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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 NTRS2014

AVCOAT Density Characterization for Orion Multi-Purpose Crew Vehicle

The Orion Multi-Purpose Crew Vehicle (MPCV) will transport four crew members to and from lunar-class orbital destinations. The first orbital Exploration Flight Test (EFT-1) is scheduled for December 2014 and will provide valuable data on several systems, including the heat shield. The heat shield material is AvcoatTM, a mid-density ablator. Specifically, the heat shield contains a fiberglass-phenolic honeycomb structure filled with an ablative epoxy novolac resin. Post-flight characterization of the EFT-1 thermal protection system will be conducted in order to study the material response and measure the char front of the material. Avcoat density profiling will be conducted to study three critical material zones: char, pyrolysis, and virgin states as a function of material depth. As part of a ground test campaign, Avcoat coupons are tested at the NASA Ames Research Center Arc Jet Complex. The test campaign is set forth to study material response based on environments, perform Avcoat material density characterization, and compare the char depths from the HEAT sensor and density profiling studies. These investigations will then be compared to flight data in order to improve upon TPS material response models.

AVCOAT↗
NASA NTRS2019

Bumper: A Tool for Analyzing Spacecraft Micrometeoroid and Orbital Debris Risk

“Bumper” is NASA’s computer program for analyzing spacecraft micrometeoroid and orbital debris (MMOD) risk. Bumper was developed in the late-1980s and has been continuously used and maintained since. The user base has grown from a few government entities to now include numerous commercial entities as well. The NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Team is responsible for all aspects of the Bumper software. Bumper has been used to characterize MMOD risk on hundreds of spacecraft. All of the International Space Station (ISS) modules, visiting vehicles and numerous external components and systems have been analyzed. Bumper was used to analyze each of the Space Shuttle missions since STS-50. The Orion Multi-Purpose Crew Vehicle (MPCV) MMOD shielding is being developed using Bumper as well. Bumper has also been used on numerous telescopes (Hubble, James Webb, and Fermi Gamma-ray Space Telescopes), scientific probes (Stardust, New Horizons, Parker Solar Probe), and Earth observation satellites (Landsat, Joint Polar Satellite System). Bumper is also being used to analyze the micrometeoroid risk and support design of the Deep Space Gateway (DSG) and Mars Sample Return (MSR) missions. The HVIT Bumper Configuration Control Board (CCB) ensures that all changes to the code are approved, reviewed, and documented. Most of the changes are made to add new MMOD damage “ballistic limit equations” (BLEs). BLEs are typically added in response to completion of a hypervelocity impact (HVI) test series and development of an associated BLE. Other less frequent changes include updates of the debris or meteoroid environment models, feature enhancements, and feature retirement. Some BLEs are commercially sensitive and/or proprietary, so the CCB also manages code user-version control and software distribution. The current version – “Bumper 3” – is a FORTRAN executable that utilizes a 64-bit architecture. Bumper 3 has numerous features that make it a powerful tool for analyzing spacecraft MMOD risk. Bumper uses the latest orbital debris and micrometeoroid environment models. Bumper also easily processes large spacecraft geometry models, recognizes hidden surfaces, permits BLE assignment by name or number, and conducts quality checks of the spacecraft geometry model. Bumper 3 can also be used to estimate the effects of particle penetration through thin, high-standoff distance hardware components such as solar arrays and radiators. This is done using a special HVIT-developed technique know as the “3-Part Analysis.” The paper introduces the Bumper 3 MMOD risk analysis code and provides an example MMOD risk assessment showing Bumper’s role in the overall MMOD protection design process.

Lear, Dana M.↗
NASA NTRS2020

Feasibility Study of SDAS Instrumentation's Ability to Identify Mobile Launcher (ML)/Crawler-Transporter (CT) Modes During Rollout Operations

The Space Launch System (SLS) and its Mobile Launcher (ML) will be transported to the launch pad via the Crawler-Transporter (CT) system. Rollout (i.e., transportation) loads produce structural loads on the integrated SLS/Orion Multi-Purpose Crew Vehicle (MPCV) launch vehicle which are of a concern with respect to fatigue. As part of the risk reduction process and in addition to the modal building block test approach that has been adopted by the SLS Program, acceleration data will be obtained during rollout for use in modal parameter estimation. There are several occurrences where the ML/CT will be transported either into the Vertical Assembly Building (VAB) or to the launch pad and back without the SLS stack as part of the Kennedy Space Center (KSC) Exploration Ground Systems (EGS) Integrated Test and Checkout (ITCO). NASA KSC EGS has instrumentation installed on both the ML and CT to record data during rollout, at the launch pad, and during liftoff. The EGS instrumentation on the ML, which includes accelerometers, is referred to as the Sensor Data Acquisition System (SDAS). The EGS instrumentation on the CT, which also includes accelerometers, is referred to as the CT Data Acquisition System (CTDAS). The forces and accelerations applied to the ML and CT during a rollout event will be higher than any of the planned building block modal tests. This can be very beneficial in helping identify nonlinear behavior in the structure. Developing modal parameters from the same test hardware in multiple boundary conditions and under multiple levels of excitation is a key step in developing a well correlated FEM. The purpose of this study was three fold. First, determine the target modes of the ML/CT in its rollout configuration. Second, determine if the test degrees of freedom (DOF) corresponding to the layout of the SDAS/CTDAS accelerometers (i.e. position and orientation) is sufficient to identify the target modes. Third, determine if the Generic Rollout Forcing Functions (GRFF's) is sufficient for identifying the ML/CT target modes accounting for variations in CT speed, modal damping, and sensor/ambient background noise levels. The finding from the first part of this study identified 28 target modes of the ML/CT rollout configuration based upon Modal Effective Mass Fractions (MEFF) and engineering judgement. The finding from the second part of this study showed that the SDAS/CTDAS accelerometers (i.e. position and orientation) are able to identify a sufficient number of the target modes to support model correlation of the ML/CT FEM. The finding from the third part of this study confirms the GRFFs sufficiently excite the ML/CT such that varying quantities of the defined target modes should be able to be extracted when utilizing an Experimental Modal Analysis (EMA) Multi-Input Multi-Output (MIMO) analysis approach. An EMA analysis approach was used because Operational Modal Analysis (OMA) tools were not available and the GRFFs were sufficiently uncorrelated. Two key findings from this third part of the study are that the CT speed does not show a significant impact on the ability to extract the modal parameters and that keeping the ambient background noise observed at each accelerometer location at or below 30 µgrms is essential to the success of this approach.

Winkel, James P.↗
NASA NTRS2019

Spacecraft Requirements Development and Tailoring

Spacecraft design is managed through the use of design requirements. Requirements are flowed from the highest level, the overall spacecraft, to systems, subsystems and ultimately individual components. Through the use of requirements, each part of the spacecraft will perform the functions that are required of it and will interface to the rest of the spacecraft. Functional requirements are used to make sure every component performs as expected and interface requirements ensure that each component works within the larger design environment where it operates. Writing good requirements is difficult and the verification of requirements can be expensive and time consuming. Because of this difficulty and expense, it is important that each requirement truly be “required” and critical to the overall performance of the vehicle. It is also important that requirements can be changed or eliminated as the system matures to minimize verification cost and schedule. The Capsule Parachute Assembly System (CPAS) Project is developing the parachute system for the NASA Multi-Purpose Crew Vehicle (MPCV) Orion Spacecraft. Throughout the development and qualification cycle for CPAS, requirements have been evaluated, added, eliminated, or more generically, “tailored”, to ensure that the system performs as required while minimizing the verification cost to the Program. One facet of this tailoring has been to delete requirements that do not add value to the overall spacecraft or are not needed. A second approach to minimize the cost of requirement verification has been to evaluate requirements based on the actual design as it has matured. As the design of the parachute system has become better understood, requirements that are not applicable have been eliminated. This paper will outline the evolution of CPAS requirements over time and will show how careful and considered changes to requirements can benefit the technical solution for the overall system design while allowing a Project to control costs.

Mcmichael, James H.↗
NASA NTRS2020

Lessons Learned from Recent Space Flight Assessments

This paper highlights four space flight assessments, each with an important lesson. The first assessment points to the challenge of material substitution for weight saving. Space Shuttle’s external tank stringers were changed from Al 2024 to Al 2090 without comprehensive analysis. Lack of understanding the low Short-Transverse (S-T) strength associated with Al 2090 led to widespread cracking. The second assessment addresses the failure to understand that time-dependent relationships and loading interactions of multiple disciplines can lead to non-conservative results. An aerodynamic test article of the Orion Multi-Purpose Crew Vehicle (MPCV) Launch Abort System (LAS) was analyzed for worst-case single discipline loads, showing positive structural margins. When disciplines were combined with time dependent loading, the analysis resulted in negative margins. The third assessment highlights the pitfalls of putting blind trust in historical architecture. The MPCV re-entry heat shield adopted the Apollo design approach despite fundamental differences between the two designs (e.g., the underlying substructure design, material differences, scale, and geometry). Manufacturing resulted in cracking along seams of the cured MPCV heat shield and produced lower mechanical properties of the Avcoat witness panels. Subsequently, the design was changed to a block architecture, which introduced unperceived technical, cost, and schedule risk. The fourth assessment shows how the lack of a comprehensive investigation of design modifications and inappropriate Finite Element Analyses (FEA) can lead to trouble. A mass reduction campaign eliminated highly critical internal struts on the ISS Node-1 pressurized module based on inadequate and uncorrelated FEA. High strains were noted and ignored as a modeling aberration. A system level high fidelity FEA discovered large plastic strains in the gussets of all four radial ports. These findings initiated a full-scale test campaign, new test correlated assembly-level FEA, and significant design modifications.

James P Smith↗
NASA NTRS2021

Orion Meteoroid and Debris Analysis with a Single Kevlar® Layer Enhancement to the Propulsion Tank Multi-Layer Insulation: Comparison of the Observed Data and the Adjusted Ballistic Models

In a continual mass optimization effort for the Orion vehicle by NASA and its prime contractor Lockheed Martin Space, along with the European Space Agency (ESA) and its contractors Airbus and Thales Alenia Space-Italy (TAS-I), a series of shield characterization shots have been performed to quantify the ballistic enhancement of a single-layer of Kevlar® in multi-layer insulation (MLI). This enhanced MLI is part of Orion’s propulsion subsystem, and it is planned to replace a double-layer Kevlar® configuration starting at the Artemis IV mission. This effort has included fifty-two shield characterization shots for five different shield configurations over the four Orion propellant storage vessels. These storage vessels are located in the European Service Module (ESM). This shield characterization has been managed by the Hypervelocity Impact Technology (HVIT) group in NASA Astromaterials Research and Exploration Sciences at Johnson Space Center (JSC) for the NASA Engineering and Safety Center (NESC) and the Multi-Purpose Crew Vehicle (MPCV) program office in coordination with Lockheed Martin Space and Thales Alenia Space-Italy (TAS-I). The shield characterization has used the two-stage, light-gas-gun at the Remote Hypervelocity Test Laboratory (RHTL) of NASA JSC White Sands Test Facility (WSTF) for acceleration of projectiles to representative orbital impact speeds. From this shield characterization effort, a revised ballistic limiting equation (BLE) has been developed for each of the five representative shielding configurations of the ESM pressure vessels. This document provides a brief description of the shield configurations considered for the Orion program and the shield characterization findings. These results are compared to the assumed BLE for each configuration going into the Artemis missions that utilize this version of ballistic enhanced MLI. The models are integrated into a fourteen day High Lunar Orbit (HLO) mission as a representative reliability prediction impact for Orion, and it has been found that the predicted risk of a loss-of-crew (LOC) event is actually a little less than half of the assumed value that launched this design modification opportunity.

Joshua E Miller↗
NASA NTRS2012

NASA's Space Launch System: A Flagship for Exploration Beyond Earth's Orbit

The National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for exploration beyond Earth orbit in an austere economic climate. This fact drives the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. To arrive at the current SLS plan, government and industry experts carefully analyzed hundreds of architecture options and arrived at the one clear solution to stringent requirements for safety, affordability, and sustainability over the decades that the rocket will be in operation. This paper will explore ways to fit this major development within the funding guidelines by using existing engine assets and hardware now in testing to meet a first launch by 2017. It will explain the SLS Program s long-range plan to keep the budget within bounds, yet evolve the 70 metric ton (t) initial lift capability to 130-t lift capability after the first two flights. To achieve the evolved configuration, advanced technologies must offer appropriate return on investment to be selected through a competitive process. For context, the SLS will be larger than the Saturn V that took 12 men on 6 trips for a total of 11 days on the lunar surface over 4 decades ago. Astronauts train for long-duration voyages on the International Space Station, but have not had transportation to go beyond Earth orbit in modern times, until now. NASA is refining its mission manifest, guided by U.S. Space Policy and the Global Exploration Roadmap. Launching the Orion Multi-Purpose Crew Vehicle s (MPCV s) first autonomous certification flight in 2017, followed by a crewed flight in 2021, the SLS will offer a robust way to transport international crews and the air, water, food, and equipment they need for extended trips to asteroids, Lagrange Points, and Mars. In addition, the SLS will accommodate high-priority science experiments. SLS affordability initiatives include streamlining interfaces, applying risk-based insight into contracted work, centralizing systems engineering and integration, and nurturing a learning culture that continually benchmarks its performance against successful ventures. As this paper will explain, the SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

May, Todd A.↗
NASA NTRS2013

Modeling Complex Cross-Systems Software Interfaces Using SysML

The complex flight and ground systems for NASA human space exploration are designed, built, operated and managed as separate programs and projects. However, each system relies on one or more of the other systems in order to accomplish specific mission objectives, creating a complex, tightly coupled architecture. Thus, there is a fundamental need to understand how each system interacts with the other. To determine if a model-based system engineering approach could be utilized to assist with understanding the complex system interactions, the NASA Engineering and Safety Center (NESC) sponsored a task to develop an approach for performing cross-system behavior modeling. This paper presents the results of applying Model Based Systems Engineering (MBSE) principles using the System Modeling Language (SysML) to define cross-system behaviors and how they map to crosssystem software interfaces documented in system-level Interface Control Documents (ICDs).

Earth orbit↗
NASA NTRS2018

The SPACE Computer Code for Analyzing the International Space Station Electrical Power System: Past, Present, and Future

The System Power Analysis for Capability Evaluation (SPACE) computer code was initially developed by NASA in 1988 to assess the Space Station Freedom electric power system and later adapted to support contractor electrical power system capability analyses for the International Space Station (ISS). Over time, the code has supported many efforts such as ISS redesign activities in the early 1990s, assessment of time-phased loads against power system operating limits for future ISS assembly flights (including Certification of Flight Readiness reviews by the ISS program office), and determining the optimum solar array gimbal positions while respecting keep-out zones which minimize both solar array contamination and structural loads. The code has been validated by comparisons with ISS on-orbit data in multiple validation episodes. Recent updates to the code include the incorporation of a Lithium-Ion battery model in addition to the Nickel Hydrogen battery model and modifications to the solar array degradation model to better match on-orbit test results. SPACE has also been extended beyond the ISS to include modeling of the Orion Multi-Purpose Crew Vehicle electrical power system (SPACE-MPCV) and Mars Surface Electrical Power Systems (MSEPS). Portions of SPACE were integrated with a trajectory code to form a Solar Electric Propulsion Simulation (SEPSim), which can be used for analyzing solar electric propulsion missions. In addition, SPACE methods and subroutines have been adapted to a multitude of other projects. This paper summarizes the initial code development and subsequent code utilization in the context of the overall ISS program development and on-orbit operations. Recent updates and results from the code are discussed, including preliminary analyses for the Orion power system.

Electrical Power System↗
NASA NTRS2012

A Lunar L2-Farside Exploration and Science Mission Concept with the ORion Multi-Purpose Crew Vehicle and a Teleoperated Lander/Rover

A novel concept is presented in this paper for a human mission to the lunar L2 (Lagrange) point that would be a proving ground for future exploration missions to deep space while also overseeing scientifically important investigations. In an L2 halo orbit above the lunar farside, the astronauts would travel 15% farther from Earth than did the Apollo astronauts and spend almost three times longer in deep space. Such missions would validate the Orion MPCV's life support systems, would demonstrate the high-speed re-entry capability needed for return from deep space, and would measure astronauts' radiation dose from cosmic rays and solar flares to verify that Orion would provide sufficient protection, as it is designed to do. On this proposed mission, the astronauts would teleoperate landers and rovers on the unexplored lunar farside, which would obtain samples from the geologically interesting farside and deploy a low radio frequency telescope. Sampling the South Pole-Aitkin basin (one of the oldest impact basins in the solar system) is a key science objective of the 2011 Planetary Science Decadal Survey. Observations of the Universe's first stars/galaxies at low radio frequencies are a priority of the 2010 Astronomy & Astrophysics Decadal Survey. Such telerobotic oversight would also demonstrate capability for human and robotic cooperation on future, more complex deep space missions.

Orion Multi-Purpose Crew Vehicle (MPCV)↗
NASA NTRS2014

Evolution of MPCV Service Module Propulsion and GNC Interface Requirements

The Orion Multi-Purpose Crew Vehicle Service Module Propulsion Subsystem provides propulsion for the integrated Crew and Service Module. Updates in the exploration architecture between Constellation and MPCV as well as NASA's partnership with the European Space Agency have resulted in design changes to the SM Propulsion Subsystem and updates to the Propulsion interface requirements with Guidance Navigation and Control. This paper focuses on the Propulsion and GNC interface requirement updates between the Constellation Service Module and the European Service Module and how the requirement updates were driven or supported by architecture updates and the desired use of hardware with heritage to United States and European spacecraft for the Exploration Missions, EM-1 and EM-2.

spacecraft propulsion↗
NASA NTRS2013

The Multi-purpose Crew Vehicle European Service Module: a European Contribution to Human Exploration

This paper provides an overview of the system and subsystem configuration of the MPCV European Service Module (ESM) at Preliminary Design Review (PDR) stage as well as its perspectives of utilisation within the global space exploration endeavour. The MPCV ESM is a cylindrical module with a diameter of 4500 mm and a total length - main engine excluded - of 2700 mm. It is fitted with four solar array wings with a span of 18.8 m. Its dry mass is 3.5 metric tons and it can carry 8.6 tons of propellant. The main functions of the European Service Module are to bring the structural continuity between the launcher and the crew module, to provide propulsion to the MPCV, to ensure its thermal control as well as electrical power and to store water, oxygen and nitrogen for the mission. The current agreement foresees the development and production by Europe of one flight model, with an option for a second one. This module will be assembled in Europe and delivered to NASA in 2016. It will be used for a flight of the MPCV Orion in December 2017.

Design↗
NASA NTRS2013

The Multi-purpose Crew Vehicle European Service Module: a European Contribution to Human Exploration

This paper provides an overview of the system and subsystem configuration of the MPCV European Service Module (ESM) at Preliminary Design Review (PDR) stage as well as its perspectives of utilisation within the global space exploration endeavour. The MPCV ESM is a cylindrical module with a diameter of 4500 mm and a total length – main engine excluded – of 2700 mm. It is fitted with four solar array wings with a span of 18.8 m. Its dry mass is 3.5 metric tons and it can carry 8.6 tons of propellant. The main functions of the European Service Module are to bring the structural continuity between the launcher and the crew module, to provide propulsion to the MPCV, to ensure its thermal control as well as electrical power and to store water, oxygen and nitrogen for the mission. The current agreement foresees the development and production by Europe of one flight model, with an option for a second one. This module will be assembled in Europe and delivered to NASA in 2016. It will be used for a flight of the MPCV Orion in December 2017.

European Service Module↗
NASA NTRS2011

Feasibility Study of an Airbag-Based Crew Impact Attenuation System for the Orion MPCV

Airbag-based methods for crew impact attenuation have been highlighted as a potential lightweight means of enabling safe land-landings for the Orion Multi-Purpose Crew Vehicle, and the next generation of ballistic shaped spacecraft. To investigate the performance feasibility of this concept during a nominal 7.62m/s Orion landing, a full-scale personal airbag system 24% lighter than the Orion baseline has been developed, and subjected to 38 drop tests on land. Through this effort, the system has demonstrated the ability to maintain the risk of injury to an occupant during a 7.85m/s, 0 deg. impact angle land-landing to within the NASA specified limit of 0.5%. In accomplishing this, the airbag-based crew impact attenuation concept has been proven to be feasible. Moreover, the obtained test results suggest that by implementing anti-bottoming airbags to prevent direct contact between the system and the landing surface, the system performance during landings with 0 deg impact angles can be further improved, by at least a factor of two. Additionally, a series of drop tests from the nominal Orion impact angle of 30 deg indicated that severe injury risk levels would be sustained beyond impact velocities of 5m/s. This is a result of the differential stroking of the airbags within the system causing a shearing effect between the occupant seat structure and the spacecraft floor, removing significant stroke from the airbags.

Do, Sydney↗
NASA NTRS2012

Future Concepts for Integrating the Space Launch System and the Multi-Purpose Crew Vehicle into a Reusable Space Transportation Infrastructure

A space transportation infrastructure is described that utilizes the Space Launch System (SLS), the Mulit-Purpose Crew Vehicle (MPCV), the International Space Station (ISS), and propellant depot servicing platforms to support all foreseeable missions in the Earth-Moon vicinity and deep space out to Mars. The infrastructure utilizes current expendable launch vehicle (ELV) systems such as the Delta IV Heavy, Atlas V, and Falcon 9, for commercial crew, cargo, and propellant launches to a Low-Earth-Orbit (LEO) Depot and/or the ISS. The SLS provides all payload and propellant launches to the Earth-Moon Langrange Point 1 (EML1) Depot to support new reusable in-space transportation vehicles. The ISS or follow-on LEO Depot supports missions to Geosynchronous Earth Orbit (GEO) for satellite servicing and to Earth-Moon L1 for EML1 Depot missions. The EML1 Depot supports Lunar, Earth-Sun L2 (ESL2), Asteroid, and Mars missions. New vehicle design concepts are presented that can be launched utilizing the SLS and current ELV systems. These new reusable vehicle concepts include a Crew Transfer Vehicle (CTV) derived from the MPCV and a reusable Cryogenic Propulsion Stage (CPS) for crew transportation between the LEO Depot, EML1 Depot and missions beyond the Earth-Moon vicinity; a new reusable Lunar Lander for crew transportation between the EML1 Depot and the lunar surface; and a new reusable Deep Space Habitat (DSH) with a CTV to support crew missions from the EML1 Depot to ESL2, Asteroids, and a Mars Orbital Depot. The LEO Depot, EML1 Depot, and Mars Orbital Depot are based on International Space Station (ISS) heritage hardware. Data provided includes the number of launches required for each mission utilizing SLS and current ELV systems (Delta IV Heavy or equivalent) and the approximate vehicle masses and propellant requirements. Also included is a discussion on affordability with ideas on technologies that could reduce the number of launches required and thoughts on how this infrastructure might be implemented incrementally over the next few decades. The potential benefits of this infrastructure include competitive bidding for ELV flights and propellant services, development of new reusable in-space vehicles, and development of a robust multiuse infrastructure that can support many government and commercial missions simultaneously.

Smitherman, David↗
NASA NTRS2014

Orion Multi-Purpose Crew Vehicle Active Thermal Control and Environmental Control and Life Support Development Status

The Orion Multi Purpose Crew Vehicle (MPCV) is the first crew transport vehicle to be developed by the National Aeronautics and Space Administration (NASA) in the last thirty years. Orion is currently being developed to transport the crew safely beyond Earth orbit. This year, the vehicle focused on building the Exploration Flight Test 1 (EFT1) vehicle to be launched in September of 2014. The development of the Orion Active Thermal Control (ATCS) and Environmental Control and Life Support (ECLS) System, focused on the integrating the components into the EFT1 vehicle and preparing them for launch. Work also has started on preliminary design reviews for the manned vehicle. Additional development work is underway to keep the remaining component progressing towards implementation on the flight tests of EM1 in 2017 and of EM2 in 2020. This paper covers the Orion ECLS development from April 2013 to April 2014.

Lewis, John F.↗