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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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At least 163 records · Page 9
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NASA NTRS2005

STS-114: Discovery Mission Status Briefing

Paul Hill, STS-114 Lead Shuttle Flight Director, talks about the imagery that was captured during the first twenty four hours in orbit. He expresses that new data was captured during ascent of the Space Shuttle Discovery through imagery and in-orbit handheld photographs of the Orbital Maneuvering system (OMS) pods were taken. Laser surveys were also taken of both the wing leading edges and nose caps using the Orbiter Boom and Sensor System (OBSS) instrument package. He presents raw footage from the Laser Dynamic Range Imager (LDRI) at the end of the OBSS showing RCC panels and tiles. He also answers questions from the news media about the possible damage to the Orbiter and debris during lift-off.

Source record↗
NASA NTRS2005

STS-114: Discovery Post MMT Briefing

Wayne Hale, Space Shuttle Deputy Program Manager, is presented in this STS-114 Discovery Post Mission Management Team (MMT) briefing. He begins by talking about obtaining clearance from the Reinforced Carbon-Carbon (RCC) material. He then describes the supplies such as eleven water containers and the transfer of 50 additional pounds of Oxygen to the International Space Station. Hale presents a video of a billowed thermal blanket next to the commander's window on the port side of the Space Shuttle Discovery that seems to be of some concern. He answers questions from the news media about the dimensions of this blanket, and the dangers of getting close to this blanket during the Extravehicular Activity (EVA) to repair the gap fillers.

Source record↗
NASA NTRS2005

Nondestructive Evaluation Tests Performed on Space Shuttle Leading- Edge Materials Subjected to Impact

In support of the space shuttle Return To Flight efforts at the NASA Glenn Research Center, a series of nondestructive evaluation (NDE) tests were performed on reinforced carbon/carbon (RCC) composite panels subjected to ballistic foam impact. The impact tests were conducted to refine and verify analytical models of an external tank foam strike on the space shuttle leading edge. The NDE tests were conducted to quantify the size and location of the resulting damage zone as well as to identify hidden damage.

Roth, Don J.↗
NASA NTRS2005

Followup to Columbia Investigation: Reinforced Carbon/Carbon From the Breach Location in the Wing Leading Edge Studied

Initial estimates on the temperature and conditions of the breach in the Space Shuttle Columbia's wing focused on analyses of the slag deposits. These deposits are complex mixtures of the reinforced carbon/carbon (RCC) constituents, insulation material, and wing structural materials. Identification of melted/solidified Cerachrome insulation (Thermal Ceramics, Inc., Augusta, GA) indicated that the temperatures at the breach had exceeded 1760 C.

Jacobson, Nathan S.↗
NASA NTRS2005

Flexible Metallic Overwrap Concept Developed for On-Orbit Repair of Space Shuttle Orbiter Leading Edges

The Columbia accident has focused attention on the critical need for on-orbit repair concepts for leading edges in the event that damage is incurred during space shuttle orbiter flight. Damage that is considered as potentially catastrophic for orbiter leading edges ranges from simple cracks to holes as large as 16 in. in diameter. NASA is particularly interested in examining potential solutions for areas of larger damage since such a problem was identified as the cause for the Columbia disaster. One possible idea for the on-orbit repair of the reinforced carbon/carbon (RCC) leading edges is an overwrap concept that would use a metallic sheet flexible enough to conform to the contours of the orbiter and robust enough to protect any problem area from catastrophic failure during reentry. The simplified view of the application of a refractory metal sheet over a mockup of shuttle orbiter panel 9, which experiences the highest temperatures on the shuttle during reentry is shown. The metallic overwrap concept is attractive because of its versatility as well as the ease with which it can be included in an onboard repair kit. Reentry of the orbiter into Earth's atmosphere imposes extreme requirements on repair materials. Temperatures can exceed 1650 C for up to 15 min in the presence of an extremely oxidizing plasma environment. Several other factors are critical, including catalysity, emissivity, and vibrational and aerodynamic loads. Materials chosen for this application will need to be evaluated with respect to high-temperature capability, resistance to oxidation, strength, coefficient of thermal expansion, and thermal conductivity. The temperature profile across panel 9 during reentry as well as a schematic of the overwrap concept itself is shown.

Ritzert, Frank J.↗
NASA NTRS2005

NASA Research Center Contributions to Space Shuttle Return to Flight (SSRTF)

Contributions provided by the NASA Research Centers to key Space Shuttle return-to-flight milestones, with an emphasis on debris and Thermal Protection System (TPS) damage characterization, are described herein. Several CAIB recommendations and Space Shuttle Program directives deal with the mitigation of external tank foam insulation as a debris source, including material characterization as well as potential design changes, and an understanding of Orbiter TPS material characteristics, damage scenarios, and repair options. Ames, Glenn, and Langley Research Centers have performed analytic studies, conducted experimental testing, and developed new technologies, analysis tools, and hardware to contribute to each of these recommendations. For the External Tank (ET), these include studies of spray-on foam insulation (SOFI), investigations of potential design changes, and applications of advanced non-destructive evaluation (NDE) technologies to understand ET TPS shedding during liftoff and ascent. The end-to-end debris assessment included transport analysis to determine the probabilities of impact for various debris sources. For the Orbiter, methods were developed, and validated through experimental testing, to determine thresholds for potential damage of Orbiter TPS components. Analysis tools were developed and validated for on-orbit TPS damage assessments, especially in the area of aerothermal environments. Advanced NDE technologies were also applied to the Orbiter TPS components, including sensor technologies to detect wing leading edge impacts during liftoff and ascent. Work is continuing to develop certified TPS repair options and to develop improved methodologies for reinforced carbon-carbon (RCC) damage progression to assist in on-orbit repair decision philosophy.

Cockrell, Charles E., Jr.↗
NASA NTRS2005

Inspection of the Math Model Tools for On-Orbit Assessment of Impact Damage Report

In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments, and real-time on-orbit assessments. The tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.

Harris, Charles E.↗
NASA NTRS2005

Micro-Flying Robotics in Space Missions

The Columbia Accident Investigation Board issued a major recommendation to NASA. Prior to return to flight, NASA should develop and implement a comprehensive inspection plan to determine the structural integrity of all Reinforced Carbon-Carbon (RCC) system components. This inspection plan should take advantage of advanced non-destructive inspection technology. This paper describes a non-intrusive technology with a micro-flying robot to continuously monitor inside a space vehicle for any stress related fissures, cracks and foreign material embedded in walls, tubes etc.

Bardina, Jorge↗
NASA NTRS2006

Characterization of Space Shuttle Thermal Protection System (TPS) Materials for Return-to-Flight following the Shuttle Columbia Accident Investigation

During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included

Wingard, Doug↗
NASA NTRS2007

Space Shuttle MMOD Threat Mitigation Techniques

Prior to each shuttle mission, threat assessments are performed to determine the risk of critical penetration, payload bay door radiator tube leak and crew module window replacement from Micrometeoroid and Orbital Debris (MMOD). Mission parameters, such as vehicle attitude, exposure time and altitude are used as inputs for the analysis. Ballistic limit equations, based on hypervelocity impact testing of shuttle materials are used to estimate the critical particle diameters of the outer surfaces of the vehicle. The assessments are performed using the BUMPER computer code at the NASA/JSC Hypervelocity Impact Technology Facility (HITF). The most critical involves the calculation of Loss of Crew and Vehicle (LOCV) risk. In recent years, NASA has implemented several techniques to reduce the risk to the Shuttle from MMOD impacts. This paper will describe on-orbit inspection of the reinforced carbon-carbon (RCC) regions and the methods used discern hypervelocity impact damage. Impact damage contingency plans and on-orbit repair techniques will also be discussed. The wing leading edge impact detection system (WLEIDS) and it's role in the reduction of on-orbit risk reduction will be presented. Finally, an analysis of the effectivity of alternative shuttle flight attitudes on MMOD risk will be demonstrated.

Hyde, Justin L.↗
NASA NTRS2007

EVA Hazards due to TPS Inspection and Repair

Tile inspection and repair activities have implicit hazards associated with them. When an Extra Vehicular Activities (EVA) crewmember and associated hardware are added into the equation, additional hazards are introduced. Potential hazards to the Extravehicular Mobility Unit (EMU), the Orbiter or the crew member themselves are created. In order to accurately assess the risk of performing a TPS inspection or repair, an accurate evaluation of potential hazards and how adequately these hazards are controlled is essential. The EMU could become damaged due to sharp edges, protrusions, thermal extremes, molten metal or impact with the Orbiter. Tools, tethers and the presence of a crew member in the vicinity of the Orbiter Thermal Protection System (TPS) pose hazards to the Orbiter. Hazards such as additional tile or Reinforced Carbon-Carbon (RCC) damage from a loose tool, safety tethers, crewmember or arm impact are introduced. Additionally, there are hazards to the crew which should be addressed. Crew hazards include laser injury, electrical shock, inability to return to the airlock for EMU failures or Orbiter rapid safing scenarios, as well as the potential inadvertent release of a crew member from the arm/boom. The aforementioned hazards are controlled in various ways. Generally, these controls are addressed operationally versus by design, as the majority of the interfaces are to the Orbiter and the Orbiter design did not originally account for tile repair. The Shuttle Remote Manipulator System (SRMS), for instance, was originally designed to deploy experiments, and therefore has insufficient design controls for retention of the Orbiter Boom Sensor System (OBSS). Although multiple methods to repair the Orbiter TPS exist, the majority of the hazards are applicable no matter which specific repair method is being performed. TPS Inspection performed via EVA also presents some of the same hazards. Therefore, the hazards common to all TPS inspection or repair methods will be addressed.

Stewart, Christine E.↗
NASA NTRS2007

Hypervelocity Impact (HVI): WLE High Fidelity Specimen RCC16R - Volume 7

During 2003 and 2004, the Johnson Space Center's White Sands Testing Facility in Las Cruces, New Mexico conducted hypervelocity impact tests on the space shuttle wing leading edge. Hypervelocity impact tests were conducted to determine if Micro-Meteoroid/Orbital Debris impacts could be reliably detected and located using simple passive ultrasonic methods. The objective of Target RCC16R was to study hypervelocity impacts through the reinforced carbon-carbon (RCC) panels of the Wing Leading Edge. Impact damage was detected using lightweight, low power instrumentation capable of being used in flight.

Gorman, Michael R.↗
NASA NTRS2007

Inspection of the Math Model Tools for On-Orbit Assessment of Impact Damage Report

In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments. In addition, the tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.

Harris, Charles E.↗
NASA NTRS2008

Oxidation of Carbon/Carbon through Coating Cracks

Reinforced carbon/carbon (RCC) is used to protect the wing leading edge and nose cap of the Space Shuttle Orbiter on re-entry. It is composed of a lay-up of carbon/carbon fabric protected by a SiC conversion coating. Due to the thermal expansion mismatch of the carbon/carbon and the SiC, the SiC cracks on cool-down from the processing temperature. The cracks act as pathways for oxidation of the carbon/carbon. A model for the diffusion controlled oxidation of carbon/carbon through machined slots and cracks is developed and compared to laboratory experiments. A symmetric cylindrical oxidation cavity develops under the slots, confirming diffusion control. Comparison of cross sectional dimensions as a function of oxidation time shows good agreement with the model. A second set of oxidation experiments was done with samples with only the natural craze cracks, using weight loss as an index of oxidation. The agreement of these rates with the model is quite reasonab

Jacobson, N. S.↗
NASA NTRS2009

Micrometeoroid and Orbital Debris Threat Mitigation Techniques for the Space Shuttle Orbiter

An overview of significant Micrometeoroid and Orbital Debris (MMOD) impacts on the Payload Bay Door radiators, wing leading edge reinforced carbon-carbon panels and crew module windows will be presented, along with a discussion of the techniques NASA has implemented to reduce the risk from MMOD impacts. The concept of "Late Inspection" of the Nose Cap and Wing leading Edge (WLE) Reinforced Carbon Carbon (RCC) regions will be introduced. An alternative mated attitude with the International Space Station (ISS) on shuttle MMOD risk will also be presented. The significant threat mitigation effect of these two techniques will be demonstrated. The wing leading edge impact detection system, on-orbit repair techniques and disabled vehicle contingency plans will also be discussed.

Hyde, James L.↗
NASA NTRS2009

Recent Shuttle Post Flight MMOD Inspection Highlights

Post flight inspections on the Space Shuttle Atlantis conducted after the STS-11.5 mission revealed a 0.11 inch (2.8 mm) hole in the outer face sheet of the starboard payload bay door radiator panel #4. The payload bay door radiators in this region are 0.5 inch (12.7 mm) thick aluminum honeycomb with 0.011 in (0.279 mm) thick aluminum face sheets topped with 0.005 in (0.127 mm) silver-Teflon tape. Inner face sheet damage included a 0.267 in (6.78 mm) long through crack with measureable deformation in the area of 0.2 in (5.1 mm). There was also a 0.031 in (0.787 nun) diameter hole in the rear face sheet. A large approximately l in (25 mm) diameter region of honeycomb was also destroyed. Since the radiators are located on the inside of the shuttle payload bay doors which are closed during ascent and reentry, the damage could only have occurred during the on-orbit portion of the mission. During the August 2007 STS-118 mission to the International Space Station, a micro-meteoroid or orbital debris (MMOD) particle impacted and completely penetrated one of shuttle Endeavour's radiator panels and the underlying thermal control system (TCS) blanket, leaving deposits on (but no damage to) the payload bay door. While it is not unusual for shuttle orbiters to be impacted by small MMOD particles, the damage from this impact is larger than any previously seen on the shuttle radiator panels. One of the largest impacts ever observed on a crew module window occurred during the November 2008 STS-126 mission to the International Space Station. Damage to the window was documented by the crew on orbit. Post flight inspection revealed a 0.4 in (10.8 mm) crater in the window pane, with a depth of 0.03 in (0.76 mm). The window pane was replaced due to the damage caused by this impact. Analysis performed on residue contained in dental mold impressions taken of the site indicated that a meteoroid particle produced this large damage site. The post flight inspection after the subsequent mission, STS-119 in March of 2009, produced a large MMOD impact feature in a wing leading edge reinforced carbon-carbon panel. The crater measured 0.18 in (4.5 nun) in diameter and was nearly 0.037 in (0.93 nun) deep. The thickness of the silicon carbide coating that protects the carbon substrate is nominally 0.02 in (0.5 nun) to 0.04 in (1 mm), making this a significant impact into the RCC. The damage occurred on the upper surface of the panel, which experiences lower heat loads on re-entry. This poster will document the data collected from the impact sites and will include results of the Scanning Electron Microscope/Energy Dispersive X-ray (SEM/EDX) analysis. Evidence will be presented that suggests a source of the impacts.

Hyed, James L.↗
NASA NTRS2009

Model for the Effect of Fiber Bridging on the Fracture Resistance of Reinforced-Carbon-Carbon

A micromechanical methodology has been developed for analyzing fiber bridging and resistance-curve behavior in reinforced-carbon-carbon (RCC) panels with a three-dimensional (3D) composite architecture and a silicon carbide (SiC) surface coating. The methodology involves treating fiber bridging traction on the crack surfaces in terms of a weight function approach and a bridging law that relates the bridging stress to the crack opening displacement. A procedure has been developed to deduce material constants in the bridging law from the linear portion of the K-resistance curve. This report contains information on the application of procedures and outcomes.

Chan, Kwai S.↗
NASA NTRS2010

Fracture Mechanics Analyses of Reinforced Carbon-Carbon Wing-Leading-Edge Panels

Fracture mechanics analyses of subsurface defects within the joggle regions of the Space Shuttle wing-leading-edge RCC panels are performed. A 2D plane strain idealized joggle finite element model is developed to study the fracture behavior of the panels for three distinct loading conditions - lift-off and ascent, on-orbit, and entry. For lift-off and ascent, an estimated bounding aerodynamic pressure load is used for the analyses, while for on-orbit and entry, thermo-mechanical analyses are performed using the extreme cold and hot temperatures experienced by the panels. In addition, a best estimate for the material stress-free temperature is used in the thermo-mechanical analyses. In the finite element models, the substrate and coating are modeled separately as two distinct materials. Subsurface defects are introduced at the coating-substrate interface and within the substrate. The objective of the fracture mechanics analyses is to evaluate the defect driving forces, which are characterized by the strain energy release rates, and determine if defects can become unstable for each of the loading conditions.

Raju, Ivatury S.↗