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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 NTRSDate not supplied

PTD: Enabling New Space Technologies

Significant advances in the capabilities of small spacecraft over the past 20 years, coupled with improved access to space from a variety of launch platforms have created new opportunities for scientific exploration and commercial application using these high-value (and yet low cost) platforms. Continued development and demonstration of key technologies are improving the performance of the 3U and 6U class CubeSats while expanding the small spacecraft reach into larger platforms, such as 12U and ESPA class missions. The availability and relatively low cost of CubeSat spacecraft allows key technologies to be flight qualified, bridging the TRL 6/7 gap and making truly novel and enabling technologies available to much larger missions in the planning stages at NASA. The key is connecting the technologists with the flight opportunity in a time and cost efficient manner. NASA’s Small Satellite Technology (SST) program is using existing commercial spacecraft to provide a common bus for technology demonstration, taking advantage of their proven platforms and system with proven flight heritage and extensive infrastructure. In this paper we discuss the Pathfinder Technology Demonstrator (PTD) series of four spacecraft and the CubeSat Laser Infrared CrosslinK (CLICK) series of three spacecraft, the approach SST took in facilitating the missions, the successes of those missions as well as lessons learned in the process. NASA’s PTD spacecraft series is demonstrating a variety of new technologies on-orbit, providing proof of the maturity of these significant new technologies, and enhancing the performance of future CubeSats. Each of the four PTD mission consists of one 6-unit (6U) CubeSat weighing approximately 12 kilograms and measuring approximately 30 centimeters x 25 centimeters x 10 centimeters, characterizing its payload within 90 days of orbit insertion. The spacecraft bus, integration and test, and mission operations services are being provided by Terran Orbital. The PTD missions have demonstrated a novel nano-spacecraft compatible propulsion systems (enabling deep space and maneuverable Cubeat missions) and an optical communications system (enabling high data rate collection and communications) already. The CLICK missions are demonstrating compact space-to-space optical communications first with the CLICK A technology demonstrator (already flown) and finally with the CLICK BC dual spacecraft mission. Both projects are part of the SST program within the NASA Space Technology Mission Directorate. SST is chartered to develop and demonstrate technologies to enhance and expand the capabilities of small spacecraft with a particular focus on enabling new mission architectures through the use of small spacecraft, expanding the reach of small spacecraft to new destinations, and augmenting future missions with supporting small spacecraft.

J. Hanson↗
NASA NTRS2024

Gateway to the Future: Lessons Learned in Development of the Refueling Systems for NASA's First Lunar Space Station

Developed in collaboration with international and commercial partners, Gateway will be humanity’s first space station around the Moon as a vital component of NASA’s deep space exploration plans to the Moon, Mars and beyond. As part of it’s focus on developing a sustainable, long term lunar capability, both it’s Xenon based Solar Electric Propulsion System, as well as it’s bi-propellant Reaction Control System of the Gateway are designed to be on-orbit refuellable. Through design studies, numerical modeling, hardware development, and early testing, the system architecture has undergone significant changes to meet mission requirements and utilize evolving hardware capabilities between concept formulation and it’s successful completion of it’s Critical Design Review. This paper presents key lessons learned during this process, highlighting specific design elements and test results that contribute to a robust and adaptable refueling system for the Gateway.

Christopher Radke↗
NASA NTRSDate not supplied

Development of an Ejectable Data Recorder Ejection Mechanism for the Low Earth Orbit Flight Test of an Inflatable Decelerator

On November 10, 2022, the 1100kg (2,425 lbs.) LOFTID Reentry Vehicle (RV) was launched on a United Launch Alliance Atlas V as a secondary payload with the Joint Polar Surveyor System-2. The 6-meter diameter (~20 ft.) aeroshell (a type of heat shield) entered the atmosphere at 8 kilometers per second (18,000 miles per hour), and flew nominally, enduring the intended heat pulse that saw temperatures exceeding 1371˚C (2500˚F) on the front side while the payload skin remained only about 38˚C (100˚F). The RV exceeded Mach 30 and the heat-affected aeroshell withstood a pressure pulse that exerted 9g’s deceleration maintaining stable flight through the hypersonic, supersonic, transonic, and subsonic regimes to the parachute deployment. As part of the Agency’s strategic goal “to extend human presence deeper into space and to the moon for sustainable long-term exploration and utilization”, the LOFTID inflatable aerodynamic decelerator or aeroshell technology could one day help land humans on Mars. As with any flight test, data collection is of utmost importance. Without a data downlink and a possibility of the RV sinking before the recovery crew got to it, a secondary data collection method was introduced. The RV would eject a data recorder, which would have a duplicate copy of the on-board flight date, before splashdown and be retrieved separately. This paper discusses the development of the ejection mechanism used to eject the data recorder from the RV during the test flight. The development includes discussions of design constraints, a design overview, the testing program, and lessons learned throughout the process all the way through successful data recorder recovery.

mechanism↗
NASA NTRSDate not supplied

X-57 Traction Power and Command Systems Development

This paper describes the final, as-built design of the X‑57 Maxwell aircraft power and command system architecture that implements the electrified propulsion capability. The development of the traction power, command, and avionics power subsystems proceeded as planned at the initial project critical design review, but improvements to the design were identified following the development of detailed operations concepts and integrated subsystem and system testing. The redundant architecture with A‑side and B‑side buses provided a robust framework for a developmental system that would turn out to have a lower technology readiness than had been assumed upon project formulation. As the project team identified reliability or performance gaps in the electrified propulsion powertrain components and their interactions with the other vehicle systems, the traction power, command, and avionics architectures were modified to accommodate the modified systems. Following the publication of the planned design approach at the critical design review milestone [1], the project team developed the flight hardware and software, integrated the systems, and adjusted the design and qualification activities to address gaps in the components, system architecture, and requirements as the gaps were realized. In addition to inherent challenges in development of these subsystems, the integration of this new technology with adjacent critical systems in an aircraft configuration posed additional challenges that drove design considerations across the subsystem development and the other vehicle systems. Integration complications included electromagnetic compatibility, thermal performance, and tolerance of single-point failures internal and external to the powerplant. Development of a qualification program was required for the new motors, inverters, and batteries, and hardware performance during component qualification fed back into the development process and led lessons learned and redesign of key elements.

distributed propulsion↗
NASA NTRS2024

Gateway to the Future: Lessons Learned in Development of the Refueling Systems for NASA's First Lunar Space Station

Developed in collaboration with international and commercial partners, Gateway will be humanity’s first crewed space station around the Moon as a vital component of NASA’s Artemis Program for exploration to the Moon, Mars and beyond. As part of it’s focus on developing a sustainable, long term lunar capability, both Xenon based Solar Electric Propulsion System, as well as bi-propellant Reaction Control System of Gateway are designed to be on-orbit refuelable. Through design studies, numerical modeling, hardware development, and substantial testing, the system architecture has undergone significant changes to meet mission requirements and utilize evolving hardware capabilities between concept formulation and the successful completion of its Critical Design Review. This paper presents key lessons learned during this process, highlighting specific design elements and test results that contribute to a robust and adaptable refueling system for the Gateway.

Christopher Radke↗
NASA NTRS2009

Lessons Learned for Cx PRACA. Constellation Program Problem Reporting, Analysis and Corrective Action Process and System

This slide presentation reviews the Constellation Program Problem Reporting, Analysis and Corrective Action Process and System (Cx PRACA). The goal of the Cx PRACA is to incorporate Lessons learned from the Shuttle, ISS, and Orbiter programs by creating a single tool for managing the PRACA process, that clearly defines the scope of PRACA applicability and what must be reported, and defines the ownership and responsibility for managing the PRACA process including disposition approval authority. CxP PRACA is a process, supported by a single information gathering data module which will be integrated with a single CxP Information System, providing interoperability, import and export capability making the CxP PRACA a more effective and user friendly technical and management tool.

Kelle, Pido I.↗
NASA NTRS2016

Laboratory Testing and Performance Verification of the CHARIS Integral Field Spectrograph

The Coronagraphic High Angular Resolution Imaging Spectrograph (CHARIS) is an integral field spectrograph (IFS) that has been built for the Subaru telescope. CHARIS has two imaging modes; the high-resolution mode is R82, R69, and R82 in J, H, and K bands respectively while the low-resolution discovery mode uses a second low-resolution prism with R19 spanning 1.15-2.37 microns (J+H+K bands). The discovery mode is meant to augment the low inner working angle of the Subaru Coronagraphic Extreme Adaptive Optics (SCExAO) adaptive optics system, which feeds CHARIS a coronagraphic image. The goal is to detect and characterize brown dwarfs and hot Jovian planets down to contrasts five orders of magnitude dimmer than their parent star at an inner working angle as low as 80 milliarcseconds. CHARIS constrains spectral crosstalk through several key aspects of the optical design. Additionally, the repeatability of alignment of certain optical components is critical to the calibrations required for the data pipeline. Specifically the relative alignment of the lens let array, prism, and detector must be highly stable and repeatable between imaging modes. We report on the measured repeatability and stability of these mechanisms, measurements of spectral crosstalk in the instrument, and the propagation of these errors through the data pipeline. Another key design feature of CHARIS is the prism, which pairs Barium Fluoride with Ohara L-BBH2 high index glass. The dispersion of the prism is significantly more uniform than other glass choices, and the CHARIS prisms represent the first NIR astronomical instrument that uses L-BBH2as the high index material. This material choice was key to the utility of the discovery mode, so significant efforts were put into cryogenic characterization of the material. The final performance of the prism assemblies in their operating environment is described in detail. The spectrograph is going through final alignment, cryogenic cycling, and is being delivered to the Subaru telescope in April 2016. This paper is a report on the laboratory performance of the spectrograph, and its current status in the commissioning process so that observers will better understand the instrument capabilities. We will also discuss the lessons learned during the testing process and their impact on future high-contrast imaging spectrographs for wavefront control.

Coronagraphic High Angular Resolution Imaging Spec↗
NASA NTRS2006

NASA Crew Launch Vehicle Approach Builds on Lessons from Past and Present Missions

The United States Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with a new human-rated system suitable for missions to the Moon and Mars. The Crew Exploration Vehicle (CEV) that the new Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station and be capable of carrying crews back to lunar orbit and of supporting missions to Mars orbit. NASA is using its extensive experience gained from past and ongoing launch vehicle programs to maximize the CLV system design approach, with the objective of reducing total lifecycle costs through operational efficiencies. To provide in-depth data for selecting this follow-on launch vehicle, the Exploration Systems Architecture Study was conducted during the summer of 2005, following the confirmation of the new NASA Administrator. A team of aerospace subject matter experts used technical, budget, and schedule objectives to analyze a number of potential launch systems, with a focus on human rating for exploration missions. The results showed that a variant of the Space Shuttle, utilizing the reusable Solid Rocket Booster as the first stage, along with a new upper stage that uses a derivative of the RS-25 Space Shuttle Main Engine to deliver 25 metric tons to low-Earth orbit, was the best choice to reduce the risks associated with fielding a new system in a timely manner. The CLV Project, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operation of this new human-rated system. The CLV Project works closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch system . leveraging a wealth of lessons learned from Shuttle operations. The CL V is being designed to reduce costs through a number of methods, ranging from validating requirements to conducting trades studies against the concept design. Innovations such as automated processing will build on lessons learned from the Shuttle, other launch systems, Department of Defense operations experience, and subscale flight tests such as the Delta Clipper-Experimental Advanced (DCXA) vehicle operations that utilized minimal touch labor, automated cryogen ic propellant loading , and an 8-hour turnaround for a cryogenic propulsion system. For the CLV, the results of hazard analyses are contributing to an integrated vehicle health monitoring system that will troubleshoot anomalies and determine which ones can be solved without human intervention. Such advances will help streamline the mission operations process for pilots and ground controllers alike. In fiscal year 2005, NASA invested approximately $4.5 billion of its $16 bill ion budget on the Space Shuttle. The ultimate goal of the CLV Project is to deliver a safe, reliable system designed to minimize lifecycle costs so that NASA's budget can be invested in missions of scientific discovery. Lessons learned from developing the CLV will be applied to the growth path for future systems, including a heavy lift launch vehicle.

Dumbacher, Daniel L.↗
NASA NTRS2006

REIMR - A Process for Utilizing Liquid Rocket Propulsion-Oriented 'Lessons Learned' to Mitigate Development Risk in Nuclear Thermal Propulsion

This paper is a summary overview of a study conducted at the NASA Marshall Space Flight Center (NASA MSFC) during the initial phases of the Space Launch Initiative (SLI) program to evaluate a large number of technical problems associated with the design, development, test, evaluation and operation of several major liquid propellant rocket engine systems (i.e., SSME, Fastrac, J-2, F-1). One of the primary results of this study was the identification of the Fundamental Root Causes that enabled the technical problems to manifest, and practices that can be implemented to prevent them from recurring in future propulsion system development efforts, such as that which is currently envisioned in the field of nuclear thermal propulsion (NTF). This paper will discuss the Fundamental Root Causes, cite some examples of how the technical problems arose from them, and provide a discussion of how they can be mitigated or avoided in the development of an NTP system

Ballard, RIchard O.↗
NASA NTRS2022

Flight Rule Design, Implementation, Verification, and Validation for the Psyche Mission

NASA Jet Propulsion Lab (JPL)’s upcoming mission Psyche will begin its journey to the asteroid (16) Psyche in late 2022 in an effort to better understand its origins and, in turn, better understand our own. Operating the spacecraft safely will require the dedicated efforts of a small team that understands the spacecraft’s operational constraints, as well as a set of powerful spacecraft models designed to catch command errors that can pose risks to mission success. One of the responsibilities of the operations team is to ensure adherence to a set of Flight Rules written by spacecraft and instrument experts that are designed to mitigate these risks. Psyche’s innovations in Flight Rule design principles and advancements in the tools and processes used to implement and check Flight Rules are discussed. A comparison of Psyche’s approach to Flight Rules to other JPL missions will provide lessons learned for future missions that must perform constraint checking during operations. Flight Rule development faces several major challenges. First, flight rule developers must work with Subject Matter Experts (SME) to write the rules in a way that captures the intent of the constraint in a straightforward, enforceable manner. Second, software implementers must correctly interpret flight rules into code so that it meets the original intent of the SME. Finally, a means must be provided for SMEs to validate flight rule implementations without requiring them to understand the underlying software. Innovative processes intended to efficiently close the loop between stakeholders and software developers are described, such as the use of test-driven development to provide stakeholders with easy-to-review implementations. New guidelines for flight rule writing, designed to address these challenges, are described for future missions to adopt and build upon. Psyche Mission System has a variety of new and heritage tools that improve in the Flight Rule validation and checking process. Psyche developed a powerful, new tool called RandSEQ and made significant improvements to Octopusjam, two valuable tools that aid the development of Flight Rule unit tests. Advancements in the models and processes for performing sequence validation with SEQuence GENerator (SEQGEN), the primary, high-heritage tool used for automated flight rule checks on Psyche, are described. The development of new software and the advancements to existing software put Psyche at the forefront of Flight Rule technology. All missions must perform detailed constraint checking, so a comparison of Psyche’s approach to some of these items to the approaches taken by other missions such as Dawn, M2020, and Europa Clipper is done, specifically to examine SME-developer communication, tools used, and development process. Lessons learned from this comparison will be provided.

Weise, Tim↗
NASA NTRS2005

Vehicle Integrated Performance Analysis, the VIPA Experience: Reconnecting with Technical Integration

Today's NASA is facing significant challenges and changes. The Exploration initiative indicates a large increase in projects with limited increase in budget. The Columbia report has criticized NASA for its lack of insight and technical integration impacting its ability to provide safety. The Aldridge report is advocating NASA find new ways of doing business. Very early in the Space Launch Initiative (SLI) program a small team of engineers at MSFC were asked to propose a process for performing a system level assessment of a launch vehicle. The request was aimed primarily at providing insight and making NASA a "smart buyer." Out of this effort the VIPA team was created. The difference between the VIPA effort and many integration attempts is that VIPA focuses on using experienced people from various disciplines and a process which focuses them on a technically integrated assessment. Most previous attempts have focused on developing an all encompassing software tool. In addition, VIPA anchored its process formulation in the experience of its members and in early developmental Space Shuttle experience. The primary reference for this is NASA-TP-2001-210092, "Launch Vehicle Design Process: Characterization, Technical Integration, and Lessons Learned," and discussions with its authors. The foundations of VIPA's process are described. The VIPA team also recognized the need to drive detailed analysis earlier in the design process. Analyses and techniques typically done in later design phases, are brought forward using improved computing technology. The intent is to allow the identification of significant sensitivities, trades, and design issues much earlier in the program. This process is driven by the T-model for Technical Integration described in the aforementioned reference. VIPA's approach to performing system level technical integration is discussed in detail. Proposed definitions are offered to clarify this discussion and the general systems integration dialog. VIPA's capabilities and process can now be used to significantly enhance the development and monitoring of realizable project requirements. This is done through the use of VIPA's V-model. Starting with a given concept, VIPA's assessment validates the concept's stated performance, identifies significant issues either with the concept or the requirements, and then re-integrates these issues to determine impacts. This process is discussed along with a description of how it may be integrated into a program's insight and review process. The VIPA process has been employed successfully on several projects including SLI, Orbital Space Plane (OSP), and several heavy lift concepts for Exploration. It has also been proposed for use on the Jupiter Icy Moon (JIMO) spacecraft. The VIPA process has gained favor with both engineering and project organizations for being responsive and insightful. Selected results from these assessments will be presented.

McGhee, David S.↗
NASA NTRS2018

New Metadata Capabilities within NASA's Common Metadata Repository (CMR)

This talk will convey the new capabilities and features of the UMM-Variables and the UMM-Services metadata model within the Common Metadata Repository (CMR) and how community engagement through the ESDIS Standards Office (ESO) review shaped the new versions of the models. The Unified Metadata Model (UMM) provides a common metadata model to unify legacy systems (i.e. GCMD (Global Change Master Directory), ECHO (Earth Observing System (EOS) Clearinghouse)) with new systems (i.e. CMR). The rationale and migration process of the Service Entry Resource Format (SERF) to the UMM-S will also be conveyed. The talk will conclude with discussing issues and lessons learned from the review process and how future reviews will be conducted to ensure a more targeted, meaningful review with a faster turn-around time for triage and implementation.

Earth Observing System↗
NASA NTRS2005

Lessons Learned From Developing Three Generations of Remote Sensing Science Data Processing Systems

The Biospheric Information Systems Branch at NASA s Goddard Space Flight Center has developed three generations of Science Investigator-led Processing Systems for use with various remote sensing instruments. The first system is used for data from the MODIS instruments flown on NASA s Earth Observing Systems @OS) Terra and Aqua Spacecraft launched in 1999 and 2002 respectively. The second generation is for the Ozone Measuring Instrument flying on the EOS Aura spacecraft launched in 2004. We are now developing a third generation of the system for evaluation science data processing for the Ozone Mapping and Profiler Suite (OMPS) to be flown by the NPOESS Preparatory Project (NPP) in 2006. The initial system was based on large scale proprietary hardware, operating and database systems. The current OMI system and the OMPS system being developed are based on commodity hardware, the LINUX Operating System and on PostgreSQL, an Open Source RDBMS. The new system distributes its data archive across multiple server hosts and processes jobs on multiple processor boxes. We have created several instances of this system, including one for operational processing, one for testing and reprocessing and one for applications development and scientific analysis. Prior to receiving the first data from OMI we applied the system to reprocessing information from the Solar Backscatter Ultraviolet (SBUV) and Total Ozone Mapping Spectrometer (TOMS) instruments flown from 1978 until now. The system was able to process 25 years (108,000 orbits) of data and produce 800,000 files (400 GiB) of level 2 and level 3 products in less than a week. We will describe the lessons we have learned and tradeoffs between system design, hardware, operating systems, operational staffing, user support and operational procedures. During each generational phase, the system has become more generic and reusable. While the system is not currently shrink wrapped we believe it is to the point where it could be readily adopted, with substantial cost savings, for other similar tasks.

Tilmes, Curt↗
NASA NTRS2014

ISS Ammonia Pump Failure, Recovery, and Lesson Learned A Hydrodynamic Bearing Perspective

The design, development, and operation of long duration spaceflight hardware has become an evolutionary process in which meticulous attention to details and lessons learned from previous experiences play a critical role. Invaluable to this process is the ability to retrieve and examine spaceflight hardware that has experienced a premature failure. While these situations are rare and unfortunate, the failure investigation and recovery from the event serve a valuable purpose in advancing future space mechanism development. Such a scenario began on July 31, 2010 with the premature failure of an ammonia pump on the external active thermal control system of the International Space Station. The ground-based inspections of the returned pump and ensuing failure investigation revealed five potential bearing forces that were un-accounted for in the design phase and qualification testing of the pump. These forces could combine in a number of random orientations to overload the pump bearings leading to solid-surface contact, wear, and premature failure. The recovery plan identified one of these five forces as being related to the square of the operating speed of the pump and this fact was used to recover design life through a change in flight rules for the operation of the pump module. Through the course of the failure investigation, recovery, and follow-on assessment of pump wear life, design guidance has been developed to improve the life of future mechanically pumped thermal control systems for both human and robotic exploration missions.

Bruckner, Robert J.↗
NASA NTRS2016

Human Mars Landing Site and Impacts on Mars Surface Operations

This paper describes NASA's initial steps for identifying and evaluating candidate Exploration Zones (EZs) and Regions of Interests (ROIs) for the first human crews that will explore the surface of Mars. NASA's current effort to define the exploration of this planet by human crews, known as the Evolvable Mars Campaign (EMC), provides the context in which these EZs and ROIs are being considered. The EMC spans all aspects of a human Mars mission including launch from Earth, transit to and from Mars, and operations on the surface of Mars. An EZ is a collection of ROIs located within approximately 100 kilometers of a centralized landing site. ROIs are areas relevant for scientific investigation and/or development/maturation of capabilities and resources necessary for a sustainable human presence. The EZ also contains one or more landing sites and a habitation site that will be used by multiple human crews during missions to explore and utilize the ROIs within the EZ. With the EMC as a conceptual basis, the EZ model has been refined to a point where specific site selection criteria for scientific exploration and in situ resource utilization can be defined. In 2015 these criteria were distributed to the planetary sciences community and the in situ resource utilization and civil engineering communities as part of a call for EZ proposals. The resulting "First Landing Site/Exploration Zone Workshop for Human Missions to the Surface of Mars" was held in October 2015 during which 47 proposals for EZs and ROIs were presented and discussed. Proposed locations spanned all longitudes and all allowable latitudes (+/- 50 degrees). Proposed justification for selecting one of these EZs also spanned a significant portion of the scientific and resource criteria provided to the community. Several important findings resulted from this Workshop including: (a) a strong consensus that, at a scale of 100 km (radius), multiple places on Mars exist that have both sufficient scientific interest to sustain multiple crews of exploring astronauts, AND potential resource deposits for ISRU indicating the current EZ definition is viable and should be retained for now, (b) new data types (needed for more definitive analysis of EZs) argued strongly for a new orbiter mission, and possibly one or more surface missions, to obtain these data, (c) a general consensus that this Workshop was an excellent start to identifying a place where future human missions to Mars can productively explore this planet and learn to live and work there for the long term. Building on these findings, HEOMD and SMD are: (a) refining the EZ selection criteria and overall selection process to improve on lessons learned from the first EZ workshop, (b) using these proposed locations to develop "reference EZs" for assessment purposes (primarily engineering assessments), (c) gathering data and conducting analyses to better understanding the different potential sources for water, including the ease of extraction and purification, and (d) assessing trends in additional data that are needed to better characterize EZs proposed at the workshop and how these data needs impact the design and operation of future robotic Mars missions.

Hoffman, Stephen J.↗
NASA NTRS2014

Cost Analysis in a Multi-Mission Operations Environment

Spacecraft control centers have evolved from dedicated, single-mission or single mission-type support to multi-mission, service-oriented support for operating a variety of mission types. At the same time, available money for projects is shrinking and competition for new missions is increasing. These factors drive the need for an accurate and flexible model to support estimating service costs for new or extended missions; the cost model in turn drives the need for an accurate and efficient approach to service cost analysis. The National Aeronautics and Space Administration (NASA) Huntsville Operations Support Center (HOSC) at Marshall Space Flight Center (MSFC) provides operations services to a variety of customers around the world. HOSC customers range from launch vehicle test flights; to International Space Station (ISS) payloads; to small, short duration missions; and has included long duration flagship missions. The HOSC recently completed a detailed analysis of service costs as part of the development of a complete service cost model. The cost analysis process required the team to address a number of issues. One of the primary issues involves the difficulty of reverse engineering individual mission costs in a highly efficient multi-mission environment, along with a related issue of the value of detailed metrics or data to the cost model versus the cost of obtaining accurate data. Another concern is the difficulty of balancing costs between missions of different types and size and extrapolating costs to different mission types. The cost analysis also had to address issues relating to providing shared, cloud-like services in a government environment, and then assigning an uncertainty or risk factor to cost estimates that are based on current technology, but will be executed using future technology. Finally the cost analysis needed to consider how to validate the resulting cost models taking into account the non-homogeneous nature of the available cost data and the decreasing flight rate. This paper presents the issues encountered during the HOSC cost analysis process, and the associated lessons learned. These lessons can be used when planning for a new multi-mission operations center or in the transformation from a dedicated control center to multi-center operations, as an aid in defining processes that support future cost analysis and estimation. The lessons can also be used by mature service-oriented, multi-mission control centers to streamline or refine their cost analysis process.

Felton, Larry↗
NASA NTRS2014

Cost Analysis In A Multi-Mission Operations Environment

Spacecraft control centers have evolved from dedicated, single-mission or single missiontype support to multi-mission, service-oriented support for operating a variety of mission types. At the same time, available money for projects is shrinking and competition for new missions is increasing. These factors drive the need for an accurate and flexible model to support estimating service costs for new or extended missions; the cost model in turn drives the need for an accurate and efficient approach to service cost analysis. The National Aeronautics and Space Administration (NASA) Huntsville Operations Support Center (HOSC) at Marshall Space Flight Center (MSFC) provides operations services to a variety of customers around the world. HOSC customers range from launch vehicle test flights; to International Space Station (ISS) payloads; to small, short duration missions; and has included long duration flagship missions. The HOSC recently completed a detailed analysis of service costs as part of the development of a complete service cost model. The cost analysis process required the team to address a number of issues. One of the primary issues involves the difficulty of reverse engineering individual mission costs in a highly efficient multimission environment, along with a related issue of the value of detailed metrics or data to the cost model versus the cost of obtaining accurate data. Another concern is the difficulty of balancing costs between missions of different types and size and extrapolating costs to different mission types. The cost analysis also had to address issues relating to providing shared, cloud-like services in a government environment, and then assigning an uncertainty or risk factor to cost estimates that are based on current technology, but will be executed using future technology. Finally the cost analysis needed to consider how to validate the resulting cost models taking into account the non-homogeneous nature of the available cost data and the decreasing flight rate. This paper presents the issues encountered during the HOSC cost analysis process, and the associated lessons learned. These lessons can be used when planning for a new multi-mission operations center or in the transformation from a dedicated control center to multi-center operations, as an aid in defining processes that support future cost analysis and estimation. The lessons can also be used by mature serviceoriented, multi-mission control centers to streamline or refine their cost analysis process.

Newhouse, M.↗
NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗