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The thermal telemetry from the first test flight, an assessment of post-flight inspections of the recovered vehicle, and a review of the thermal design and model of the vehicle will be presented along with several lessons learned.
All structural systems possess a basic set of physical characteristics unique to that system. These unique physical characteristics include items such as mass distribution and damping. When specified, they allow engineers to understand and predict how a structural system behaves under given loading conditions and different methods of control. These physical properties of launch vehicles may be predicted by analysis or measured by certain types of tests. Generally, these properties are predicted by analysis during the design phase of a launch vehicle and then verified by testing before the vehicle becomes operational. A ground vibration test (GVT) is intended to measure by test the fundamental dynamic characteristics of launch vehicles during various phases of flight. During the series of tests, properties such as natural frequencies, mode shapes, and transfer functions are measured directly. These data will then be used to calibrate loads and control systems analysis models for verifying analyses of the launch vehicle. NASA manned launch vehicles have undergone ground vibration testing leading to the development of successful launch vehicles. A GVT was not performed on the inaugural launch of the unmanned Delta III which was lost during launch. Subsequent analyses indicated had a GVT been performed, it would have identified instability issues avoiding loss of the vehicle. This discussion will address GVT planning, set-up, execution and analyses, for the Saturn and Shuttle programs, and will also focus on the current and on-going planning for the Ares I and V Integrated Vehicle Ground Vibration Test (IVGVT).
The adaptation of a proven wind tunnel test technique, known as Videogrammetry, to flight testing of full-scale vehicles is presented. A description is presented of the technique used at NASA's Dryden Flight Research Center for the measurement of the change in wing twist and deflection of an F/A-18 research aircraft as a function of both time and aerodynamic load. Requirements for in-flight measurements are compared and contrasted with those for wind tunnel testing. The methodology for the flight-testing technique and differences compared to wind tunnel testing are given. Measurement and operational comparisons to an older in-flight system known as the Flight Deflection Measurement System (FDMS) are presented.
The adaptation of a proven wind tunnel test technique, known as Videogrammetry, to flight testing of full-scale vehicles is presented. A description is presented of the technique used at NASA's Dryden Flight Research Center for the measurement of the change in wing twist and deflection of an F/A-18 research aircraft as a function of both time and aerodynamic load. Requirements for in-flight measurements are compared and contrasted with those for wind tunnel testing. The methodology for the flight-testing technique and differences compared to wind tunnel testing are given. Measurement and operational comparisons to an older in-flight system known as the Flight Deflection Measurement System (FDMS) are presented.
Criteria and procedures for testing spacecraft structural elements and components
The Unsteady Pressure-Sensitive Paint (uPSP) Development Team outof NASA Ames Research Center (ARC) has spent the past five yearsimproving the systems and processes to advance the uPSP technology for production-level wind tunnel testing. Already considered turnkey for small-scale and research applications, development in acquisition, calibration, data transfer, and data processing were needed to be useful to customers testing at NASA wind tunnels. This development focused at ARC at the Unitary Plan Wind Tunnel (UPWT) 11-by 11-ft Transonic Wind Tunnel due to the large optical access of the test section and the NASA Advanced Supercomputer(NAS), also located at ARC. A Launch Vehicle Demonstration Test (LVDT) at the UPWT represents a milestone of this initial phase of development where several new improvements were demonstrated in a production wind tunnel environment for the first time. LVDT was conducted in April 2024 and used a 4% forebody Space Launch System (SLS) Block 1B model as the test article. Both a crew and cargo configuration were tested, with varying Mach numbers, pressures, model positions, and camera magnifications. This paper summarizes the details of the test and is part of a collection with four additional papers that provide greater detail on: high-speed lifetime methodology, spectral proper orthogonal decomposition analysis, quality of high-resolution data compared to Corcos model, and data quality, calibration, and uncertainty.
The variable terrain tilt platform (VTTP) is a means of providing simulated terrain for mobility testing of engineering models of the Mars Exploration Rovers. The VTTP could also be used for testing the ability of other robotic land vehicles (and small vehicles in general) to move across terrain under diverse conditions of slope and surface texture, and in the presence of obstacles of various sizes and shapes. The VTTP consists mostly of a 16-ft-(4.88-m)-square tilt table. The tilt can be adjusted to any angle between 0 (horizontal) and 25 . The test surface of the table can be left bare; can be covered with hard, high-friction material; or can be covered with sand, gravel, and/or other ground-simulating material or combination of materials to a thickness of as much as 6 in. (approx. 15 cm). Models of rocks, trenches, and other obstacles can be placed on the simulated terrain. For example, for one of the Mars- Rover tests, a high-friction mat was attached to the platform, then a 6-in.- ( 15 cm) deep layer of dry, loose beach sand was deposited on the mat. The choice of these two driving surface materials was meant to bound the range of variability of terrain that the rover was expected to encounter on the Martian surface. At each of the different angles at which tests were performed, for some of the tests, rocklike concrete obstacles ranging in height from 10 to 25 cm were placed in the path of the rover (see figure). The development of the VTTP was accompanied by development of a methodology of testing to characterize the performance and modes of failure of a vehicle under test. In addition to variations in slope, ground material, and obstacles, testing typically includes driving up-slope, down-slope, cross-slope, and at intermediate angles relative to slope. Testing includes recording of drive-motor currents, wheel speeds, articulation of suspension mechanisms, and the actual path of the vehicle over the simulated terrain. The collected data can be used to compute curves that summarize torque, speed, power-demand, and slip characteristics of wheels during the traverse.
The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, is scheduled for launch in 2009. Ares IX will use a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle is not practical within project constraints, modal tests for several configurations in the nominal integration flow were defined to calibrate the FEM. A traceability study by Aerospace Corporation was used to identify the critical modes for the tested configurations. Test configurations included two partial stacks and the full Ares I-X launch vehicle on the Mobile Launcher Platform. This paper provides an overview for companion papers in the Ares I-X Modal Test Session. The requirements flow down, pre-test analysis, constraints and overall test planning are described.
NASA's Low Density Supersonic Decelerator (LDSD) program was established to identify, develop, and eventually qualify to Test [i.e. Technology] Readiness Level (TRL) - 6 aerodynamic decelerators for eventual use on Mars. Through comprehensive Mars application studies, two distinct Supersonic Inflatable Aerodynamic Decelerator (SIAD) designs were chosen that afforded the optimum balance of benefit, cost, and development risk. In addition, a Supersonic Disk Sail (SSDS) parachute design was chosen that satisfied the same criteria. The final phase of the multi-tiered qualification process involves Earth Supersonic Flight Dynamics Tests (SFDTs) within environmental conditions similar to those that would be experienced during a Mars Entry, Descent, and Landing (EDL) mission. The first of these flight tests (i.e. SFDT-1) was completed on June 28, 2014 with two more tests scheduled for the summer of 2015 and 2016, respectively. The basic flight design for all the SFDT flights is for the SFDT test vehicle to be ferried to a float altitude of 120 kilo-feet by a 34 thousand cubic feet (Mcf) heavy lift helium balloon. Once float altitude is reached, the test vehicle is released from the balloon, spun-up for stability, and accelerated to supersonic speeds using a Star48 solid rocket motor. After burnout of the Star48 motor the vehicle decelerates to pre-flight selected test conditions for the deployment of the SIAD system. After further deceleration with the SIAD deployed, the SSDS parachute is then deployed stressing the performance of the parachute in the wake of the SIAD augmented blunt body. The test vehicle/SIAD/parachute system then descends to splashdown in the Pacific Ocean for eventual recovery. This paper will discuss the development of both the test vehicle and the trajectory sequence including design trade-offs resulting from the interaction of both engineering efforts. In addition, the SFDT-1 nominal trajectory design and associated sensitivities will be discussed as well as an overview of the on-board flight software used to trigger and sequence the main flight events necessary to deploy the deceleration technologies. Finally, as-flown performance of the SFDT-1 system will be discussed.
Evaluation and checkout of saturn class launch vehicles using ibm 7090 computer
Testing of fasteners, bolts, rivets, and fastener materials - high temperature alloys
Standardization of structural acceptance tests conducted on flight hardware
Tests were carried out on both synthetic and real wash water derived from clothes laundry to determine the utility of reverse osmosis in recovering the water for recycle use. A blend membrane made from cellulose di- and triacetates, and a cross-linked cellulose acetate/methacrylate were evaluated. Both were found acceptable. A number of detergents were evaluated, including a cationic detergent, sodium dodecyl sulfate, potassium palmitate, and sodium dodecylbenzenesulfonate. The tests were all made at a temperature of 165 F to minimize microbial growth. Long-term (15 to 30 day) runs were made at 600 and 400 psi on laundry water which was pretreated either by alum addition and sand filtration or by filtration only through 0.5 micron filters. A 30-day run was made using a 2-in. diameter by 22-in. long spiral module at 400 psig with filtering as the pretreatment. The membrane fouling by colloidal matter was found to be controllable. The unit produced initially 55 gal/day and 27 gal/day after 30 days.
A flight technique which uses the remotely augmented vehicle (RAV) concept is developed to flight test advanced control law concepts. The design, development and flight test validation of a RAV system mechanized on a digital fly-by-wire aircraft are described, and future applications are discussed. Flight experiments investigate complete inner loop, low sample rate, and adaptive control system mechanisms. The technique, which utilizes a ground-based FORTRAN programmable digital computer and up and down telemetry links is found to provide the flexibility necessary to effectively investigate alternate control law mechanisms in flight.
Dynamic testing of Saturn vehicles and role in control system design
The NASA Engineering and Safety Center (NESC) is developing the Max Launch Abort System (MLAS) as a risk-mitigation design should problems arise with the baseline Orion spacecraft launch abort design. The Max in MLAS is dedicated to Max Faget, the renowned NASA spacecraft designer. The MLAS flight test vehicle consists of boost skirt, coast skirt and the MLAS fairing which houses a full scale boilerplate Orion Crew Module (CM). The objective of the flight test is to prove that the CM can be released from the MLAS fairing during pad abort conditions without detrimental recontact between the CM and fairing, achieving performance similar to the Orion launch abort system. The boost and coast skirts provide the necessary thrust and stability to achieve the flight test conditions and are released prior to the test -- much like the Little Joe booster was used in the Apollo Launch Escape System tests. To achieve the test objective, two parachutes are deployed from the fairing to reorient the CM/fairing to a heatshield first orientation. The parachutes then provide the force necessary to reduce the total angle of attack and body angular rates required for safe release of the CM from the fairing. A secondary test objective after CM release from the fairing is to investigate the removal of the CM forward bay cover (FBC) with CM drogue parachutes for the purpose of attempting to synchronously deploying a set of CM main parachutes. Although multiple parachute deployments are used in the MLAS flight test vehicle to complete its objective, there are only two parachute types employed in the flight test. Five of the nine parachutes used for MLAS are 27.6 ft D(sub 0) ribbon parachutes, and the remaining four are standard G-12 cargo parachutes. This paper presents an overview of the 27.6 ft D(sub 0) ribbon parachute system employed on the MLAS flight test vehicle for coast skirt separation, fairing reorientation, and as drogue parachutes for the CM after separation from the fairing. Discussion will include: the process used to select this design, previously proven as a spin/stall recovery parachute; descriptions of all components of the parachute system; the minor modifications necessary to adapt the parachute to the MLAS program; the techniques used to analyze the parachute for the multiple roles it performs; a discussion of the rigging techniques used to interface the parachute system to the vehicle; and a brief description of how the evolution of the program affected parachute usage and analysis. An overview of the Objective system, rationale for the MLAS approach and the future of the program will also be presented. We hope to have flight test results to report at the time of the Conference Presentation.
NASA has tested the Max Launch Abort System (MLAS) as a risk-mitigation design should problems arise with the baseline Orion spacecraft launch abort design. The Max in MLAS is not Maximum, but rather dedicated to Max Faget, The renowned NASA Spacecraft designer. In the fall of 2009, the mission was flown, with great success, from the NASA Wallops Flight Facility. The MLAS flight test vehicle prototype consists of a boost ring, coast ring, and the MLAS fairing itself, which houses an Orion Command Module (CM) boilerplate. The objective of the MLAS flight test is to reorient the fairing with the CM, weighing approximately 29,000 lbs and traveling 290 fps, 180 degrees to an orientation suitable for the release of the CM during a pad abort and low altitude abort. Although multiple parachute deployments are used in the MLAS flight test vehicle to complete its objective, there are only two parachute types employed in the flight test. Five of the nine parachutes used for MLAS are 27.6 ft DO ribbon parachutes, and the remaining four are standard G-12 cargo parachutes. This paper presents an overview of the 27.6 ft DO ribbon parachute system employed on the MLAS flight test vehicle for coast ring separation, fairing reorientation, and as drogue parachutes for the CM after separation from the fairing. Discussion will include: the process used to select this design, previously proven as a spin/stall recovery parachute; descriptions of all components of the parachute system; the minor modifications necessary to adapt the parachute to the MLAS program; the techniques used to analyze the parachute for the multiple roles it performs; a discussion of the rigging techniques used to interface the parachute system to the vehicle; a brief description of how the evolution of the program affected parachute usage and analysis; and a summary of the results of the flight test, including video of the flight test and subsequent summary analysis. . A discussion of the flight test which was highly successful as well as the flight test observations will be a significant portion of the review.
The work done by Thermacore, Inc., Lancaster, Pennsylvania, for the Phase 1, 1992 SBIR National Aeronautics and Space Administration Contract, 'Insoluble Coatings for Stirling Engine Heat Pipe Condenser Surfaces' is described. The work was performed between January 1992 and July 1992. Stirling heat engines are being developed for electrical power generation use on manned and unmanned earth orbital and planetary missions. Dish Stirling solar systems and nuclear reactor Stirling systems are two of the most promising applications of the Stirling engine electrical power generation technology. The sources of thermal energy used to drive the Stirling engine typically are non-uniform in temperature and heat flux. Liquid metal heat pipe receivers are used as thermal transformers and isothermalizers to deliver the thermal energy at a uniform high temperature to the heat input section of the Stirling engine. The use of a heat pipe receiver greatly enhances system efficiency and potential life span. One issue that is raised during the design phase of heat pipe receivers is the potential solubility corrosion of the Stirling engine heat input section by the liquid metal working fluid. This Phase 1 effort initiated a program to evaluate and demonstrate coatings, applied to nickel based Stirling engine heater head materials, that are practically 'insoluble' in sodium, potassium, and NaK. This program initiated a study of nickel aluminide as a coating and developed and demonstrated a heat pipe test vehicle that can be used to test candidate materials and coatings. Nickel 200 and nickel aluminide coated Nickel 200 were tested for 1000 hours at 800 C at a condensation heat flux of 25 W/sq cm. Subsequent analyses of the samples showed no visible sign of solubility corrosion of either coated or uncoated samples. The analysis technique, photomicrographs at 200X, has a resolution of better than 2.5 microns (.0001 in). The results indicate that the heat pipe environment is not directly comparable to liquid metal pumped loop data, that nickel aluminide is still a leading candidate for solubility corrosion protection, and that longer duration tests are required to reach a definitive conclusion whether coatings are required at all. Should further testing be required, the test vehicle and analytical tools were developed.