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NASA NTRS2016

Secondary Payload Opportunities on NASA's Space Launch System (SLS) Enable Science and Deep Space Exploration

For the first time in almost 40 years, a NASA human-rated launch vehicle has completed its Critical Design Review (CDR). With this milestone, NASA's Space Launch System (SLS) and Orion spacecraft are on the path to launch a new era of deep space exploration. This first launch of SLS and the Orion Spacecraft is planned no later than November 2018 and will fly along a trans-lunar trajectory, testing the performance of the SLS and Orion systems for future missions. NASA is making investments to expand the science and exploration capability of the SLS by developing the capability to deploy small satellites during the trans-lunar phase of the mission trajectory. Exploration Mission 1 (EM-1) will include thirteen 6U Cubesat small satellites to be deployed beyond low earth orbit. By providing an earth-escape trajectory, opportunities are created for the advancement of small satellite subsystems, including deep space communications and in-space propulsion. This SLS capability also creates low-cost options for addressing existing Agency strategic knowledge gaps and affordable science missions. A new approach to payload integration and mission assurance is needed to ensure safety of the vehicle, while also maintaining reasonable costs for the small payload developer teams. SLS EM-1 will provide the framework and serve as a test flight, not only for vehicle systems, but also payload accommodations, ground processing, and on-orbit operations. Through developing the requirements and integration processes for EM-1, NASA is outlining the framework for the evolved configuration of secondary payloads on SLS Block upgrades. The lessons learned from the EM-1 mission will be applied to processes and products developed for future block upgrades. In the heavy-lift configuration of SLS, payload accommodations will increase for secondary opportunities including small satellites larger than the traditional Cubesat class payload. The payload mission concept of operations, proposed payload capacity of SLS, and the payload requirements for launch and deployment will be described to provide potential payload users an understanding of this unique exploration capability.

Singer, Jody↗
NASA NTRSDate not supplied

Space Launch System: SLS Real Time Rollout Monitoring for MPCV

The NASA Space Launch System (SLS) rocket, Orion spacecraft, and Mobile Launcher (ML) are transported to Pad 39B from the Vehicle Assembly Building on a large, tracked vehicle known as the Crawler Transporter (CT). The CT is a holdover from the Apollo and Space Shuttle programs but has been extensively upgraded to accommodate the SLS. The Dynamic Rollout Test (DRT) on March 17, 2022 marked the first full rollout of the SLS and ML. Analysis indicated that loads and vibrations would be well below design limits, but out of an abundance of caution it was decided to monitor the response in real time during the rollout to assure that loads remained within predicted limits. This first rollout was outfitted with extensive test instrumentation such as accelerometers, pressure sensors, and strain gauges. This instrumentation remained in place following the integrated vehicle modal test and was being used for additional Operational Modal Analysis (OMA) during the rollout in addition to the real-time monitoring. This presentation discusses the specific loads and accelerations monitored during the rollout, how and why those responses were chosen, and how the system was implemented. Finally, a post-rollout loads reconstruction is used to assess the process and the analysis tools used for the rollout analysis.

SLS↗
NASA NTRS2018

Space Launch System (SLS) Mission Planner's Guide

The purpose of this Space Launch System (SLS) Mission Planner's Guide (MPG) is to provide future payload developers/users with sufficient insight to support preliminary SLS mission planning. Consequently, this SLS MPG is not intended to be a payload requirements document; rather, it organizes and details SLS interfaces/accommodations in a manner similar to that of current Expendable Launch Vehicle (ELV) user guides to support early feasibility assessment. Like ELV Programs, once approved to fly on SLS, specific payload requirements will be defined in unique documentation.

Smith, David Alan↗
NASA NTRS2018

Space Launch System (SLS) Mission Planner’s Guide

The purpose of this Space Launch System (SLS) Mission Planner’s Guide (MPG) is to provide future payload developers/users with sufficient insight to support preliminary SLS mission planning. Consequently, this SLS MPG is not intended to be a payload requirements document; rather, it organizes and details SLS interfaces/accommodations in a manner similar to that of current Expendable Launch Vehicle (ELV) user guides to support early feasibility assessments. Like ELV programs, specific payload requirements will be defined in unique documentation once manifested to fly on SLS. SLS users requiring additional mission planning information or more detailed technical interchange concerning specific SLS accommodations should contact the SLS Spacecraft/Payload Integration and Evolution (SPIE) office.

Smith, David Alan↗
NASA NTRS2012

NASA's Space Launch System (SLS): A New National Capability

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) will contribute a new national capability for human space flight and scientific missions to low- Earth orbit (LEO) and beyond. Exploration beyond Earth orbit will be an enduring legacy to future generations, confirming America s desire to explore, learn, and progress. The SLS Program, managed at NASA s Marshall Space Fight Center, will develop the heavy lift vehicle that will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and science experiments for missions beyond Earth s orbit. This paper gives an overview of the SLS design and management approach against a backdrop of the missions it will empower. It will detail the plan to move from the computerized drawing board to the launch pad in the near term, as well as summarize the innovative approaches the SLS team is applying to deliver a safe, affordable, and sustainable long-range national capability.

May, Todd A.↗
NASA NTRS2012

NASA's Space Launch System (SLS) Program: Mars Program Utilization

NASA's Space Launch System is being designed for safe, affordable, and sustainable human and scientific exploration missions beyond Earth's orbit (BEO), as directed by the NASA Authorization Act of 2010 and NASA's 2011 Strategic Plan. This paper describes how the SLS can dramatically change the Mars program's science and human exploration capabilities and objectives. Specifically, through its high-velocity change (delta V) and payload capabilities, SLS enables Mars science missions of unprecedented size and scope. By providing direct trajectories to Mars, SLS eliminates the need for complicated gravity-assist missions around other bodies in the solar system, reducing mission time, complexity, and cost. SLS's large payload capacity also allows for larger, more capable spacecraft or landers with more instruments, which can eliminate the need for complex packaging or "folding" mechanisms. By offering this capability, SLS can enable more science to be done more quickly than would be possible through other delivery mechanisms using longer mission times.

May, Todd A.↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the NASA Space Launch System (SLS) program. Testing was needed because SLS ascent loads are 35% higher than Space Shuttle loads. Objectives of testing were to determine margins of safety, demonstrate reliability, and validate analytical models. Testing combined with analysis was able to show heritage forward skirts were acceptable to use on the SLS program.

Lohrer, J. D.↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Introduction: (a) Structural testing was performed to evaluate Space Shuttle heritage forward skirts for use on the Space Launch System (SLS) program, (b) Testing was required because SLS loads are approximately 35% greater than shuttle loads; and (c) Two forwards skirts were tested to failure.

Lohrer, Joe↗
NASA NTRS2018

Methodologies for Verification and Validation of Space Launch System (SLS) Structural Dynamic Models

Responses to challenges associated with verification and validation (V&V) of Space Launch System (SLS) structural dynamics models are presented in this paper. Four methodologies addressing specific requirements for V&V are discussed. (1) Residual Mode Augmentation (RMA), which has gained acceptance by various principals in the NASA community, defines efficient and accurate FEM modal sensitivity models that are useful in test-analysis correlation and reconciliation and parametric uncertainty studies. (2) Modified Guyan Reduction (MGR) and Harmonic Reduction (HR, introduced in 1976), developed to remedy difficulties encountered with the widely used Classical Guyan Reduction (CGR) method, are presented. MGR and HR are particularly relevant for estimation of "body dominant" target modes of shell-type SLS assemblies that have numerous "body", "breathing" and local component constituents. Realities associated with configuration features and "imperfections" cause "body" and "breathing" mode characteristics to mix resulting in a lack of clarity in the understanding and correlation of FEM- and test-derived modal data. (3) Mode Consolidation (MC) is a newly introduced procedure designed to effectively "de-feature" FEM and experimental modes of detailed structural shell assemblies for unambiguous estimation of "body" dominant target modes. Finally, (4) Experimental Mode Verification (EMV) is a procedure that addresses ambiguities associated with experimental modal analysis of complex structural systems. Specifically, EMV directly separates well-defined modal data from spurious and poorly excited modal data employing newly introduced graphical and coherence metrics.

Coppolino, Robert N.↗
NASA NTRS2014

Flight Testing of the Space Launch System (SLS) Adaptive Augmenting Control (AAC) Algorithm on an F/A-18

The Marshall Space Flight Center (MSFC) Flight Mechanics and Analysis Division developed an adaptive augmenting control (AAC) algorithm for launch vehicles that improves robustness and performance on an as-needed basis by adapting a classical control algorithm to unexpected environments or variations in vehicle dynamics. This was baselined as part of the Space Launch System (SLS) flight control system. The NASA Engineering and Safety Center (NESC) was asked to partner with the SLS Program and the Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP) to flight test the AAC algorithm on a manned aircraft that can achieve a high level of dynamic similarity to a launch vehicle and raise the technology readiness of the algorithm early in the program. This document reports the outcome of the NESC assessment.

Dennehy, Cornelius J.↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗
NASA NTRS2020

Booster Obsolescence and Life Extension (BOLE) for Space Launch System (SLS)

A human mission to the moon and Mars is the stated space exploration goal of the United States and the international community. To achieve these goals, NASA is developing the Space Launch System (SLS) and the Orion crew capsule as key elements in the architecture for missions to the moon and Mars. As part of the SLS Booster Obsolescence and Life Extension (BOLE) program, Northrop Grumman Space Systems is working to address booster obsolescence issues in design and manufacturing. The upgraded boosters will also provide increased performance that will benefit future lunar campaigns, science missions, and the eventual Mars campaign.

Tobias, Mark E.↗
NASA NTRS2019

Booster Obsolescence and Life Extension (BOLE) for Space Launch System (SLS)

A human mission to the moon and Mars is the stated space exploration goal of the United States and the international community. To achieve these goals, NASA is developing the Space Launch System (SLS) and the Orion crew capsule as key elements in the architecture for missions to the moon and Mars. As part of the SLS Booster Obsolescence and Life Extension (BOLE) program, Northrop Grumman Innovation Systems is working to address booster obsolescence issues in design and manufacturing. The upgraded boosters will also provide increased performance that will benefit future lunar campaigns, science missions, and the eventual Mars campaign.

Tobias, Mark E.↗
NASA NTRS2021

Damage Tolerance of Candidate Sandwich Structure for the Space Launch System (SLS) Payload Adapter Fitting (PAF)

This Technical Memorandum presents results from a damage tolerance study undertaken in support of the payload adapter fitting (PAF) for the Space Launch System (SLS) program at NASA’s Marshall Space Flight Center (MSFC). The study consisted of determining the compression-after-impact (CAI) strength of candidate carbon/epoxy face sheet sandwich structure that has been identified for potential use to manufacture the PAF hardware. Two types of core material that have been considered for use on the PAF structure were used in this study. One was an aluminum honeycomb and the other was a Rohacell foam. Levels of barely visible impact damage (BVID) were determined for the types of sandwich structure tested in this study and this level of damage was used for CAI strength testing. It was found that the honeycomb core sandwich structure failed by face sheet failure and the foam core sandwich structure failed by core shear failure. CAI strength values were normalized by weight of the sandwich structure since lower mass is desirable for this structure.

sandwich structure↗
NASA NTRS2024

The Effects of Peel Ply on the Damage Tolerance Characteristics of the Space Launch System (SLS) Payload Adapter Fitting (PAF)

A payload adaptor fitting (PAF) has been manufactured at NASA’s Marshall Space Flight Center (MSFC) in support of the Space Launch System (SLS) program. This structure is essentially a large cone made up of eight curved “lobes” that are joined together to form the cone. The lobes were manufactured via automated fiber placement (AFP). The PAF will carry predominantly compressive loads thus compression strength will be the focus of this study. The lobes are sandwich structure made with aluminum honeycomb core and carbon/epoxy face sheets. The lobes will be inserted into metallic rings at the top and bottom of the cone to form the full cone. Both front and back exterior surfaces of each lobe have a plain weave fabric placed at ±45⁰ to the vertical direction to help prevent fiber “breakout” during drilling. The face sheet of each lobe is thickest at the top and plies are dropped as the cone reaches the main acreage in the bottom section of the cone. The entire structure used resin impregnated peel ply that, once removed, supplies a good bonding surface for secondary bonding steps. The peel ply can be removed either directly after cure, or just before any bonding operation. Since foreign object impact can occur to the structure at any time during its life, damage tolerance of the PAF structure both with and without peel ply needed to be addressed because a previous study, albeit with limited data, showed some significant differences in damage tolerance whether the peel ply was present or not [1]. A literature search showed no results for comparing impact damage on composite laminates with and without peel ply. Load versus deflection of impact curves, visual damage, dent depth, damage as ascertained by thermography and cross-sectional microscopy were evaluated as part of the damage resistance of the structure. Compression After Impact (CAI) was performed to assess damage tolerance. The impact tests were conducted on representative specimens both with and without the peel ply present.

Sandwich Structure↗
NASA NTRS2018

Methodologies for Verification and Validation of Space Launch System (SLS) Structural Dynamic Models: Appendices

Verification and validation (V&V) is a highly challenging undertaking for SLS structural dynamics models due to the magnitude and complexity of SLS subassemblies and subassemblies. Responses to challenges associated with V&V of Space Launch System (SLS) structural dynamics models are presented in Volume I of this paper. Four methodologies addressing specific requirements for V&V are discussed. (1) Residual Mode Augmentation (RMA). (2) Modified Guyan Reduction (MGR) and Harmonic Reduction (HR, introduced in 1976). (3) Mode Consolidation (MC). Finally, (4) Experimental Mode Verification (EMV). This document contains the appendices to Volume I.

Coppolino, Robert N.↗
NASA NTRS2018

Development of the Multi-Purpose Transportation System for the Space Launch System (SLS) Core Stage (CS) Flight Article

NASA's Multi-Purpose Transportation System (MPTS) is designed to transport the Space Launch System (SLS) vehicle segments by waterway and roadway. It is tasked with transporting the vehicle from where it is manufactured to its intermediate test location and final launch destination. Its design incorporates mechanisms that release degrees of freedom to prevent excessive loading during transit and ensure a successful delivery of the vehicle to its intended destination. In addition to the Core Stage (CS) flight article, the system will also move three Structural Test Articles (STAs), the Dynamic Demonstration Unit (DDU), and a simulated CS Pathfinder (weight, center of gravity, outer mold line dimensions, and overall length) over road terrain at four NASA centers and on the Pegasus barge. The MPTS independently supports the article at both ends while operating as a combined unit through automated monitoring of its released degree of freedom and corrective responses. This allows the system to constrain its payload in a statically determinate manner while traversing highly variable terrain. Multi-body simulation of the transportation route is useful to predict free-body motion within its range of mobility. The MPTS has completed its design and analysis developmental cycles. This paper describes the design challenges encountered in developing this system of large-scale structure, which incorporates complex mechanisms. The unique techniques and methodologies developed for analytical assessment of the hardware are also discussed.

Sandridge, Sarah↗