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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Command and Control System Automated Testing

The Kennedy Space Center (KSC) has developed its own Command and Control System for the launch of the Space Launch System (SLS) and Orion capsule. The Command and Control System (CCS) is used by console engineers for the launch and system checkout of aerospace vehicles. The CCS allows console engineers to read data from the flight hardware on the launch pad and from the ground control systems and allows console engineers to issue commands, like opening a valve, to the flight hardware and ground control systems. The CCS needs to interact with thousands of devices and hardware controllers for the spacecraft and ground systems, receive data from these devices, distribute the data to console engineers in real-time, and allow console engineers to issue commands to manipulate hardware on the launch pad. The system needs to be robust, fault tolerant, responsive, and fast. In order to keep up with the pace of development of the CCS, a Test Automation System (TAS) is needed to validate the integrity of the system as a whole along with its individual components. Automated tests allow for faster development time, since tests can be ran through a Continuous Integration system and allow developers to check their code faster. Currently, the different modules, classes, and functions that make up the CCS are tested at the unit level, and the system level, with all the modules working together. My project was to implement a system for the data protocol layer of the Command Control System to be tested as a complete functional unit, with all of its classes and functions working together, but independent of the other modules of the CCS.

Automated TestingTest Automation↗
NASA NTRS1979

KSC facilities status and planned management operations

A status report is presented on facilities and planned operations at the Kennedy Space Center with reference to Space Shuttle launch activities. The facilities are essentially complete, with all new construction and modifications to existing buildings almost finished. Some activity is still in progress at Pad A and on the Mobile Launcher due to changes in requirements but is not expected to affect the launch schedule. The installation and testing of the ground checkout equipment that will be used to test the flight hardware is now in operation. The Launch Processing System is currently supporting the development of the applications software that will perform the testing of this flight hardware.

Gray, R. H.↗
NASA NTRS2011

Qualification of Electrical Ground Support Equipment for New Space Programs

With the Space Shuttle program coming to an end, the National Aeronautics and Space Administration (NASA) is moving to a new space flight program that will allow expeditions beyond low earth orbit. The space vehicles required to comply with these missions will be carrying heavy payloads. This implies that the Earth departure stage capabilities must be of higher magnitudes, given the current propulsion technology. The engineering design of the new flight hardware comes with some structural, thermal, propulsion and other subsystems' challenges. Meanwhile, the necessary ground support equipment (GSE) used to test, validate, verify and process the flight hardware must withstand the new program specifications. This paper intends to provide the qualification considerations during implementation of new electrical GSE for space programs. A team of engineers was formed to embark on this task, and facilitate the logistics process and ensure that the electrical, mechanical and fluids subsystems conduct the proper level of testing. Ultimately, each subsystem must certify that each piece of ground support equipment used in the field is capable of withstanding the strenuous vibration, acoustics, environmental, thermal and Electromagnetic Interference (EMf) levels experienced during pre-launch, launch and post-launch activities. The benefits of capturing and sharing these findings will provide technical, cost savings and schedule impacts infon11ation to both the technical and management community. Keywords: Qualification; Testing; Ground Support Equipment; Electromagnetic Interference Testing; Vibration Testing; Acoustic Testing; Power Spectral Density.

SotoToro, Felix A.↗
NASA NTRS2010

Pre-Flight Tests with Astronauts, Flight and Ground Hardware, to Assure On-Orbit Success

On-Orbit Constraints Test (OOCT's) refers to mating flight hardware together on the ground before they will be mated on-orbit or on the Lunar surface. The concept seems simple but it can be difficult to perform operations like this on the ground when the flight hardware is being designed to be mated on-orbit in a zero-g/vacuum environment of space or low-g/vacuum environment on the Lunar/Mars Surface. Also some of the items are manufactured years apart so how are mating tasks performed on these components if one piece is on-orbit/on Lunar/Mars surface before its mating piece is planned to be built. Both the Internal Vehicular Activity (IVA) and Extra-Vehicular Activity (EVA) OOCT's performed at Kennedy Space Center will be presented in this paper. Details include how OOCT's should mimic on-orbit/Lunar/Mars surface operational scenarios, a series of photographs will be shown that were taken during OOCT's performed on International Space Station (ISS) flight elements, lessons learned as a result of the OOCT's will be presented and the paper will conclude with possible applications to Moon and Mars Surface operations planned for the Constellation Program.

Haddad Michael E.↗
NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗
NASA NTRS2011

Statistical Analysis of an Infrared Thermography Inspection of Reinforced Carbon-Carbon

Each piece of flight hardware being used on the shuttle must be analyzed and pass NASA requirements before the shuttle is ready for launch. One tool used to detect cracks that lie within flight hardware is Infrared Flash Thermography. This is a non-destructive testing technique which uses an intense flash of light to heat up the surface of a material after which an Infrared camera is used to record the cooling of the material. Since cracks within the material obstruct the natural heat flow through the material, they are visible when viewing the data from the Infrared camera. We used Ecotherm, a software program, to collect data pertaining to the delaminations and analyzed the data using Ecotherm and University of Dayton Log Logistic Probability of Detection (POD) Software. The goal was to reproduce the statistical analysis produced by the University of Dayton software, by using scatter plots, log transforms, and residuals to test the assumption of normality for the residuals.

Comeaux, Kayla↗
NASA NTRS1992

New Ways Of Doing Business (NWODB) cost quantification analysis

The cost of designing, producing, and operating typical aerospace flight hardware is necessarily more expensive than most other human endeavors. Because of the more stringent environment of space, hardware designed to operate there will probably always be more expensive than similar hardware which is designed for less taxing environments. It is the thesis of this study that there are very significant improvements that can be made in the cost of aerospace flight hardware.

Hamaker, Joseph W.↗
NASA NTRS1985

Importance of Gravity for Plant Growth and Behavior

Flight experiments on the importance of gravity to plant growth and behavior are reported. The following studies were undertaken: (1) hyperastic responses to incremental changes of an axially imposed centripetal force; (2) Spacelab-1 experiments, methods for preparing soil in flight hardware containers were impound, to ensure desired moisture content and minimal contamination probability; (3) mesocotyl growth patterns were established by Avena lore exposure to red light during early seedling outogency; (4) the development of flight hardware; (5) choice of member of seedlings in each cube; (6) data processing and reduction; (7) clinostat validation; circummutation in space was more vigorous than on Earth based clinostat.

Brown, A. H.↗
NASA NTRS2004

STS-107 Mission after the Mission: Recovery of Data from the Debris of Columbia

STS-107 was a 16-day, dedicated research mission that included over 80 experiments, spanning many disciplines including biology, physics, chemistry, and earth sciences, including many student experiments. The mission was considered a resounding success until February 1, 2003, when tragedy struck the Columbia and her crew as she re-entered the atmosphere over Texas. During the mission, approximately one third of the overall data was obtained but much more was stored in the flight hardware systems. This paper documents a new set of STS-107 experiment objectives, a "mission after the mission," in which several experiment teams attempted, and, in many cases succeeded, to recover data from their flight hardware, now debris. A description of the data recovery efforts is included for these five experiment facilities: Combustion Module-2, Critical Viscosity of Xenon-2, Commercial Instrumentation Technology Associates Biomedical Experiments-2, Biological Research in Canisters-14, and Commercial Protein Crystal Growth.

Over, A. P.↗
NASA NTRS1993

Control structural interaction testbed: A model for multiple flexible body verification

Conventional end-to-end ground tests for verification of control system performance become increasingly complicated with the development of large, multiple flexible body spacecraft structures. The expense of accurately reproducing the on-orbit dynamic environment and the attendant difficulties in reducing and accounting for ground test effects limits the value of these tests. TRW has developed a building block approach whereby a combination of analysis, simulation, and test has replaced end-to-end performance verification by ground test. Tests are performed at the component, subsystem, and system level on engineering testbeds. These tests are aimed at authenticating models to be used in end-to-end performance verification simulations: component and subassembly engineering tests and analyses establish models and critical parameters, unit level engineering and acceptance tests refine models, and subsystem level tests confirm the models' overall behavior. The Precision Control of Agile Spacecraft (PCAS) project has developed a control structural interaction testbed with a multibody flexible structure to investigate new methods of precision control. This testbed is a model for TRW's approach to verifying control system performance. This approach has several advantages: (1) no allocation for test measurement errors is required, increasing flight hardware design allocations; (2) the approach permits greater latitude in investigating off-nominal conditions and parametric sensitivities; and (3) the simulation approach is cost effective, because the investment is in understanding the root behavior of the flight hardware and not in the ground test equipment and environment.

Chory, M. A.↗
NASA NTRS2006

Overview of Mars Science Laboratory (MSL) Environmental Program

This viewgraph presentation is an overview of the Mars Science Laboratory (MSL) program. The engineering objectives of the program are to create a Mobile Science Laboratory capable of one Mars Year surface operational lifetime (670 Martian sols = 687 Earth days). It will be able to land and operation over wide range of latitudes, altitudes and seasons It must have controlled propulsive landing and demonstrate improved landing precision via guided entry The general science objectives are to perform science that will focus on Mars habitability, perform next generation analytical laboratory science investigations, perform remote sensing/contact investigations and carry a suite of environmental monitoring instruments. Specific scientific objectives of the MSL are: (1) Characterization of geological features, contributing to deciphering geological history and the processes that have modified rocks and regolith, including the role of water. (2) Determination of the mineralogy and chemical composition (including an inventory of elements such as C, H, N, O, P, S, etc. known to be building blocks for life) of surface and near-surface materials. (3) Determination of energy sources that could be used to sustain biological processes. (4) Characterization of organic compounds and potential biomarkers in representative regolith, rocks, and ices. (5) Determination the stable isotopic and noble gas composition of the present-day bulk atmosphere. (6) Identification potential bio-signatures (chemical, textural, isotopic) in rocks and regolith. (7) Characterization of the broad spectrum of surface radiation, including galactic cosmic radiation, solar proton events, and secondary neutrons. (8) Characterization of the local environment, including basic meteorology, the state and cycling of water and C02, and the near-surface distribution of hydrogen. Several views of the planned MSL and the rover are shown. The MSL environmental program is to: (1) Ensure the flight hardware design is capable of surviving all the environments throughout its mission life time, including ground, transportation, launch, cruise, entry decent and landing (EDL) and surface operation environments. (2) Verify environmental testing and analysis have adequately validated the flight hardware's ability to withstand all natural, self-induced, and mission-activity-induced environments. The planned tests to ascertain the capability of the MSL to perform as desired are reviewed.

spacecraft↗
NASA NTRS2015

NASA's Rodent Research Project: Validation of Capabilities for Conducting Long Duration Experiments in Space

Research using rodents is an essential tool for advancing biomedical research on Earth and in space. Prior rodent experiments on the Shuttle were limited by the short flight duration. The International Space Station (ISS) provides a new platform for conducting rodent experiments under long duration conditions. Rodent Research (RR)-1 was conducted to validate flight hardware, operations, and science capabilities that were developed at the NASA Ames Research Center. Twenty C57BL6J adult female mice were launched on Sept 21, 2014 in a Dragon Capsule (SpaceX-4), then transferred to the ISS for a total time of 21-22 days (10 commercial mice) or 37 days (10 validation mice). Tissues collected on-orbit were either rapidly frozen or preserved in RNAlater at -80C (n2group) until their return to Earth. Remaining carcasses on-orbit were rapidly frozen for dissection post-flight. The three controls groups at Kennedy Space Center consisted of: Basal mice euthanized at the time of launch, Vivarium controls housed in standard cages, and Ground Controls (GC) housed in flight hardware within an environmental chamber. Upon return to Earth, there were no differences in body weights between Flight (FLT) and GC at the end of the 37 days in space. Liver enzyme activity levels of FLT mice and all control mice were similar in magnitude to those of the samples that were processed under optimal conditions in the laboratory. Liver samples dissected on-orbit yielded high quality RNA (RIN8.99+-0.59, n7). Liver samples dissected post-flight from the intact, frozen FLT carcasses yielded RIN of 7.27 +- 0.52 (n6). Additionally, wet weights of various tissues were measured. Adrenal glands and spleen showed no significant differences in FLT compared to GC although thymus and livers weights were significantly greater in FLT compared to GC. Over 3,000 tissue aliquots collected post-flight from the four groups of mice were deposited into the Ames Life Science Data Archives for future Biospecimen Sharing Program. Together, the RR validation flight successfully demonstrates the capability to support long-duration experimentation on the ISS to achieve both basic science and biomedical objectives.

spaceflight↗
NASA NTRS2006

Advanced Coating Removal Techniques

An important step in the repair and protection against corrosion damage is the safe removal of the oxidation and protective coatings without further damaging the integrity of the substrate. Two such methods that are proving to be safe and effective in this task are liquid nitrogen and laser removal operations. Laser technology used for the removal of protective coatings is currently being researched and implemented in various areas of the aerospace industry. Delivering thousands of focused energy pulses, the laser ablates the coating surface by heating and dissolving the material applied to the substrate. The metal substrate will reflect the laser and redirect the energy to any remaining protective coating, thus preventing any collateral damage the substrate may suffer throughout the process. Liquid nitrogen jets are comparable to blasting with an ultra high-pressure water jet but without the residual liquid that requires collection and removal .As the liquid nitrogen reaches the surface it is transformed into gaseous nitrogen and reenters the atmosphere without any contamination to surrounding hardware. These innovative technologies simplify corrosion repair by eliminating hazardous chemicals and repetitive manual labor from the coating removal process. One very significant advantage is the reduction of particulate contamination exposure to personnel. With the removal of coatings adjacent to sensitive flight hardware, a benefit of each technique for the space program is that no contamination such as beads, water, or sanding residue is left behind when the job is finished. One primary concern is the safe removal of coatings from thin aluminum honeycomb face sheet. NASA recently conducted thermal testing on liquid nitrogen systems and found that no damage occurred on 1/6", aluminum substrates. Wright Patterson Air Force Base in conjunction with Boeing and NASA is currently testing the laser remOval technique for process qualification. Other applications of liquid nitrogen operations include cutting of both soft and hard materials. While the laser will not cut materials, it can be used to roughen surfaces and to remove other materials from the substrate including oil, grease, and mold. The space program can benefit from several of these applications with the need for precise removal of coatings and other organic compounds in areas adjacent to sensitive space flight hardware. Significant advantages are evident when comparing liquid nitrogen and laser removal operations over current techniques of media blasting and sanding.

Seibert, Jon↗
NASA NTRSDate not supplied

Documentarian’s Support Role: Recording Active Research for Outreach

The Space Crop Production Team at NASA’s Kennedy Space Center recently conducted a campaign of parabolic flights to study the best techniques for harvesting and collecting microgreens in microgravity. During this process, the research team invited a student with scientific training to the field sites, contributing as the documentarian and aiding in recording audio visual data. The documentarian was tasked with photographing and filming the preparation of experiments for parabolic flight, hardware installation in the parabolic flight plane, the crew performing their experiments, and the harvesting hardware and samples post-flight. Through having a documentarian on the team during experiments, the processes of problem-solving, teamwork, and data collection were able to be captured. This allows for these methods to be reflected upon post-experiment as a means of improving the procedures for the future. Additionally, the picture and video evidence became data that were analyzed following the flight test. The Space Crop Production team benefited by having a documentarian present, as they were able to develop a 45 second social media video with the intent of being published through official NASA outlets. Longer videos for classroom use are also in work. In addition to outreach usage, the collection of footage and visual data the documentarian provides has the potential to be scientifically published both in video-based scientific journals, and as supplemental data in online journal publications. Capturing research in this manner helps share an unseen side of the research practices with a larger audience and increases the potential for scientific engagement and activation.

Christopher Bermudez↗
NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Water Processor Assembly↗
NASA NTRS1971

Planetary quarantine: Principles, methods, and problems.

Microbial survival in deep space environment, contamination of planets by nonsterile flight hardware, and hazards of back contamination are among the topics covered in papers concerned with the analytical basis for planetary quarantine. The development of the technology and policies of planetary quarantine is covered in contributions on microbiologic assay and sterilization of space flight hardware and control of microbial contamination. A comprehensive subject index is included. Individual items are abstracted in this issue.

Hall, L. B.↗
NASA NTRS2013

Microbiological Sampling Methods and Sanitation of Edible Plants Grown on ISS

Pathogenic microbes on the surfaces of salad crops and growth chambers pose a threat to the health of crew on International Space Station. For astronauts to safely consume spacegrown vegetables produced in NASA's new vegetable production unit, VEGGIE, three technical challenges must be overcome: real-time sampling, microbiological analysis, and sanitation. Raphanus sativus cultivar Cherry Bomb II and Latuca sativa cultivar Outredgeous, two saled crops to be grown in VEGGIE, were inoculated with Salmonella enterica serovar Typhimurium (S. Typhimurium), a bacterium known to cause food-borne illness~ Tape- and swab-based sampling techniques were optimized for use in microgravity and assessed for effectiveness in recovery of bacteria from crop surfaces: Rapid pathogen detection and molecular analyses were performed via quantitative real-time polymerase chain reactiop using LightCycler® 480 and RAZOR® EX, a scaled-down instrument that is undergoing evaluation and testing for future flight hardware. These methods were compared with conventional, culture-based methods for the recovery of S. Typhimurium colonies. A sterile wipe saturated with a citric acid-based, food-grade sanitizer was applied to two different surface materials used in VEGGIE flight hardware that had been contaminated with the bacterium Pseudomonas aeruginosa,. another known human pathogen. To sanitize surfaces, wipes were saturated with either the sanitizer or sterile deionized water and applied to each surface. Colony forming units of P. aeruginosa grown on tryptic soy agar plates were enumerated from surface samples after sanitization treatments. Depending on the VEGGIE hardware material, 2- to 4.5-log10 reductions in colony-forming units were observed after sanitization. The difference in recovery of S. Typhimurium between tape- and swab- based sampling techniques was insignificant. RAZOR® EX rapidly detected S. Typhimurium present in both raw culture and extracted DNA samples.

Parrish, Charles H. II↗
NASA NTRS1994

BSM Delta Qualification 2, volume 2

This report, presented in three volumes, provides the results of a two-motor Delta Qualification 2 program conducted in 1993 to certify the following enhancements for incorporation into booster separation motor (BSM) flight hardware: vulcanized-in-place nozzle aft closure insulation; new iso-static ATJ bulk graphite throat insert material; adhesive EA 9394 for bonding the nozzle throat, igniter grain rod/centering insert/igniter case; deletion of the igniter adapter insulator ring; deletion of the igniter adapter/igniter case interface RTV; and deletion of loctite from igniter retainer plate threads. The enhancements above directly resulted from (1) the BSM total quality management (TQM) team initiatives to enhance the BSM producibility, and (2) the necessity to qualify new throat insert and adhesive systems to replace existing materials that will not be available. Testing was completed at both the component and motor levels. Component testing was accomplished to screen candidate materials (e.g., throat materials, adhesive systems) and to optimize processes (e.g., aft closure insulator vulcanization approach) prior to their incorporation into the test motors. Motor tests -- consisting of two motors, randomly selected by USBI's on-site quality personnel from production lot AAY, which were modified to accept the enhancements -- were completed to provide the final qualification of the enhancements for incorporation into flight hardware. Volume 2 details the environmental testing (vibration and shock) conducted at Marshall Space Flight Center (MSFC) to which the motors were subjected prior to static tests.

Source record↗