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Spaceflight Over the Last Ten Years: Failures and Fix-ups 2013 - 2022 RAMS XV Conference

This project is an overview and analysis of the past ten years (2013 – present) in global spaceflight, highlighting the orbital launches of countries, particularly the failures that occurred, the reasons they occurred, and a breakdown of the related statistics and background information. The analysis is conducted from a perspective of reliability and maintainability engineering and Probabilistic Risk Assessment (PRA) to formulate a quantifiable understanding of the data and how it is pertinent to Safety and Mission Assurance (SMA) in spaceflight. There is a breakdown by country or group, timelines, and number of launches. The failures over the years are categorized, all given a broad analysis of subsystem failures and details of events. A few failures are given a more in-depth analysis of root causes and failure modes determined by their unique or common nature. The data is retrieved from online, publicly available sources.

Quinn Slaugenhoupt↗

Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems

In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.

Kurt A Polzin↗

A Taylor weak-statement algorithm for hyperbolic conservation laws

Finite element analysis, applied to computational fluid dynamics (CFD) problem classes, presents a formal procedure for establishing the ingredients of a discrete approximation numerical solution algorithm. A classical Galerkin weak-statement formulation, formed on a Taylor series extension of the conservation law system, is developed herein that embeds a set of parameters eligible for constraint according to specification of suitable norms. The derived family of Taylor weak statements is shown to contain, as special cases, over one dozen independently derived CFD algorithms published over the past several decades for the high speed flow problem class. A theoretical analysis is completed that facilitates direct qualitative comparisons. Numerical results for definitive linear and nonlinear test problems permit direct quantitative performance comparisons.

Baker, A. J.↗

Whole body cleaning agent containing N-acyltaurate

The subject invention relates to a human cleansing agent particularly suitable for use in long duration spaceflight and to a method of bathing with the agent. The agent of the subject invention is in the form of a paste having a pH of 5.0 to 7.9 which comprises an acyltaurate, a skin conditioner, a hair conditioner, and a preservative. More specifically, it includes sodium N-coconut acid-N-methyl taurate, in combination with soybean lecithin, polyquaternium 16, and formalin. This particular combination satisfies the following objectives: (1) that it be usable with a minimum amount of water per shower (approximately 1 gallon); (2) that it be easily separated from the water for purposes of water reclamation; (3) that it be pH compatible with skin and hair; (4) that it rinse well in deionized water; (5) that it be mild to skin and eyes; (6) that it effectively clean both skin and hair; (7) that it be suitable for use in zero gravity; and (8) that it provide ease of combing of wet and dry hair. The method of the invention includes the steps of wetting the skin and hair with a small quantity of water, lathering the skin with the paste, rinsing the lather from the skin and hair with a small quantity of water to produce a rinse water containing the cleansing agent, defoaming the rinse water, and supplying the defoamed rinse water to a water reclamation unit for recycling the water. The novelty of the invention appears to lie in the particular formulation of the cleansing agent and its method of use which provide optimal results under the given constraints and objectives.

Lentsch, Steven E.↗

Systems engineering studies of on-orbit assembly operation

While the practice of construction has a long history, the underlying theory of construction is relatively young. Very little has been documented as to techniques of logistic support, construction planning, construction scheduling, construction testing, and inspection. The lack of 'systems approaches' to construction processes is certainly one of the most serious roadblocks to the construction of space structures. System engineering research efforts at CSC are aimed at developing concepts and tools which contribute to a systems theory of space construction. The research is also aimed at providing means for trade-offs of design parameters for other research areas in CSC. Systems engineering activity at CSC has divided space construction into the areas of orbital assembly, lunar base construction, interplanetary transport vehicle construction, and Mars base construction. A brief summary of recent results is given. Several models for 'launch-on-time' were developed. Launch-on-time is a critical concept to the assembly of such Earth-orbiting structures as the Space Station Freedom, and to planetary orbiters such as the Mars transfer vehicle. CSC has developed a launch vehicle selection model which uses linear programming to find optimal combinations of launch vehicles of various sizes (Atlas, Titan, Shuttles, HLLV's) to support SEI missions. Recently, the Center developed a cost trade-off model for studying on orbit assembly logistics. With this model it was determined that the most effective size of the HLLV would be in the range of 120 to 200 metric tons to LEO, which is consistent with the choices of General Stafford's Synthesis Group Report. A second-generation Dynamic Construction Activities Model ('DYCAM') process model has been under development, based on our past results in interruptability and our initial DYCAM model. This second-generation model is built on the paradigm of knowledge-based expert systems. It is aimed at providing answers to two questions: (1) what are some necessary or sufficient conditions for judging conceptual designs of spacecraft?, and (2) can a methodology be formulated such that these conditions may be used to provide computer-aided tools for evaluating conceptual designs and planning for space assembly sequences? Early simulation results indicate that the DYCAM model has a clear ability to emulate and simulate human orbital construction processes.

Morgenthaler, George W.↗

Calculation of compressible boundary layer flow about airfoils by a finite element/finite difference method

Preliminary results are presented of a finite element/finite difference method (semidiscrete Galerkin method) used to calculate compressible boundary layer flow about airfoils, in which the group finite element scheme is applied to the Dorodnitsyn formulation of the boundary layer equations. The semidiscrete Galerkin (SDG) method promises to be fast, accurate and computationally efficient. The SDG method can also be applied to any smoothly connected airfoil shape without modification and possesses the potential capability of calculating boundary layer solutions beyond flow separation. Results are presented for low speed laminar flow past a circular cylinder and past a NACA 0012 airfoil at zero angle of attack at a Mach number of 0.5. Also shown are results for compressible flow past a flat plate for a Mach number range of 0 to 10 and results for incompressible turbulent flow past a flat plate. All numerical solutions assume an attached boundary layer.

Strong, Stuart L.↗

Design of launch systems using continuous improvement process

The purpose of this paper is to identify a systematic process for improving ground operations for future launch systems. This approach is based on the Total Quality Management (TQM) continuous improvement process. While the continuous improvement process is normally identified with making incremental changes to an existing system, it can be used on new systems if they use past experience as a knowledge base. In the case of the Reusable Launch Vehicle (RLV), the Space Shuttle operations provide many lessons. The TQM methodology used for this paper will be borrowed from the United States Air Force 'Quality Air Force' Program. There is a general overview of the continuous improvement process, with concentration on the formulation phase. During this phase critical analyses are conducted to determine the strategy and goals for the remaining development process. These analyses include analyzing the mission from the customers point of view, developing an operations concept for the future, assessing current capabilities and determining the gap to be closed between current capabilities and future needs and requirements. A brief analyses of the RLV, relative to the Space Shuttle, will be used to illustrate the concept. Using the continuous improvement design concept has many advantages. These include a customer oriented process which will develop a more marketable product and a better integration of operations and systems during the design phase. But, the use of TQM techniques will require changes, including more discipline in the design process and more emphasis on data gathering for operational systems. The benefits will far outweigh the additional effort.

Brown, Richard W.↗

Development of an Innovative Algorithm for Aerodynamics-Structure Interaction Using Lattice Boltzmann Method

The lattice Boltzmann equation (LBE) is a kinetic formulation which offers an alternative computational method capable of solving fluid dynamics for various systems. Major advantages of the method are owing to the fact that the solution for the particle distribution functions is explicit, easy to implement, and the algorithm is natural to parallelize. In this final report, we summarize the works accomplished in the past three years. Since most works have been published, the technical details can be found in the literature. Brief summary will be provided in this report. In this project, a second-order accurate treatment of boundary condition in the LBE method is developed for a curved boundary and tested successfully in various 2-D and 3-D configurations. To evaluate the aerodynamic force on a body in the context of LBE method, several force evaluation schemes have been investigated. A simple momentum exchange method is shown to give reliable and accurate values for the force on a body in both 2-D and 3-D cases. Various 3-D LBE models have been assessed in terms of efficiency, accuracy, and robustness. In general, accurate 3-D results can be obtained using LBE methods. The 3-D 19-bit model is found to be the best one among the 15-bit, 19-bit, and 27-bit LBE models. To achieve desired grid resolution and to accommodate the far field boundary conditions in aerodynamics computations, a multi-block LBE method is developed by dividing the flow field into various blocks each having constant lattice spacing. Substantial contribution to the LBE method is also made through the development of a new, generalized lattice Boltzmann equation constructed in the moment space in order to improve the computational stability, detailed theoretical analysis on the stability, dispersion, and dissipation characteristics of the LBE method, and computational studies of high Reynolds number flows with singular gradients. Finally, a finite difference-based lattice Boltzmann method is developed for inviscid compressible flows.

Mei, Ren-Wei↗

Propulsion Ground Testing: Planning for the Future

Advanced planners are constantly being asked to plan for the provision of future test capability. Historically, this capability is provided either by substantial investment in new test facility capabilities, or in the substantial investment in the modification of pre-exiting test facilities. The key words in the previous sentence are 'substantial investment.' In the evolving environment of increasingly constrained resources, how is an advanced planner to plan for the provisions of such capabilities? Additionally, the conundrum exists that program formulation decisions are being made based on both life cycle cost decisions in an environment in which the more immediate challenge of front-end capital investment oftentimes is the linchpin upon which early decisions are made. In such an environment, how are plans and decisions made? This paper cites examples of decisions made in the past in the area of both major test facility upgrades, as well as major new test facility investment.

Bruce, Robert↗

Real-time in Situ Signal-to-noise Ratio Estimation for the Assessment of Operational Communications Links

The work presented here formulates the rigorous statistical basis for the correct estimation of communication link SNR of a BPSK, QPSK, and for that matter, any M-ary phase-modulated digital signal from what is known about its statistical behavior at the output of the receiver demodulator. Many methods to accomplish this have been proposed and implemented in the past but all of them are based on tacit and unwarranted assumptions and are thus defective. However, the basic idea is well founded, i.e., the signal at the output of a communications demodulator has convolved within it the prevailing SNR characteristic of the link. The acquisition of the SNR characteristic is of the utmost importance to a communications system that must remain reliable in adverse propagation conditions. This work provides a correct and consistent mathematical basis for the proper statistical 'deconvolution' of the output of a demodulator to yield a measure of the SNR. The use of such techniques will alleviate the need and expense for a separate propagation link to assess the propagation conditions prevailing on the communications link. Furthermore, they are applicable for every situation involving the digital transmission of data over planetary and space communications links.

Manning, Robert M.↗

The solution of the Navier-Stokes equations using Gauss-Seidel line relaxation

The Navier-Stokes equations in an implicit flux-split difference formulation are solved numerically using a Gauss-Seidel line-relaxation procedure. Particular attention is given to the selection of flux-vector splitting method and flux splitting in boundary layers. Results for sample problems involving (1) turbulent supersonic flow over a cone and (2) the viscous hypersonic flow of a chemically reacting gas in thermal nonequilibrium past a blunted cone are presented in extensive graphs and briefly characterized. The present flux-split procedures are shown to provide accurate shear-layer calculations.

Maccormack, Robert W.↗

Aerodynamic stability and heating analyses for the aeroassist flight experiment vehicle

Since ground based flow simulations are presently unable to model flight conditions expected for AOTVs (Aeroassist Orbital Transfer Vehicle) and other hypersonic space vehicles, computer codes are being developed to provide design parameters necessary for structure, guidance, and control aspects. Over the past four years, VRFLO (Viscous Reactive Flow) has been written to model finite-rate chemistry and viscous effects for a variety of aerobrake bodies. VRFLO includes a number of unique features that are summarized as follows: (1) Grid generation is an integral part of the code for several aerobrake configurations which includes the wake flow region; (2) The formulation is valid for three air chemical models; (3) An ADI central difference technique is used to solve the Navier-Stokes and species continuity equations in split groups; and (4) Grid density and numerical damping are minimized by shock-fitting and conformal mapping of body points.

Mcgary, J.↗

Propulsion Ground Testing: Planning for the Future

Advanced planners are constantly being asked to plan for the provision of future test capability. Historically, this capability is provided either by substantial investment in new test facility capabilities, or in the substantial investment in the modification of pre- existing test capabilities. The key words in the previous sentence are "substantial investment". In the evolving environment of increasingly constrained resources, how is an advanced planner to plan for the provisions of such capabilities? Additionally, the conundrum exists that program formulation decisions are being made based upon both life cycle cost decisions in an environment in which the more immediate challenge of "front-end" capital investment? Often times is the linch-pin upon which early decisions are made. In such an environment, how are plans and decisions made? This paper cites examples of decisions made in the past in the area of both major test facility upgrades, as well as major new test facility investment.

Aerospace Systems↗

Recent progress in finite-volume calculations for wing-fuselage combinations

Progress in the application of finite-volume methods to the calculation of transonic potential flows past general wing-body combinations is reviewed. Two different methods of generating boundary-conforming grids are investigated, and the results compared to provide an estimate of solution sensitivity to grid geometry. Both conservative and quasi-conservative difference schemes are used in one of the coordinate systems. Results show that the error introduced by the quasi-conservative formulation seems to be small, although a one-dimensional analysis suggests that schemes of this type do not necessarily produce mass-conserving shocks. Comparison of calculated results with experimental data for realistic fuselage geometries clearly shows the importance of modelling the effect of fuselage geometry upon the wing pressure distribution.

Caughey, D. A.↗

The 3-D viscous flow CFD analysis of the propeller effect on an advanced ducted propeller subsonic inlet

A time marching Navier-Stokes code called PARC3D was used to study the 3-D viscous flow associated with an advanced ducted propeller (ADP) subsonic inlet at take-off operating conditions. At a free stream Mach number of 0.2, experimental data for the inlet-with-propeller test model indicated that the airflow was attached on the cowl windward lip at an angle of attack of 25 degrees became unstable at 29 degrees, and separated at 30 degrees. An experimental study with a similar inlet and with no propeller (through-flow) indicated that flow separation occurred at an angle of attack a few degrees below the value observed when the inlet was tested with the propeller. This tends to indicate that the propeller exerts a favorable effect on the inlet performance. During the through-flow experiment a stationary blockage device was used to successfully simulate the propeller effect on the inlet flow field at angles of attack. In the present numerical study, this flow blockage was modeled via a PARC3D computational boundary condition (BC) called the screen BC. The principle formulation of this BC was based on the one-and-half dimension actuator disk theory. This screen BC was applied at the inlet propeller face station of the computational grid. Numerical results were obtained with and without the screen BC. The application of the screen BC in this numerical study provided results which are similar to the results of past experimental efforts in which either the blockage device or the propeller was used.

Iek, Chanthy↗

The Transition from Spacecraft Development Ot Flight Operation: Human Factor Considerations

In the field of aeronautics and astronautics, a paradigm shift has been witnessed by those in academia, research and development, and private industry. Long development life cycles and the budgets to support such programs and projects has given way to aggressive task schedules and leaner resources to draw from all the while challenging assigned individuals to create and produce improved products of processes. however, this "faster, better, cheaper" concept cannot merely be applied to the design, development, and test of complex systems such as earth-orbiting of interplanetary robotic spacecraft. Full advantage is not possible without due consideration and application to mission operations planning and flight operations, Equally as important as the flight system, the mission operations system consisting of qualified personnel, ground hardware and software tools, and verified and validated operational processes, should also be regarded as a complex system requiring personnel to draw upon formal education, training, related experiences, and heuristic reasoning in engineering an effective and efficient system. Unquestionably, qualified personnel are the most important elements of a mission operations system. This paper examines the experiences of the Deep Space I Project, the first in a series of new technology in-flight validation missions sponsored by the United States National Aeronautics and Space Administration (NASA), specifically, in developing a subsystems analysis and technology validation team comprised of former spacecraft development personnel. Human factor considerations are investigated from initial concept/vision formulation; through operational process development; personnel test and training; to initial uplink product development and test support. Emphasis has been placed on challenges and applied or recommended solutions, so as to provide opportunities for future programs and projects to address and disposition potential issues and concerns as early as possible to reap the benefits associated with learning from other's past experiences.

Basilio, Ralph R.↗

Computation of Transonic Flows Using Potential Methods

The proposed paper will describe the state of the art associated with numerical solution of the full or exact velocity potential equation for solving transonic, external-aerodynamic flows. The presentation will begin with a review of the literature emphasizing research activities of the past decade. Next, the various forms of the full or exact velocity potential equation, the equation's corresponding mathematical characteristics, and the derivation assumptions will be presented and described in detail. Impact of the derivation assumptions on simulation accuracy, especially with respect to shock wave capture, will be presented and discussed relative to the more complete Euler or Navier-Stokes formulations. The technical presentation will continue with a description of recently developed full potential numerical approach characteristics. This description will include governing equation nondimensionalization, physical-to-computational-domain mapping procedures, a limited description of grid generation requirements, the spatial discretization scheme, numerical implementation of boundary conditions, and the iteration scheme. The next portion of the presentation will present and discuss numerical results for several two- and three-dimensional aerodynamic applications. Included in the results section will be a discussion and demonstration of a typical grid refinement analysis for determining spatial convergence of the numerical solution and level of solution accuracy. Computer timings for a variety of full potential applications will be compared and contrasted with similar results for the Euler equation formulation. Finally. the presentation will end with concluding remarks and recommendations for future work.

Hoist, Terry L.↗

Nanotechnology Investigated for Future Gelled and Metallized Gelled Fuels

The objective of this research is to create combustion data for gelled and metallized gelled fuels using unique nanometer-sized gellant particles and/or nanometer-sized aluminum particles. Researchers at the NASA Glenn Research Center are formulating the fuels for both gas turbine and pulsed detonation engines. We intend to demonstrate metallized gelled fuel ignition characteristics for pulse detonation engines with JP/aluminum fuel and for gas turbine engines with gelled JP, propane, and methane fuel. The fuels to be created are revolutionary as they will deliver the highest theoretically maximum performance of gelled and metallized gelled fuels. Past combustion work has used micrometer-sized particles, which have limited the combustion performance of gelled and metallized gelled fuels. The new fuel used nanometer-sized aluminum oxide particles, which reduce the losses due to mismatch in the gas and solid phases in the exhaust. Gelled fuels provide higher density, added safety, reduced fuel slosh, reduced leakage, and increased exhaust velocity. Altogether, these benefits reduce the overall size and mass of the vehicle, increasing its flexibility.

Palaszewski, Bryan A.↗