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At least 235 records · Page 13
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NASA NTRS2010

Design of Fiber Reinforced Foam Sandwich Panels for Large Ares V Structural Applications

The preliminary design of three major structural components within NASA's Ares V heavy lift vehicle using a novel fiber reinforced foam composite sandwich panel concept is presented. The Ares V payload shroud, interstage, and core intertank are designed for minimum mass using this panel concept, which consists of integral composite webs separated by structural foam between two composite facesheets. The HyperSizer structural sizing software, in conjunction with NASTRAN finite element analyses, is used. However, since HyperSizer does not currently include a panel concept for fiber reinforced foam, the sizing was performed using two separate approaches. In the first, the panel core is treated as an effective (homogenized) material, whose properties are provided by the vendor. In the second approach, the panel is treated as a blade stiffened sandwich panel, with the mass of the foam added after completion of the panel sizing. Details of the sizing for each of the three Ares V components are given, and it is demonstrated that the two panel sizing approaches are in reasonable agreement for thinner panel designs, but as the panel thickness increases, the blade stiffened sandwich panel approach yields heavier panel designs. This is due to the effects of local buckling, which are not considered in the effective core property approach.

Bednarcyk, Brett A.↗
NASA NTRS2011

An Overview of Ares-I CFD Ascent Aerodynamic Data Development And Analysis Based on USM3D

An overview of the computational results obtained from the NASA Langley developed unstructured grid, Reynolds-averaged Navier-Stokes flow solver USM3D, in support of the Ares-I project within the NASA s Constellation program, are presented. The numerical data are obtained for representative flow conditions pertinent to the ascent phase of the trajectory at both wind tunnel and flight Reynolds number without including any propulsion effects. The USM3D flow solver has been designated to have the primary role within the Ares-I project in developing the computational aerodynamic data for the vehicle while other flow solvers, namely OVERFLOW and FUN3D, have supporting roles to provide complementary results for fewer cases as part of the verification process to ensure code-to-code solution consistency. Similarly, as part of the solution validation efforts, the predicted numerical results are correlated with the aerodynamic wind tunnel data that have been generated within the project in the past few years. Sample aerodynamic results and the processes established for the computational solution/data development for the evolving Ares-I design cycles are presented.

FUN3D↗
NASA NTRS2010

Utilizing NX Advanced Simulation for NASA's New Mobile Launcher for Ares-l

This slide presentation reviews the use of NX to simulate the new Mobile Launcher (ML) for the Ares-I. It includes: a comparison of the sizes of the Saturn 5, the Space Shuttle, the Ares I, and the Ares V, with the height, and payload capability; the loads control plan; drawings of the base framing, the underside of the ML, beam arrangement, and the finished base and the origin of the 3D CAD data. It also reviews the modeling approach, meshing. the assembly Finite Element Modeling, the model summary. and beam improvements.

Brown, Christopher↗
NASA NTRS2010

STEM Education Efforts in the Ares Projects

According to the National Science Foundation, of the more than 4 million first university degrees awarded in science and engineering in 2006, students in China earned about 21%, those in the European Union earned about 19%, and those in the United States earned about 11%. Statistics like these are of great interest to NASA's Ares Projects, which are responsible for building the rockets for the U.S. Constellation Program to send humans beyond low-Earth orbit. Science, technology, engineering, and mathematics students are essential for the long-term sustainability of any space program. Since the Projects creation, the Ares Outreach Team has used a variety of STEM-related media, methods, and materials to engage students, educators, and the general public in Constellation's mission. Like Project Apollo, the nation s exploration destinations and the vehicles used to get there can inspire students to learn more about STEM. Ares has been particularly active in public outreach to schools in Northern Alabama; on the Internet via outreach and grade-specific educational materials; and in more informal social media settings such as YouTube and Facebook. These combined efforts remain integral to America s space program, regardless of its future direction.

Doreswamy, Rajiv↗
NASA NTRS2011

Human Factors Analysis to Improve the Processing of Ares-1 Launch Vehicle

This slide presentation reviews the use of Human Factors analysis in improving the ground processing procedures for the Ares-1 launch vehicle. The light vehicle engineering designers for Ares-l launch vehicle had to design the flight vehicle for effective, efficient and safe ground operations in the cramped dimensions in a rocket design. The use of a mockup of the area where the technician would be required to work proved to be a very effective method to promote the collaboration between the Ares-1 designers and the ground operations personnel.

Stambolian, Damon B.↗
NASA NTRS2011

An Assessment of Ares I-X Aeroacoustic Measurements with Comparisons to Pre-Flight Wind Tunnel Test Results

During the recent successful launch of the Ares I-X Flight Test Vehicle, aeroacoustic data was gathered at fifty-seven locations along the vehicle as part of the Developmental Flight Instrumentation. Several of the Ares I-X aeroacoustic measurements were placed to duplicate measurement locations prescribed in pre-flight, sub-scale wind tunnel tests. For these duplicated measurement locations, comparisons have been made between aeroacoustic data gathered during the ascent phase of the Ares I-X flight test and wind tunnel test data. These comparisons have been made at closely matching flight conditions (Mach number and vehicle attitude) in order to preserve a one-to-one relationship between the flight and wind tunnel data. These comparisons and the current wind tunnel to flight scaling methodology are presented and discussed. The implications of using wind tunnel test data scaled under the current methodology to predict conceptual launch vehicle aeroacoustic environments are also discussed.

Nance, Donald K.↗
NASA NTRS2011

Ares I-X Range Safety Analyses Overview

Ares I-X was the first test flight of NASA's Constellation Program's Ares I Crew Launch Vehicle designed to provide manned access to low Earth orbit. As a one-time test flight, the Air Force's 45th Space Wing required a series of Range Safety analysis data products to be developed for the specified launch date and mission trajectory prior to granting flight approval on the Eastern Range. The range safety data package is required to ensure that the public, launch area, and launch complex personnel and resources are provided with an acceptable level of safety and that all aspects of prelaunch and launch operations adhere to applicable public laws. The analysis data products, defined in the Air Force Space Command Manual 91-710, Volume 2, consisted of a nominal trajectory, three sigma trajectory envelopes, stage impact footprints, acoustic intensity contours, trajectory turn angles resulting from potential vehicle malfunctions (including flight software failures), characterization of potential debris, and debris impact footprints. These data products were developed under the auspices of the Constellation's Program Launch Constellation Range Safety Panel and its Range Safety Trajectory Working Group with the intent of beginning the framework for the operational vehicle data products and providing programmatic review and oversight. A multi-center NASA team in conjunction with the 45th Space Wing, collaborated within the Trajectory Working Group forum to define the data product development processes, performed the analyses necessary to generate the data products, and performed independent verification and validation of the data products. This paper outlines the Range Safety data requirements and provides an overview of the processes established to develop both the data products and the individual analyses used to develop the data products, and it summarizes the results of the analyses required for the Ares I-X launch.

Starr, Brett R.↗
NASA NTRS2011

Ares I-X Range Safety Flight Envelope Analysis

Ares I-X was the first test flight of NASA's Constellation Program's Ares I Crew Launch Vehicle designed to provide manned access to low Earth orbit. As a one-time test flight, the Air Force's 45th Space Wing required a series of Range Safety analysis data products to be developed for the specified launch date and mission trajectory prior to granting flight approval on the Eastern Range. The range safety data package is required to ensure that the public, launch area, and launch complex personnel and resources are provided with an acceptable level of safety and that all aspects of prelaunch and launch operations adhere to applicable public laws. The analysis data products, defined in the Air Force Space Command Manual 91-710, Volume 2, consisted of a nominal trajectory, three sigma trajectory envelopes, stage impact footprints, acoustic intensity contours, trajectory turn angles resulting from potential vehicle malfunctions (including flight software failures), characterization of potential debris, and debris impact footprints. These data products were developed under the auspices of the Constellation's Program Launch Constellation Range Safety Panel and its Range Safety Trajectory Working Group with the intent of beginning the framework for the operational vehicle data products and providing programmatic review and oversight. A multi-center NASA team in conjunction with the 45th Space Wing, collaborated within the Trajectory Working Group forum to define the data product development processes, performed the analyses necessary to generate the data products, and performed independent verification and validation of the data products. This paper outlines the Range Safety data requirements and provides an overview of the processes established to develop both the data products and the individual analyses used to develop the data products, and it summarizes the results of the analyses required for the Ares I-X launch.

Starr, Brett R.↗
NASA NTRS2011

Comparison of Ares I-X Wind-Tunnel Derived Buffet Environment with Flight Data

The Ares I-X Flight Test Vehicle (FTV), launched in October 2009, carried with it over 243 buffet verification pressure sensors and was one of the most heavily instrumented launch vehicle flight tests. This flight test represented a unique opportunity for NASA and its partners to compare the wind-tunnel derived buffet environment with that measured during the flight of Ares I-X. It is necessary to define the launch vehicle buffet loads to ensure that structural components and vehicle subsystems possess adequate strength, stress, and fatigue margins when the vehicle structural dynamic response to buffet forcing functions are considered. Ares I-X buffet forcing functions were obtained via wind-tunnel testing of a rigid buffet model (RBM) instrumented with hundreds of unsteady pressure transducers designed to measure the buffet environment across the desired frequency range. This paper discusses the comparison of RBM and FTV buffet environments, including fluctuating pressure coefficient and normalized sectional buffet forcing function root-mean-square magnitudes, frequency content of power-spectral density functions, and force magnitudes of an alternating flow phenomena. Comparison of wind-tunnel model and flight test vehicle buffet environments show very good agreement with root-mean-square magnitudes of buffet forcing functions at the majority of vehicle stations. Spectra proved a challenge to compare because of different wind-tunnel and flight test conditions and data acquisition rates. However, meaningful and promising comparisons of buffet spectra are presented. Lastly, the buffet loads resulting from the transition of subsonic separated flow to supersonic attached flow were significantly over-predicted by wind-tunnel results.

Piatak, David J.↗
NASA NTRS2011

Reconstruction of Ares I-X Integrated Vehicle Rollout Loads

The measurements taken during the Ares I-X test flight provided a unique opportunity to assess the accuracy of the models and methods used to analyze the loads and accelerations present in the planned Ares I vehicle. During the rollout of the integrated vehicle from the Vehicle Assembly Building (VAB) to the launch pad, the vehicle and its supporting structure are subjected to wind loads and the vibrations produced by the crawler-transporter (CT) that is carrying it. While the loads induced on the vehicle during this period are generally low relative to those experienced in flight, the rollout is a period of operation of primary interest to those designing both the ground support equipment and the interfaces between the launch vehicle and its supporting structure. In this paper, the methods used for reconstructing the loads during the rollout phase are described. The results generated are compared to measured values, leading to insight into the accuracy of the Ares I assessment techniques.

Chamberlain, Matthew K.↗
NASA NTRS2011

Ares I-X Separation and Reentry Trajectory Analyses

The Ares I-X Flight Test Vehicle was launched on October 28, 2009 and was the first and only test flight of NASA s two-stage Ares I launch vehicle design. The launch was successful and the flight test met all of its primary and secondary objectives. This paper discusses the stage separation and reentry trajectory analysis that was performed in support of the Ares I-X test flight. Pre-flight analyses were conducted to assess the risk of stage recontact during separation, to evaluate the first stage flight dynamics during reentry, and to define the range safety impact ellipses of both stages. The results of these pre-flight analyses were compared with available flight data. On-board video taken during flight showed that the flight test vehicle successfully separated without any recontact. Reconstructed trajectory data also showed that first stage flight dynamics were well characterized by pre-flight Monte Carlo results. In addition, comparisons with flight data indicated that the complex interference aerodynamic models employed in the reentry simulation were effective in capturing the flight dynamics during separation. Finally, the splash-down locations of both stages were well within predicted impact ellipses.

Tartabini, Paul V.↗
NASA NTRS2011

Ares I-X First Stage Internal Aft Skirt Re-Entry Heating Data and Modeling

The CLVSTATE engineering code is being used to predict Ares-I launch vehicle first stage reentry aerodynamic heating. An engineering analysis is developed which yields reasonable predictions for the timing of the first stage aft skirt thermal curtain failure and the resulting internal gas temperatures. The analysis is based on correlations of the Ares I-X internal aft skirt gas temperatures and has been implemented into CLVSTATE. Validation of the thermal curtain opening models has been accomplished using additional Ares I-X thermocouple, calorimeter and pressure flight data. In addition, a technique which accounts for radiation losses at high altitudes has been developed which improves the gas temperature measurements obtained by the gas temperature probes (GTP). Updates to the CLVSTATE models are shown to improve the accuracy of the internal aft skirt heating predictions which will result in increased confidence in future vehicle designs

Schmitz, Craig P.↗
NASA NTRS2011

Reconstruction of Ares I-X Integrated Vehicle Rollout Loads

The measurements taken during the Ares I-X test flight provided a unique opportunity to assess the accuracy of the models and methods used to analyze the loads and accelerations present in the planned Ares I vehicle. During the rollout of the integrated vehicle from the Vehicle Assembly Building (VAB) to the launch pad, the vehicle and its supporting structure are subjected to wind loads and the vibrations produced by the crawler-transporter (CT) that is carrying it. While the loads induced on the vehicle during this period are generally low relative to those experienced in flight, the rollout is a period of operation of primary interest to those designing both the ground support equipment and the interfaces between the launch vehicle and its supporting structure. In this paper, the methods used for reconstructing the loads during the rollout phase are described. The results generated are compared to measured values, leading to insight into the accuracy of the Ares I assessment techniques.

Chamberlain, Matthew K.↗
NASA NTRS2011

Ares I Scale Model Acoustic Test Lift-Off Acoustics

The lift-off acoustic (LOA) environment is an important design factor for any launch vehicle. For the Ares I vehicle, the LOA environments were derived by scaling flight data from other launch vehicles. The Ares I LOA predicted environments are compared to the Ares I Scale Model Acoustic Test (ASMAT) preliminary results.

Counter, Douglas D.↗
NASA NTRS2011

5 Percent Ares I Scale Model Acoustic Test: Overpressure Characterization and Analysis

During the ignition of a ducted solid rocket motor (SRM), rapid expansion of injected hot gases from the motor into a confined volume causes the development of a steep fronted wave. This low frequency transient wave propagates outward from the exhaust duct, impinging the vehicle and ground structures. An unsuppressed overpressure wave can potentially cause modal excitation in the structures and vehicle, subsequently leading to damage. This presentation details the ignition transient f indings from the 5% Ares I Scale Model Acoustic Test (ASMAT). The primary events of the ignition transient environment induced by the SRM are the ignition overpressure (IOP), duct overpressure (DOP), and source overpressure (SOP). The resulting observations include successful knockdown of the IOP environment through use of a Space Shuttle derived IOP suppression system, a potential load applied to the vehicle stemming from instantaneous asymmetrical IOP and DOP wave impingement, and launch complex geometric influences on the environment. The results are scaled to a full-scale Ares I equivalent and compared with heritage data including Ares I-X and both suppressed and unsuppressed Space Shuttle IOP environments.

Alvord, David↗
NASA NTRS2011

Overview of the Ares I Scale Model Acoustic Test Program

Launch environments, such as lift-off acoustic (LOA) and ignition overpressure (IOP), are important design factors for any vehicle and are dependent upon the design of both the vehicle and the ground systems. LOA environments are used directly in the development of vehicle vibro-acoustic environments and IOP is used in the loads assessment. The NASA Constellation Program had several risks to the development of the Ares I vehicle linked to LOA. The risks included cost, schedule and technical impacts for component qualification due to high predicted vibro-acoustic environments. One solution is to mitigate the environment at the component level. However, where the environment is too severe for component survivability, reduction of the environment itself is required. The Ares I Scale Model Acoustic Test (ASMAT) program was implemented to verify the Ares I LOA and IOP environments for the vehicle and ground systems including the Mobile Launcher (ML) and tower. An additional objective was to determine the acoustic reduction for the LOA environment with an above deck water sound suppression system. ASMAT was a development test performed at the Marshall Space Flight Center (MSFC) East Test Area (ETA) Test Stand 116 (TS 116). The ASMAT program is described in this presentation.

Counter, Douglas D.↗
NASA NTRS2011

NASA Ares I Launch Vehicle Roll and Reaction Control Systems Lessons Learned

On April 15, 2010 President Barak Obama made the official announcement that the Constellation Program, which included the Ares I launch vehicle, would be canceled. NASA s Ares I launch vehicle was being designed to launch the Orion Crew Exploration Vehicle, returning humans to the moon, Mars, and beyond. It consisted of a First Stage (FS) five segment solid rocket booster and a liquid J-2X Upper Stage (US) engine. Roll control for the FS was planned to be handled by a dedicated Roll Control System (RoCS), located on the connecting interstage. Induced yaw or pitch moments experienced during FS ascent would have been handled by vectoring of the booster nozzle. After FS booster separation, the US Reaction Control System (ReCS) would have provided the US Element with three degrees of freedom control as needed. The lessons learned documented in this paper will be focused on the technical designs and producibility of both systems along with the partnership between NASA and Boeing, who was on contract to build the Ares I US Element, which included the FS RoCS and US ReCS. In regards to partnership, focus will be placed on integration along with technical work accomplished by Boeing with special emphasis on each task order. In summary, this paper attempts to capture key lessons learned that should be helpful in the development of future launch vehicle RCS designs.

Butt, Adam↗
NASA NTRS2012

Robotic Manufacturing of 5.5 Meter Cryogenic Fuel Tank Dome Assemblies for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration's (NASA's) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA), the common bulkhead manufacturing development articles (CBMDA) and the thermal protection system demonstration dome (TPS Dome). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminumlithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. An overview of the manufacturing processes will be discussed. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) and the TPS Dome will also be highlighted. Each CBMDA and the TPS Dome consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. The TPS Dome has an additional aluminum alloy 2195 barrel section welded to the y-ring. Manufacturing solutions will be discussed including "fixtureless" welding with self reacting friction stir welding.

Jones, Ronald E.↗