ability of cross-cultural values to explain national differences in flight outcomes was examined. Cultural values were found to covary in a predicted way with national differences, but the absence of necessary data in the NTSB reports and limitations in the research method that was used prevented a clear understanding of the causal impact of cultural values. Moreover, individual differences such as personality traits were not examined in this study. Davis and Kuang (2001) report results of this second study. The research summarized in the current report extends this previous research by directly assessing cultural and individual differences among students from the United States and China who were trained to fly in a flight simulator using desktop computer workstations. The research design used in this study allowed delineation of the impact of national origin, cultural values, personality traits, cognitive style, shared mental model, and task workload on teamwork, error management and flight outcomes. We briefly review the literature that documents the importance of teamwork and error management and its impact on flight crew performance. We next examine teamwork and crew resource management training designed to improve teamwork. This is followed by discussion of the potential influence of national culture on teamwork and crew resource management. We then examine the influence of other individual and team differences, such as personality traits, cognitive style, shared mental model, and task workload. We provide a heuristic model that depicts the influence of national culture and individual differences on teamwork, error management and flight outcomes. The results demonstrate the usefulness of the model for future research.

Davis, Donald D.↗