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At least 1,801 records · Page 100

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

The United States (US) 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 new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success.

Dumbacher, Daniel L.↗

STS-114: Discovery Mission Status Briefing

Phil Engelauf, STS-114 Mission Operations Representative reports: the orbital rendezvous was successful, and today's activities includes initial preparations of the next day's extravehicular activities (EVA); he specifically mentioned tile repair, wiring on the outside of the vehicle to try to recover CMG2 (Control Moment Gyro), and preparation for the external stowage platform. John Shannon, Manager of the Space Shuttle Operations and Integration reports from Engineering standpoint that the composites of the underside of the tile surface seen from pictures taken during the pitch maneuver were extremely clean; the Engineering staff continues to look at the focus inspection data from the orbital boom sensor system (OBSS) and other data to assess the condition of the vehicle. Solid rocket boosters were retrieved and are towed back to the Air Force hangar in Cape Carneval. Six target inspection (nose gear doors, gap fillers, chine area, external tank doors, trailing edge, and ice), and arm operations, foam, conservation measures, shuttle air lock, aerodynamics assessment and re-entry were topics covered with the News media.

Source record↗

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.

Sutter, James K.↗

Shuttle flight rate - An inside look

A detailed description of the Shuttle's four major hardware elements (Orbiter, Main Engine, Solid Rocket Booster, and External Tank) is given. Their design complexity and the Kennedy Space Center Space Shuttle processing capability are the main factors determining Shuttle flight frequency. In addition to KSC efficiency, the National Space Transportation System program management and strategic planning techniques are also factors toward improving the Shuttle flight rate. As a result, the KSC facilities are being upgraded, new facilities are being added, and necessary plans are in place to support the flight rate requirements.

Ellis, Larry C.↗

Numerical Evaluation of Mode 1 Stress Intensity Factor as a Function of Material Orientation For BX-265 Foam Insulation Material

Foam; a cellular material, is found all around us. Bone and cork are examples of biological cell materials. Many forms of man-made foam have found practical applications as insulating materials. NASA uses the BX-265 foam insulation material on the external tank (ET) for the Space Shuttle. This is a type of Spray-on Foam Insulation (SOFI), similar to the material used to insulate attics in residential construction. This foam material is a good insulator and is very lightweight, making it suitable for space applications. Breakup of segments of this foam insulation on the shuttle ET impacting the shuttle thermal protection tiles during liftoff is believed to have caused the space shuttle Columbia failure during re-entry. NASA engineers are very interested in understanding the processes that govern the breakup/fracture of this complex material from the shuttle ET. The foam is anisotropic in nature and the required stress and fracture mechanics analysis must include the effects of the direction dependence on material properties. Material testing at NASA MSFC has indicated that the foam can be modeled as a transversely isotropic material. As a first step toward understanding the fracture mechanics of this material, we present a general theoretical and numerical framework for computing stress intensity factors (SIFs), under mixed-mode loading conditions, taking into account the material anisotropy. We present mode I SIFs for middle tension - M(T) - test specimens, using 3D finite element stress analysis (ANSYS) and FRANC3D fracture analysis software, developed by the Cornel1 Fracture Group. Mode I SIF values are presented for a range of foam material orientations. Also, NASA has recorded the failure load for various M(T) specimens. For a linear analysis, the mode I SIF will scale with the far-field load. This allows us to numerically estimate the mode I fracture toughness for this material. The results represent a quantitative basis for evaluating the strength and fracture properties of anisotropic foam insulation material.

Knudsen, Erik↗

A Framework for Assessing the Reusability of Hardware (Reusable Rocket Engines)

Within the past few years, there has been a renewed interest in reusability as it applies to space flight hardware. Commercial companies such as Space Exploration Technologies Corporation (SpaceX), Blue Origin, and United Launch Alliance (ULA) are pursuing reusable hardware. Even foreign companies are pursuing this option. The Indian Space Research Organization (ISRO) launched a reusable space plane technology demonstrator and Airbus Defense and Space is planning to recover the main engines and avionics from its Advanced Expendable Launcher with Innovative engine Economy [1] [2]. To date, the Space Shuttle remains as the only Reusable Launch (RLV) to have flown repeated missions and the Space Shutte Main Engine (SSME) is the only demonstrated reusable engine. Whether the hardware being considered for reuse is a launch vehicle (fully reusable), a first stage (partially reusable), or a booster engine (single component), the overall governing process is the same; it must be recovered and recertified for flight. Therefore, there is a need to identify the key factors in determining the reusability of flight hardware. This paper begins with defining reusability to set the context, addresses the significance of reuse, and discusses areas that limit successful implementation. Finally, this research identifies the factors that should be considered when incorporating reuse.

Childress-Thompson, Rhonda↗

Comparison of heating rate calculations with experimental data on a modified Shuttle orbiter at Mach 6

Heating-rate calculations from an 'engineering' code and a 'benchmark' Navier-Stokes code are compared with experimental wind tunnel data obtained on a 'modified' 0.0075-scale Shuttle orbiter at a Mach number of 6 and a freestream Reynolds number of 1.9 x 10 to the 6th/m. Comparisons are presented along the windward symmetry plane, in a circumferential direction around the body, and along the wing leading edge at angles of attack of 30 and 40 deg. Both codes provide accurate predictions of the heating rate over most of the body, but because the run time for the engineering code is relatively short, it is an ideal tool for both parametric and design studies.

Hamilton, H. H., II↗

An assessment of the potential impact of solid-fueled rocket engines in the stratosphere

The effects of shuttle-emitted HCl on stratospheric ozone are reported. A one-dimensional model of the distribution of trace constituents in the stratosphere and mesosphere is described, and chemical reactions and photodissociation rates in the chlorine chemistry are listed. Analysis of mathematical models is presented, and the results show ozone depletion when emissions are considered to be spread uniformly in the horizontal over a hemisphere and an increase in ozone when emissions are considered in a zone 1000 km wide centered at Cape Kennedy. Sensitivity studies to determine the effects of some assumptions in the model and comparisons with nitric oxide reactions are described. The importance of a two-dimensional model for a proper long term study is noted. Lists of reaction rate coefficients and photodissociation rates for the O-H-N system are included.

Whitten, R. C.↗

A Probabilistic Tool that Aids Logistics Engineers in the Establishment of High Confidence Repair Need-Dates at the NASA Shuttle Logistics Depot

The NASA Shuttle Logistics Depot (NSLD) is tasked with the responsibility for repair and manufacture of Line Replaceable Unit (LRU) hardware and components to support the Space Shuttle Orbiter. Due to shrinking budgets, cost effective repair of LRU's becomes a primary objective. To achieve this objective, is imperative that resources be assigned to those LRU's which have the greatest expectation of being needed as a spare. Forecasting the times at which spares are needed requires consideration of many significant factors including: failure rate, flight rate, spares availability, and desired level of support, among others. This paper summarizes the results of the research and development work that has been accomplished in producing an automated tool that assists in the assignment of effective repair start-times for LRU's at the NSLD. This system, called the Repair Start-time Assessment System (RSAS), uses probabilistic modeling technology to calculate a need date for a repair that considers the current repair pipeline status, as well as, serviceable spares and projections of future demands. The output from the system is a date for beginning the repair that has significantly greater confidence (in the sense that a desired probability of support is ensured) than times produced using other techniques. Since an important output of RSAS is the longest repair turn-around time that will ensure a desired probability of support, RSAS has the potential for being applied to operations at any repair depot where spares are on-hand and repair start-times are of interest. In addition, RSAS incorporates tenants of Just-in-Time (JIT) techniques in that the latest repair start-time (i.e., the latest time at which repair resources must be committed) may be calculated for every failed unit This could reduce the spares inventory for certain items, without significantly increasing the risk of unsatisfied demand.

Bullington, J. V.↗

A study of the durability of beryllium rocket engines

An experimental test program was performed to demonstrate the durability of a beryllium INTEREGEN rocket engine when operating under conditions simulating the space shuttle reaction control system. A vibration simulator was exposed to the equivalent of 100 missions of X, Y, and Z axes random vibration to demonstrate the integrity of the recently developed injector-to-chamber braze joint. An off-limits engine was hot fired under extreme conditions of mixture ratio, chamber pressure, and orifice plugging. A durability engine was exposed to six environmental cycles interspersed with hot-fire tests without intermediate cleaning, service, or maintenance. Results from this program indicate the ability of the beryllium INTEREGEN engine concept to meet the operational requirements of the space shuttle reaction control system.

Paster, R. D.↗

Shuttle Case Study Collection Website Development

As a continuation from summer 2012, the Shuttle Case Study Collection has been developed using lessons learned documented by NASA engineers, analysts, and contractors. Decades of information related to processing and launching the Space Shuttle is gathered into a single database to provide educators with an alternative means to teach real-world engineering processes. The goal is to provide additional engineering materials that enhance critical thinking, decision making, and problem solving skills. During this second phase of the project, the Shuttle Case Study Collection website was developed. Extensive HTML coding to link downloadable documents, videos, and images was required, as was training to learn NASA's Content Management System (CMS) for website design. As the final stage of the collection development, the website is designed to allow for distribution of information to the public as well as for case study report submissions from other educators online.

Ransom, Khadijah S.↗

Shuttle orbiter with telescoping main propulsion unit and payload

An improved Space Shuttle with variable internal volume is provided. The Space Shuttle Orbiter includes a telescoping main propulsion unit. This main propulsion unit contains the main rocket engines and fuel tanks and telescopes into the Space Shuttle. A variable cavity is located between this unit and the crew compartment. Accordingly, the positioning of the telescoping main propulsion unit determines the volume of the variable cavity. Thus, the volume of the variable length of the entire Space Shuttle may be increased or decreased to achieve desired configurations for optimal storage. In one embodiment of the invention, the payload also telescopes within the variable cavity.

Macconochie, Ian O.↗

Use of Probabilistic Engineering Methods in the Detailed Design and Development Phases of the NASA Ares Launch Vehicle

The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program called Constellation to send crew and cargo to the international Space Station, to the moon, and beyond. As part of the Constellation program, a new launch vehicle, Ares I, is being developed by NASA Marshall Space Flight Center. Designing a launch vehicle with high reliability and increased safety requires a significant effort in understanding design variability and design uncertainty at the various levels of the design (system, element, subsystem, component, etc.) and throughout the various design phases (conceptual, preliminary design, etc.). In a previous paper [1] we discussed a probabilistic functional failure analysis approach intended mainly to support system requirements definition, system design, and element design during the early design phases. This paper provides an overview of the application of probabilistic engineering methods to support the detailed subsystem/component design and development as part of the "Design for Reliability and Safety" approach for the new Ares I Launch Vehicle. Specifically, the paper discusses probabilistic engineering design analysis cases that had major impact on the design and manufacturing of the Space Shuttle hardware. The cases represent important lessons learned from the Space Shuttle Program and clearly demonstrate the significance of probabilistic engineering analysis in better understanding design deficiencies and identifying potential design improvement for Ares I. The paper also discusses the probabilistic functional failure analysis approach applied during the early design phases of Ares I and the forward plans for probabilistic design analysis in the detailed design and development phases.

Fayssal, Safie↗

Orbital transfer vehicle advanced expander cycle engine point design study

A detailed computer model of the expander cycle engine system steady-state operation was developed. Payload performance data for the expander cycle engine for 100K pounds and 65K pounds Space Shuttle missions were examined to establish peak payload thrusts. It was found that peak payload for the 100K pound gross weight single engine case occurred at nearly 15,000 pounds thrust for both engine mixture ratios of 6:1 and 7:1. Peak payload at engine mixture ratio of 6:1 was 4 percent greater than at 7:1 mixture ratio. The two engine configuration peak paYloads occurred at engine thrust below 7,500 pounds (extrapolated) and were lower than single engine payloads. For the 65K pound gross weight mission, peak payloads for the single engine configuration occurred at nearly 10,000 pounds for both mixture ratios. Mixture ratio of 7:1 payloads were 5 percent lower than 6:1 payloads. Two engine configuration payloads occurred at engine thrusts considerably below 10K pounds.

Martinez, A.↗

Facet-dependent electron transfer induces distinct arsenic reallocations on hematite

The interfacial electron transfer (ET) between electron shuttling compounds and iron (Fe) oxyhydroxides plays a crucial role in the reductive dissolution of Fe minerals and the fate of surface-bound arsenic (As). However, the impact of exposed facets of highly crystalline hematite on reductive dissolution and As immobilization is poorly understood. In this study, we systematically investigated the interfacial processes of the electron shuttling compound cysteine (Cys) on various facets of hematite and the reallocations of surface-bound As(III) or As(V) on the respective surfaces. Our results demonstrate that the ET process between Cys and hematite generates Fe(II) and leads to reductive dissolution, with more Fe(II) generated on {001} facets of exposed hematite nanoplates (HNPs). Reductive dissolution of hematite leads to significantly enhanced As(V) reallocations on hematite. Nevertheless, upon the addition of Cys, a raipd release of As(III) can be halted by its prompt re-adsorption, leaving the extent of As(III) immobilization on hematite unchanged throughout the course of reductive dissolution. This is due to that Fe(II) can form new precipitates with As(V), a process that is facet-dependent and influenced by water chemistry. Electrochemical analysis reveals that HNPs exhibit higher conductivity and ET ability, which is beneficial for reductive dissolution and As reallocations on hematite. In conclusion, these findings highlight the facet-dependent reallocations of As(III) and As(V) facilitated by electron shuttling compounds and have implications for the biogeochemical processes of As in soil and subsurface environments.

54 ENVIRONMENTAL SCIENCES↗

Flight test results from the CV990 simulated space shuttle during unpowered automatic approaches and landings

Unpowered automatic approaches and landings with a CV990 aircraft were conducted to study navigation, guidance, and control problems associated with terminal area approach and landing for the space shuttle. The flight tests were designed to study from 11,300 m to touchdown the performance of a navigation and guidance concept which utilized blended radio/inertial navigation using VOR, DME, and ILS as the ground navigation aids. In excess of fifty automatic approaches and landings were conducted. Preliminary results indicate that this concept may provide sufficient accuracy to accomplish automatic landing of the shuttle orbiter without air-breathing engines on a conventional size runway.

Edwards, F. G.↗

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