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At least 199 records · Page 11

Developing Empirical Lightning Cessation Forecast Guidance for the Cape Canaveral Air Force Station and Kennedy Space Center

This research addresses the 45th Weather Squadron's (45WS) need for improved guidance regarding lightning cessation at Cape Canaveral Air Force Station and Kennedy Space Center (KSC). KSC's Lightning Detection and Ranging (LDAR) network was the primary observational tool to investigate both cloud-to-ground and intracloud lightning. Five statistical and empirical schemes were created from LDAR, sounding, and radar parameters derived from 116 storms. Four of the five schemes were unsuitable for operational use since lightning advisories would be canceled prematurely, leading to safety risks to personnel. These include a correlation and regression tree analysis, three variants of multiple linear regression, event time trending, and the time delay between the greatest height of the maximum dBZ value to the last flash. These schemes failed to adequately forecast the maximum interval, the greatest time between any two flashes in the storm. The majority of storms had a maximum interval less than 10 min, which biased the schemes toward small values. Success was achieved with the percentile method (PM) by separating the maximum interval into percentiles for the 100 dependent storms.

LDAR (LIGHTNING DETECTION AND RANGING)↗

Key design issues for user terminals operating with HEO satellites

Coverage of high-latitude areas in the northern hemisphere using geostationary satellites can not be achieved with good elevation angles, and highly inclined elliptical orbits (HEO) present one possible way to overcome this problem. The high elevation angles they achieve and the relative motion of the satellites across the sky, including satellite hand-over, present a specific set of requirements for the design of user terminals, be they for communication or broadcast-reception purposed. This paper reviews key design issues for user terminals operating with satellites in highly inclined elliptical orbits. While all aspects of user terminal design are broadly covered, special emphasis is given to the antenna and RF front-end design. The types of terminals discussed include communications terminals: the hand-held, the notebook, and the vehicle-mounted types, as well as the vehicle-mounted digital audio broadcasting (DAB) receiver terminal. A number of solutions are outlined, based on tradeoffs with respect to the most significant system interface parameters such as G/T and equivalent isotropically radiated power (EIRP). Candidate antenna and front-end configurations were studied, in particular patch and helical antennas with the principal aim of deriving low cost, yet effective solutions. Issues related to achieving best EIRP for the communications terminals are presented, taking into account radiation safety limits. The differences in the design of receive only versus receive/transmit RF front-ends for HEO system terminals are highlighted and solutions for both proposed. This paper summarizes the results of internal ESTEC studies and external ESA-sponsored work concerning major user terminal parameters and design aspects performed for Archimedes -- a HEO satellite constellation for multimedia broadcasting and communications.

Stojkovic, I.↗

Statistical Detection of Atypical Aircraft Flights

A computational method and software to implement the method have been developed to sift through vast quantities of digital flight data to alert human analysts to aircraft flights that are statistically atypical in ways that signify that safety may be adversely affected. On a typical day, there are tens of thousands of flights in the United States and several times that number throughout the world. Depending on the specific aircraft design, the volume of data collected by sensors and flight recorders can range from a few dozen to several thousand parameters per second during a flight. Whereas these data have long been utilized in investigating crashes, the present method is oriented toward helping to prevent crashes by enabling routine monitoring of flight operations to identify portions of flights that may be of interest with respect to safety issues.

Statler, Irving↗

Human factors and safety in emergency medicine

A model based on an input process and outcome conceptualisation is suggested to address safety-relevant factors in emergency medicine. As shown in other dynamic and demanding environments, human factors play a decisive role in attaining high quality service. Attitudes held by health-care providers, organisational shells and work-cultural parameters determine communication, conflict resolution and workload distribution within and between teams. These factors should be taken into account to improve outcomes such as operational integrity, job satisfaction and morale.

Non-NASA Center↗

Analysis of Return and Forward Links from STARS' Flight Demonstration 1

Space-based Telemetry And Range Safety (STARS) is a Kennedy Space Center (KSC) led proof-of-concept demonstration, which utilizes NASA's space network of Tracking and Data Relay Satellites (TDRS) as a pathway for launch and mission related information streams. Flight Demonstration 1 concluded on July 15,2003 with the seventh flight of a Low Power Transmitter (LPT) a Command and Data Handler (C&DH), a twelve channel GPS receiver and associated power supplies and amplifiers. The equipment flew on NASA's F-I5 aircraft at the Dryden Flight Research Center located at Edwards Air Force Base in California. During this NASA-ASEE Faculty Fellowship, the author participated in the collection and analysis of data from the seven flights comprising Flight Demonstration 1. Specifically, the author examined the forward and return links bit energy E(sub B) (in Watt-seconds) divided by the ambient radio frequency noise N(sub 0) (in Watts / Hertz). E(sub b)/N(sub 0) is commonly thought of as a signal-to-noise parameter, which characterizes a particular received radio frequency (RF) link. Outputs from the data analysis include the construction of time lines for all flights, production of graphs of range safety values for all seven flights, histograms of range safety E(sub b)/N(sub 0) values in five dB increments, calculation of associated averages and standard deviations, production of graphs of range user E(sub b)/N(sub 0) values for the all flights, production of graphs of AGC's and E(sub b)/N(sub 0) estimates for flight 1, recorded onboard, transmitted directly to the launch head and transmitted through TDRS. The data and graphs are being used to draw conclusions related to a lower than expected signal strength seen in the range safety return link.

Gering, James A.↗

EPS (Electric Particulate Suspension) Microgravity Technology Provides NASA with New Tools

The Electric Particulate Suspension is a fire safety ignition test system being developed at Iowa State University with NASA support for evaluating combustion properties of powders, powder-gas mixtures, and pure gases in microgravity and gravitational atmospheres (quenching distance, ignition energy, flammability limits). A separate application is the use of EPS technology to control heat transfer in vacuum and space environment enclosures. In combustion testing, ignitable powders (aluminum, magnesium) are introduced in the EPS test cell and ignited by spark, while the addition of inert particles act as quenching media. As a combustion research tool, the EPS method has potential as a benchmark design for quenching powder flames that would provide NASA with a new fire safety standard for powder ignition testing. The EPS method also supports combustion modeling by providing accurate measurement of flame-quenching distance as an important parameter in laminar flame theory since it is closely related to characteristic flame thickness and flame structure. In heat transfer applications, inert powder suspensions (copper, steel) driven by electric fields regulate heat flow between adjacent surfaces enclosures both in vacuum (or gas) and microgravity. This simple E-field control can be particularly useful in space environments where physical separation is a requirement between heat exchange surfaces.

Colver, Gerald M.↗

Cross-Cutting Flight Infrastructure Improvements on M2020

Mars2020 (M2020) was formulated as a mission that leveraged as much Mars Science Laboratory (MSL) heritage as possible, while focusing major new development efforts on the original and unique elements needed to accomplish the different mission objectives. Well publicized examples of high profile new developments include precision landing, the sampling and caching system, the specific instrument suite, improved mobility via Autonomous Navigation, and later the addition of the Ingenuity helicopter. Less well known are the refinements to the core flight infrastructure, primarily in the cross-cutting functions of Telecom, Avionics, Data Management, Communications Behaviors, and Parameter Management. These enhancements are introduced predominately via flight software, and represent increases in capability that justified their inclusion in an otherwise heritage-focused project environment.Perseverance’s cross-cutting flight infrastructure improvements fall into and across the following five categories. First is a trimming of the software footprint of infrastructure modules, in order to make room for memory demands elsewhere in the system. Second is the minimization of data volume to be downlinked, through various methods such as the incorporation of new compression options. Third is the maximization of the available downlink bandwidth for data, by curtailing content-less data (fill) and introducing an improved UHF proximity link protocol. Fourth is a reduction in vulnerabilities, through increased file system redundancy, robustness, and software process monitoring. Fifth is an increase in operations efficiency by lowering file system mount times, improving parallelism between simultaneous events, minimizing the time to recover from file system errors, streamlining the purging of obsolete data, and reducing the number of commands to service parameters by a factor of 100.Individually, none of the cross-cutting infrastructure improvements are likely to garner headlines, but collectively they appreciably improve the safety and operability of Perseverance over its predecessor. This paper will describe the improvements, their promise, and where applicable, their actual impact in operations.

Bohannon, Emily↗

Morphometric Characterization of Lunar Landing Sites

As ambitious surface exploration of the Moon commences in the 2020s, it is important to develop reliable and objective metrics for understanding the quality of future landing sites. A key prerequisite for any exploration and utilization of the lunar surface is a safe landing. One of the most important methods to provide understanding of potential metrics for landing site safety in the lunar context is the systematic comparison of candidate and historic landing sites. The goal of this project is to determine the morphometric parameters of the lunar surface at 16 successful lunar landing sites where adequate data exists to execute a quantitative comparison using various parameters. Quantitative analysis of Lunar Reconnaissance Orbiter (LRO) data should inform mission planning activities by providing morphologic metrics for landing sites including slope, Terrain Ruggedness Index (TRI), and rock abundance. These comparisons will assist mission planners and exploration scientists by providing “calibration points” for using Lunar Reconnaissance Orbiter (LRO) data to successfully plan and execute lunar powered descents in the future. The metrics included in this analysis describe the form of the terrain and can be calculated for any potential future landing site. Another objective of this project is to determine how the derived morphologic parameters for the same landing site change between common pixel scales. In ideal lighting conditions, 2m/px Narrow Angle Camera Digital Terrain Models (NAC DTMs) can be assembled using stereoscopic imagery from two or more concentric orbits of the LRO. However, due to low light conditions near the lunar poles, the highest quality data for many potential lunar landing sites comes from the Lunar Orbiter Laser Altimeter (LOLA). Therefore, we seek to assess how the derived slope and TRI values change as a function of changes in the DTM postings from 2m/px to 5m/px.

J M McCallion↗

An Investigation of Candidate Sensor-Observable Wake Vortex Strength Parameters for the NASA Aircraft Vortex Spacing System (AVOSS)

The counter-rotating pair of wake vortices shed by flying aircraft can pose a threat to ensuing aircraft, particularly on landing approach. To allow adequate time for the vortices to disperse/decay, landing aircraft are required to maintain certain fixed separation distances. The Aircraft Vortex Spacing System (AVOSS), under development at NASA, is designed to prescribe safe aircraft landing approach separation distances appropriate to the ambient weather conditions. A key component of the AVOSS is a ground sensor, to ensure, safety by making wake observations to verify predicted behavior. This task requires knowledge of a flowfield strength metric which gauges the severity of disturbance an encountering aircraft could potentially experience. Several proposed strength metric concepts are defined and evaluated for various combinations of metric parameters and sensor line-of-sight elevation angles. Representative populations of generating and following aircraft types are selected, and their associated wake flowfields are modeled using various wake geometry definitions. Strength metric candidates are then rated and compared based on the correspondence of their computed values to associated aircraft response values, using basic statistical analyses.

Tatnall, Chistopher R.↗

Liquid Nitrogen Removal of Critical Aerospace Materials

Identification of innovative solutions to unique materials problems is an every-day quest for members of the aerospace community. Finding a technique that will minimize costs, maximize throughput, and generate quality results is always the target. United Space Alliance Materials Engineers recently conducted such a search in their drive to return the Space Shuttle fleet to operational status. The removal of high performance thermal coatings from solid rocket motors represents a formidable task during post flight disassembly on reusable expended hardware. The removal of these coatings from unfired motors increases the complexity and safety requirements while reducing the available facilities and approved processes. A temporary solution to this problem was identified, tested and approved during the Solid Rocket Booster (SRB) return to flight activities. Utilization of ultra high-pressure liquid nitrogen (LN2) to strip the protective coating from assembled space shuttle hardware marked the first such use of the technology in the aerospace industry. This process provides a configurable stream of liquid nitrogen (LN2) at pressures of up to 55,000 psig. The performance of a one-time certification for the removal of thermal ablatives from SRB hardware involved extensive testing to ensure adequate material removal without causing undesirable damage to the residual materials or aluminum substrates. Testing to establish appropriate process parameters such as flow, temperature and pressures of the liquid nitrogen stream provided an initial benchmark for process testing. Equipped with these initial parameters engineers were then able to establish more detailed test criteria that set the process limits. Quantifying the potential for aluminum hardware damage represented the greatest hurdle for satisfying engineers as to the safety of this process. Extensive testing for aluminum erosion, surface profiling, and substrate weight loss was performed. This successful project clearly demonstrated that the liquid nitrogen jet possesses unique strengths that align remarkably well with the unusual challenges that space hardware and missile manufacturers face on a regular basis. Performance of this task within the confines of a critical manufacturing facility marks a milestone in advanced processing.

Noah, Donald E.↗

Thermoelastic analysis of solar window of a vacuum chamber

It has been noted during space simulation test programs that the chamber penetration window becomes the limiting factor as the solar intensity increases. The temperature at the center of the window normally attains a level of 550 C, while the edge temperature remains at about 35 C. The stresses produced by this thermal gradient combined with the atmospheric pressure are studied within the framework of classical theory of elasticity. The solution for the problem is obtained by solving the static uncoupled thermoelastic equations for a circular blank, subjected to nonuniform heat on one face, by introduction of two auxiliary variables. The displacements are expressed in terms of Bessel functions and parameters of interest are computed at various mesh points of the window. The maximum principal stresses thus obtained show that even with steep temperature gradient, the safety factor is acceptable.

Amba-Rao, C. L.↗

Study of aircraft crashworthiness for fire protection

Impact-survivable postcrash fire accidents were surveyed. The data base developed includes foreign and domestic accidents involving airlines and jet aircraft. The emphasis was placed on domestic accidents, airlines, and jet aircraft due principally to availability of information. Only transport category aircraft in commercial service designed under FAR Part 25 were considered. A matrix was prepared to show the relationships between the accident characteristics and the fire fatalities. Typical postcrash fire scenaries were identified. Safety concepts were developed for three engineering categories: cabin interiors - cabin subsystems; power plant - engines and fuel systems; and structural mechanics - primary and secondary structures. The parameters identified for concept evaluation are cost, effectiveness, and societal concerns. Three concepts were selected for design definition and cost and effectiveness analysis: improved fire-resistant seat materials; anti-misting kerosene; and additional cabin emergency exits.

Cominsky, A.↗

Automated mixed traffic transit vehicle microprocessor controller

An improved Automated Mixed Traffic Vehicle (AMTV) speed control system employing a microprocessor and transistor chopper motor current controller is described and its performance is presented in terms of velocity versus time curves. The on board computer hardware and software systems are described as is the software development system. All of the programming used in this controller was implemented using FORTRAN. This microprocessor controller made possible a number of safety features and improved the comfort associated with starting and shopping. In addition, most of the vehicle's performance characteristics can be altered by simple program parameter changes. A failure analysis of the microprocessor controller was generated and the results are included. Flow diagrams for the speed control algorithms and complete FORTRAN code listings are also included.

Marks, R. A.↗

Piloted Well Clear Performance Evaluation of Detect and Avoid Systems with Suggestive Guidance

Regulations to establish operational and performance requirements for unmanned aircraft systems (UAS) are being developed by a consortium of government, industry and academic institutions (RTCA, 2013). Those requirements will apply to the new detect-and-avoid (DAA) systems and other equipment necessary to integrate UAS with the United States (U.S) National Airspace System (NAS) and will be determined according to their contribution to the overall safety case. That safety case requires demonstration that DAA-equipped UAS collectively operating in the NAS meet an airspace safety threshold (AST). Several key gaps must be closed in order to link equipment requirements to an airspace safety case. Foremost among these is calculation of the systems risk ratio, the degree to which a particular system mitigates violation of an aircraft separation standard (FAA, 2013). The risk ratio of a DAA system, in combination with risk ratios of other collision mitigation mechanisms, will determine the overall safety of the airspace measured in terms of the number of collisions per flight hour. It is not known what the effectiveness is of a pilot-in-the-loop DAA system or even what parameters of the DAA system most improve the pilots ability to maintain separation. The relationship between the DAA system design and the overall effectiveness of the DAA system that includes the pilot, expressed as a risk ratio, must be determined before DAA operational and performance requirements can be finalized. Much research has been devoted to integrating UAS into non-segregated airspace (Dalamagkidis, 2009, Ostwald, 2007, Gillian, 2012, Hesselink, 2011, Santiago, 2015, Rorie 2015 and 2016). Several traffic displays intended for use as part of a DAA system have gone through human-in-the-loop simulation and flight-testing. Most of these evaluations were part of development programs to produce a deployable system, so it is unclear how to generalize particular aspects of those designs to general requirements for future traffic displays (Calhoun, 2014). Other displays have undergone testing to collect data that may generalize to new displays, but have not been evaluated in the context of the development of an overall safety case for UAS equipped with DAA systems in the NAS (Bell, 2012). Other research efforts focus on DAA surveillance performance and separation standards. Together with this work, they are expected to facilitate validation of the airspace safety case (Park, 2014 and Johnson, 2015). The contribution of the present work is to quantify the effectiveness of the pilot-automation system to remain well clear as a function of display features and surveillance sensor error. This quantification will help enable selection of a minimum set of DAA design features that meets the AST, a set that may not be unique for all UAS platforms. A second objective is to collect and analyze pilot performance parameters that will improve the modeling of overall DAA system performance in non-human-in-the-loop simulations. Simulating the DAA-equipped UAS in such batch experiments will allow investigation of a much larger number of encounters than is possible in human simulations. This capability is necessary to demonstrate that a particular set of DAA requirements meets the AST under all foreseeable operational conditions.

detect and avoid↗

Method and system for diagnostics of apparatus

Proposed is a method, implemented in software, for estimating fault state of an apparatus outfitted with sensors. At each execution period the method processes sensor data from the apparatus to obtain a set of parity parameters, which are further used for estimating fault state. The estimation method formulates a convex optimization problem for each fault hypothesis and employs a convex solver to compute fault parameter estimates and fault likelihoods for each fault hypothesis. The highest likelihoods and corresponding parameter estimates are transmitted to a display device or an automated decision and control system. The obtained accurate estimate of fault state can be used to improve safety, performance, or maintenance processes for the apparatus.

Gorinevsky, Dimitry↗

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

A Prototype Early Planetary Organic Processor Assembly (OPA) Based on Dual-Stage Anaerobic Membrane Bioreactor (AnMBR) for Fecal and Food Waste Treatment and Resource Recovery

Long-duration, deep-space exploration and habitation missions demand robust and reliable technologies to ensure crew health, safety, and mission success. Local food production will be essential for crew nutrition and morale. However, at $10,000/lb, the payload costs and mass/volume limitations to transport and provide the necessary resources, including fertilizer, for an anticipated 30-month mission become challenging over time. For mission success and sustainability, the Environmental Control and Life Support System (ECLSS) of the near future will need to recover resources from all “waste” sources and be near-closed loop. Organic wastes (e.g., fecal and food) offer a renewable source of C, N, P, water and other trace elements necessary to sustain crop production. However, these high solidwastes are often difficult to treatdue to factors includingheterogeneity, complexity, high organic strength, and the presence of pathogens. To date, there is no flight-ready technology capable of treating mixed organic wastes, creating a technology gap for future space missions. To address this need, a prototype Organic Processor Assembly (OPA) was developed through collaboration between the University of South Florida (USF) and NASA’s Kennedy Space Center (KSC). The OPA is based on the anaerobic membrane bioreactor (AnMBR), a hybrid technology coupling high-rate anaerobic digestion with membrane filtration. The system is designed for an early planetary base (EPB) scenario to aid in closing the resource recovery loop and decreaseresupply dependence. This presentation discusses initial research pertaining to: 1) design challenges in maximizing hydraulic/organic throughputandReliability, Availability, Maintainability, and Safety(RAMS)while minimizingmass and volume; 2) create capabilities for treating simulated high solids waste under steady and non-steady state conditions; and 3) measuresolids performance parameter(s). Future research and development pertaining to further optimization on system operation, performance, and expanded treatment capabilities arepresented.

Bioreactor↗

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗