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NASA NTRS2016

Assessment of Fencing on the Orion Heatshield

This paper presents recent experimental results from arc-jet tests of the Orion heatshield that were conducted at NASA Ames Research Center. Test conditions that simulated a set of heating profiles in time representative of the Orion flight environments were used to observe their effect on Orion's block architecture in terms of differential recession or fencing. Surface recession of arc-jet models was characterized during and after testing to derive fencing profiles used for the baseline sizing of the heatshield. Arc-jet test data show that the block architecture produces varying degrees of fencing.

Ground tests↗

NASA NTRS2016

S&MA Internship to Support Orion and the European Service Module

As a University Space Research Association (USRA) intern for NASA Johnson Space Center (JSC) during the summer 2016 work term, I worked on three main projects for the Space Exploration Division (NC) of the Safety and Mission Assurance (S&MA) Directorate. I worked on all three projects concurrently. One of the projects involved facilitating the status and closure of technical actions that were created during European Service Module (ESM) safety reviews by the MPCV Safety & Engineering Review Panel (MSERP). The two main duties included accurately collecting and summarizing qualitative data, and communicating that information to the European Space Agency (ESA) and Airbus (ESA's prime contractor) in a clear, succinct and precise manner. This project also required that I create a report on the challenges and opportunities of international S&MA. With its heavy emphasis on soft skills, this project taught me how to communicate better, by showing me how to present and share information in an easy-to-read and understandable format, and by showing me how to cooperate with and culturally respect international partners on a technical project. The second project involved working with the Orion Thermal Protection System (TPS) Process Failure Modes and Effects Analysis (PFMEA) Working Group to create the first full version of the Orion TPS PFMEA. The Orion TPS PFMEA Working Group met twice a week to analyze the Avcoat block installation process for failure modes, the failure modes effects, and how such failure modes could be controlled. I was in charge of implementing changes that were discussed in meeting, but were not implemented real time. Another major task included creating a significant portion of the content alongside another team member outside the two weekly meetings. This project caused me to become knowledgeable about TPS, heatshields, space-rated manufacturing, and non-destructive evaluation (NDE). The project also helped me to become better at working with a small team and helped improved my technical communication skills. My main duty for the third project was creating a Safety Verification Tracking Log (SVTL) for the Orbital Maneuvering System Engine (OMS-E), and contacting subject matter experts to close Hazard Report (HR) control verifications. This project also required me to support other OMS-E safety process tasks, like monitoring OMS-E vibration testing for Quality Assurance (QA) purposes. This project helped me become even more proficient in Excel. Throughout the project, I gained knowledge about the OMS-E system and improved my understanding of pressure systems and propellant systems. In terms of education goals, this work term has affirmed my desire to take a few more space-related courses, like orbital mechanics, so that I can have a better understanding of human spaceflight and the industry surrounding it. However, the work term did not persuade me to pursue a master's degree. In terms of career goals, this work term has helped me clarify the direction I would like to head in the future. The perspective of three summer terms working for NASA in S&MA has allowed me to observe that most S&MA employees joined S&MA after working in other NASA directorates, such as Engineering or Flight Operations. It is my belief that it would be advantageous for both NASA and I for me to broaden my knowledge base and technical skill set by completing hands-on technical work on human spaceflight projects, and for me to integrate my safety experience directly into technical work in other directorates. The other significant advantage to this proposed situation is that if I were to eventually return to S&MA, I would be returning with a substantial set of hands-on technical experience and knowledge, which would be a significant resource for S&MA tasks and projects.

Hutcheson, Connor↗

NASA NTRS2016

Damping Effects of Drogue Parachutes on Orion Crew Module Dynamics

Because simulations of the Orion Crew Module (CM) dynamics with drogue parachutes deployed were under-predicting the amount of damping seen in free-flight tests, an attach-point damping model was applied to the Orion system. A key hypothesis in this model is that the drogue parachutes' net load vector aligns with the CM drogue attachment point velocity vector. This assumption seems reasonable and has historically produced good results, but has never been experimentally verified. The wake of the CM influences the drogue parachutes, which makes performance predictions of the parachutes difficult. Many of these effects are not currently modeled in the simulations. A forced oscillation test of the CM with parachutes was conducted in the NASA LaRC 20-Ft Vertical Spin Tunnel (VST) to gather additional data to validate and refine the attach-point damping model. A second loads balance was added to the original Orion VST model to measure the drogue parachute loads independently of the CM. The objective of the test was to identify the contribution of the drogues to CM damping and provide additional information to quantify wake effects and the interactions between the CM and parachutes. The drogue parachute force vector was shown to be highly dependent on the CM wake characteristics. Based on these wind tunnel test data, the attach-point damping model was determined to be a sufficient approximation of the parachute dynamics in relationship to the CM dynamics for preliminary entry vehicle system design. More wake effects should be included to better model the system.

Aubuchon, Vanessa V.↗

NASA NTRS2016

Crew Exploration Vehicle (CEV) (Orion) Occupant Protection: Appendices - Part 1

Dr. Nancy J. Currie, of the NASA Engineering and Safety Center (NESC), Chief Engineer at Johnson Space Center (JSC), requested an assessment of the Crew Exploration Vehicle (CEV) occupant protection as a result of issues identified by the Constellation Program and Orion Project. The NESC, in collaboration with the Human Research Program (HRP), investigated new methods associated with occupant protection for the Crew Exploration Vehicle (CEV), known as Orion. The primary objective of this assessment was to investigate new methods associated with occupant protection for the CEV, known as Orion, that would ensure the design provided minimal risk to the crew during nominal and contingency landings in an acceptable set of environmental and spacecraft failure conditions. This documents contains the appendices to the NESC assessment report. NASA/TM-2013-217380, Application of the Brinkley Dynamic Response Criterion to Spacecraft Transient Dynamic Events supersedes this document.

Currie-Gregg, Nancy J.↗

NASA NTRS2016

Crew Exploration Vehicle (CEV) (Orion) Occupant Protection

Dr. Nancy J. Currie, of the NASA Engineering and Safety Center (NESC), Chief Engineer at Johnson Space Center (JSC), requested an assessment of the Crew Exploration Vehicle (CEV) occupant protection as a result of issues identified by the Constellation Program and Orion Project. The NESC, in collaboration with the Human Research Program (HRP), investigated new methods associated with occupant protection for the Crew Exploration Vehicle (CEV), known as Orion. The primary objective of this assessment was to investigate new methods associated with occupant protection for the CEV, known as Orion, that would ensure the design provided minimal risk to the crew during nominal and contingency landings in an acceptable set of environmental and spacecraft failure conditions. This documents contains the outcome of the NESC assessment. NASA/TM-2013-217380, "Application of the Brinkley Dynamic Response Criterion to Spacecraft Transient Dynamic Events." supercedes this document.

Currie-Gregg, Nancy J.↗

NASA NTRS2016

NASA Alternative Orion Small Cell Battery Design Support

The NASA Orion Crew Module Reference Design was produced to address large scale thermal runaway (TR) hazard with specific safety controls for the Orion Spacecraft. The design presented provides the description of a full scale battery design reference for implementation as a drop in replacement to meet all spacecraft energy requirements with compatible 120 Vdc electrical and mechanical interface using small cell technology (18650) packaging. The 32V SuperBrick incorporates unique support features and an electrical bus bar arrangement that allows cells negative can insertion into heat sink that is compressively coupled to the battery enclosure to promote good thermal management. The housing design also provides an internal flame suppression "filter tray" and positive venting path internal to the enclosure to allow hot effluent ejecta to escape in the event of single cell TR. Virtual cells (14P Banks) that are supported to provide cell spacing with interstitial materials to prevent side can failures that can produce cell to cell TR propagation. These features were successfully test in four separate TR run with the full scale DTA1 test article in February 2016. Successfully Completed Test Objectives - Four separate TR test runs with Full-Scale DTA1 housing with Two SuperBricks, Two SuperBrick Emulators All Tests resulted in "clean" gas with less than 6 C rise at Battery vent All Tests resulted in less than 2 C temperature rise on cold-plate outlet All Tests resulted in less than 6 psi pressure rise in the battery housing Test Run 1 -One neighbor cell TR, highest remaining neighbor 139 C. Ejecta shorted to bus caused prolonged additional heating, One shorted cell did experience TR after 12 minutes, remaining cells had adequate thermal margin Test Run 2 - No cell to cell propagation, highest neighbor cell 112 C; Test Run 3 - No cell to cell propagation, highest neighbor cell 96 C; Test Run 4 - No cell to cell propagation, highest neighbor cell 101 C; Primary TR testing and analysis were completed and reviewed for endorsement by NASA Engineering and Safety Center team members. All Key Test Objectives were met and the small cell design alternative was demonstrated and selected to be a feasible drop in replacement for the MPCV Orion CM Battery for EM2 mission.

Haynes, Chuck↗

NASA NTRS2017

Orion Multi-Purpose Crew Vehicle Solving and Mitigating the Two Main Cluster Pendulum Problem

The Orion Multi-purpose Crew Vehicle (MPCV) Orion spacecraft will return humans from beyond earth's orbit, including Mars and will be required to land 20,000 pounds of mass safely in the ocean. The parachute system nominally lands under 3 main parachutes, but the system is designed to be fault tolerant and land under 2 main parachutes. During several of the parachute development tests, it was observed that a pendulum, or swinging, motion could develop while the Crew Module (CM) was descending under two parachutes. This pendulum effect had not been previously predicted by modeling. Landing impact analysis showed that the landing loads would double in some places across the spacecraft. The CM structural design limits would be exceeded upon landing if this pendulum motion were to occur. The Orion descent and landing team was faced with potentially millions of dollars in structural modifications and a severe mass increase. A multidisciplinary team was formed to determine root cause, model the pendulum motion, study alternate canopy planforms and assess alternate operational vehicle controls & operations providing mitigation options resulting in a reliability level deemed safe for human spaceflight. The problem and solution is a balance of risk to a known solution versus a chance to improve the landing performance for the next human-rated spacecraft.

Ali, Yasmin↗

NASA NTRS2018

ORION - Crew Module Side Hatch: Proof Pressure Test Anomaly Investigation

The Orion Multi-Purpose Crew Vehicle program was performing a proof pressure test on an engineering development unit (EDU) of the Orion Crew Module Side Hatch (CMSH) assembly. The purpose of the proof test was to demonstrate structural capability, with margin, at 1.5 times the maximum design pressure, before integrating the CMSH to the Orion Crew Module structural test article for subsequent pressure testing. The pressure test was performed at lower pressures of 3 psig, 10 psig and 15.75 psig with no apparent abnormal behavior or leaking. During pressurization to proof pressure of 23.32 psig, a loud 'pop' was heard at ~21.3 psig. Upon review into the test cell, it was noted that the hatch had prematurely separated from the proof test fixture, thus immediately ending the test. The proof pressure test was expected be a simple verification but has since evolved into a significant joint failure investigation from both Lockheed Martin and NASA.

Evernden, Brent A.↗

NASA NTRS2018

Orion Optical Navigation Progress Toward Exploration Mission 1

Optical navigation of human spacecraft was proposed on Gemini and implemented successfully on Apollo as a means of autonomously operating the vehicle in the event of lost communication with controllers on Earth. The Orion emergency return system utilizing optical navigation has matured in design over the last several years, and is currently undergoing the final implementation and test phase in preparation for Exploration Mission 1 (EM-1) in 2019. The software development is past its Critical Design Review, and is progressing through test and certification for human rating. The filter architecture uses a square-root-free UDU covariance factorization. Linear Covariance Analysis (LinCov) was used to analyze the measurement models and the measurement error models on a representative EM-1 trajectory. The Orion EM-1 flight camera was calibrated at the Johnson Space Center (JSC) electro-optics lab. To permanently stake the focal length of the camera a 500 mm focal length refractive collimator was used. Two Engineering Design Unit (EDU) cameras and an EDU star tracker were used for a live-sky test in Denver. In-space imagery with high-fidelity truth metadata is rare so these live-sky tests provide one of the closest real-world analogs to operational use. A hardware-in-the-loop test rig was developed in the Johnson Space Center Electro-Optics Lab to exercise the OpNav system prior to integrated testing on the Orion vehicle. The software is verified with synthetic images. Several hundred off-nominal images are also used to analyze robustness and fault detection in the software. These include effects such as stray light, excess radiation damage, and specular reflections, and are used to help verify the tuning parameters chosen for the algorithms such as earth atmosphere bias, minimum pixel intensity, and star detection thresholds.

Holt, Greg N.↗

NASA NTRS2018

Orion's Powered Flight Guidance Burn Options for Near Term Exploration Missions

NASA's Orion exploration spacecraft will fly more demanding mission profiles than previous NASA human flight spacecraft. Missions currently under development are destined for cislunar space. The EM-1 mission will fly unmanned to a Distant Retrograde Orbit (DRO) around the Moon. EM-2 will fly astronauts on a mission to the lunar vicinity. To fly these missions, Orion requires powered flight guidance that is more sophisticated than the orbital guidance flown on Apollo and the Space Shuttle. Orion's powered flight guidance software contains five burn guidance options. These five options are integrated into an architecture based on a proven shuttle heritage design, with a simple closed-loop guidance strategy. The architecture provides modularity, simplicity, versatility, and adaptability to future, yet-to-be-defined, exploration mission profiles. This paper provides a summary of the executive guidance architecture and details the five burn options to support both the nominal and abort profiles for the EM-1 and EM-2 missions.

Fill, Thomas↗

NASA NTRS2018

Orion Powered Flight Guidance Burn Options for Near Term Exploration

Fill, Tom↗

NASA NTRS2018

Orion Portable Fire Extinguisher Performance Testing Against a Laptop Lithium-Ion Battery Stored-Energy Fire-Method, Magnesium Fires, and Combustion By-Product Toxicity

As part of the qualification of the International Space Station (ISS) fine water mist portable fire extinguisher (PFE), several test methods were developed to determine firefighting capability against stored-energy sources. The most challenging of these devised stored-energy fire test methods proved to be the Lithium-ion (Li-ion) battery fire test scenario. The Orion crew capsule will utilize a different PFE technology from ISS (water spray rather than water mist), which spurred the need for the same type of evaluation focused on the sources of stored energy slated for use on Orion. Laptops were identified as a realistic source for stored-energy fires, requiring a modified Li-ion battery fire test scenario. In addition to open test cell (ambient oxygen concentration) testing to evaluate new proposed PFE performance, sealed chamber (20.9% and elevated oxygen concentration) testing was also performed. Chamber testing included combustion product sampling at various fire progression points for analysis and application to Orion emergency equipment design and response planning. The PFE stored-energy fire test methodology was modified and testing performed. Initial tests indicated ignition of the laptop magnesium laptop cases was possible. Additional tests were performed to characterize the laptop magnesium case fire behavior in various configurations. The new water spray PFE technology proved effective in extinguishing laptop stored-energy fires, and much was learned in the way these types of fires progressed. Findings indicate potential laptop magnesium case ignition mitigation strategies need to be further investigated.

Harper, Susana A.↗

NASA NTRS2018

Orion European Structural Test Article Propellant Tank Fill and Drain Carts

Environmental testing of the Orion European Structural Test Article (E-STA), which contains the Orion European Service Module (ESM), required that the onboard propellant tanks be filled and drained with fuel and oxidizer simulant fluids as well as pressurized and de-pressurized with an ullage gas. This conference paper will elaborate on how these objectives were fulfilled by presenting the development of derived requirements definition, initial fill and drain concepts, selection of simulant fluids, finalization of pump and pressurization design, selection of components, selection of transfer hoses and interface connections, as well as development and maintenance of budgets, schedules, reviews, construction, documentation, and test procedures. This paper also describes implementation of checkout and commissioning activities leading to successful fluid cart pumping and pressurization operations for the test campaign. The development, construction, and operation of the fluid cart pumping and pressurization systems for the Environmental testing of the Orion European Structural Test Article (E-STA), took place at the NASA Glenn Research Center's Plum Brook Station Space Environments Complex (SEC) during 2015 and 2016.

Pressurization↗

NASA NTRS2018

Orion European Structural Test Article Propellant Tank Fill and Drain Carts

Environmental testing of the Orion European Structural Test Article (E-STA), which contains the Orion European Service Module (ESM), required that the onboard propellant tanks be filled and drained with fuel and oxidizer simulant fluids as well as pressurized and depressurized with an ullage gas. This conference paper will elaborate on how these objectives were fulfilled by presenting the development of derived requirements definition, initial fill and drain concepts, selection of simulant fluids, finalization of pump and pressurization design, selection of components, and selection of transfer hoses and interface connections as well as development and maintenance of budgets, schedules, reviews, construction, documentation, and test procedures. This paper also describes the implementation of checkout and commissioning activities leading to successful fluid cart pumping and pressurization operations for the test campaign. The development, construction, and operation of the fluid cart pumping and pressurization systems for the environmental testing of the Orion E-STA, took place at NASA's Plum Brook Station Space Environments Complex (SEC) during 2015 and 2016.

FLUID TRANSFER↗

NASA NTRS2019

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the Orion program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA’s Exploration Missions. The Orion program successfully completed the EFT-1 flight test in 2014 and is currently developing the EM-1 spacecraft to meet the test objectives of an orbital mission to the moon and return to earth in 2019. Lessons learned from the EFT-1 manufacturing and flight test experience are being incorporated into a wide variety of vehicle systems and manufacturing processes to reduce risk to the Orion missions and flight crew. A critical contributor to crew safety is the heat shield that protects the crew capsule during re-entry through the earth’s atmosphere for return from deep space. The first flight test vehicle, EFT-1, was manufactured and tested in the Neil Armstrong Operations and Checkout (O&C) facility at KSC to demonstrate early risk reduction including the functionality of the Thermal Protection Systems (TPS) for capsule safe return to earth. The approach for the EFT-1 heat shield utilized a low risk approach using Apollo heritage design and manufacturing processes using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The manufacturing processes used honeycomb cell injection guns which were redeveloped from the Apollo Lunar Program processes to build the EFT-1 heat shield. The completed heat shield was transported across the country by aircraft to the O&C at KSC for installation onto the capsule. The EFT-1 heat shield successfully performed its mission and experienced ~80% of the re-entry velocity (50% heating rate) for a lunar return for an Exploration Mission. The second flight test vehicle is the EM-1 mission which will have additional flight systems installed to fly to the moon and return. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission and programmatic requirements. The design continues to use the Avcoat material, but in a “block” configuration to enable improvements in the application processes as well as additional improvements in the carrier structure design and manufacturing operations. Incorporating flight test results and producibility improvements from EFT-1 for the heat shield system design and processes have improved the thermal protection capability, improved the producibility, and cost for EM-1 flight test.

Producibility↗

NASA NTRS2018

Remote Optical Recession Measurement of Orion Thermal Protection System

For the Orion Multi-Purpose Crew Vehicle (MPCV) project, NASA is minimizing the use of onboard diagnostics, especially external sensors that penetrate the structure. Nonetheless, there is a desire to measure the Thermal Protection System (TPS) recession during reentry. One noninvasive technique currently under investigation is the insertion of indicator metals into the heatshield at varied depths and spatial locations. A remote (airborne) spectrometer detects the emissions from the ionized metal to reveal the time (thus depth) of the metal release. Innovative processing enables the emission features from trace amounts of the selected metals to be reliably detected against the complex and structured spectral background of the shock layer and ablated TPS material. The con-cept has been proven viable through ground testing at NASA HyMETS and AHF arc jet facilities using the Orion TPS material (Avcoat). This presentation highlights the parametric testing that was conducted to select the optimal indicator metals and to assess the accuracy of remote recession measurements using this technique. The CONOPS for integrating the technique into the Orion flight tests is also presented. This includes the onboard indicator metal "seeded plugs" and the offboard airborne sensor platform that would be deployed.

Scriven, Gordon↗

NASA NTRS2019

Challenges and Opportunities of International Cooperation for Safety & Mission Assurance (SMA) on the European Service Module (ESM) of the Orion Program

ESA is providing the ESM to NASA for the Orion Program in accordance with the Implementing Arrangement (IA) established between the two Agencies in 2012. This IA is a barter agreement, in which ESA provides Service Module vehicles for the first two flights of Orion in exchange for two servicing missions to the ISS. This arrangement has provided opportunities and challenges to both communities. It represents an important opportunity for ESA to build on its experience in the development and operations of ATV and play an active role in the development and flight of a manned space vehicle. This paper will explore some of the unique aspects of this arrangement as it affects Safety & Mission Assurance (SMA).The assessment of ESM compliance with applicable safety requirements is the responsibility of the Joint Safety and Engineering Review Panel (JSERP). The JSERP has two features that are relatively unique amongst NASA safety panels. First, NASA Engineering and SMA organizations co-chair this Panel. Previously, Safety has chaired, with Engineering as a member of the Panel. Inclusion of Engineering as a co-chair has offered greater leverage within the technical community. Second, the JSERP includes a second set of co-chairs from ESA Engineering and ESA Product Assurance and Safety (PA/S) organizations. This recognizes the international arrangement as one of partnership.Another source of both opportunity and challenge is the differing experience base of ESA and NASA. NASA has decades of experience in manned spaceflight, dating back to the Mercury program and following through Gemini, Apollo, Apollo-Soyuz, Skylab, Shuttle and the International Space Station. The risk posture for manned missions is much more rigorous than for unmanned missions. ESA brings a wealth of knowledge as well, with their flights of Ariane and Automated Transfer Vehicle (ATV), development and operation of the Columbus module on ISS, and satellite programs. The result is that both parties have developed paradigms related to risk and failure that contribute to ESM discussions.Orion represents humanity's first venture beyond Low-Earth Orbit (LEO) in over fifty years. Much of that experience is captured in program documents, but first-hand knowledge is limited to a few spaceflight veterans. Missions to LEO have offered the opportunity of direct, near-instantaneous communications and assistance, and the ability to return to Earth within a matter of hours in case of emergency. Outward-bound missions do not have these features and will require a more autonomous spacecraft with attendant safety-related issues.This paper will explore these and other challenges as we approach the flight of the first Orion vehicle.

Ciancone, Michael L.↗

NASA NTRS2019

Agile Approach to Assuring Software for NASA's Orion Spacecraft

Agile software development is prevalent throughout the Government, and NASA is no exception. NASA's Orion spacecraft is being developed to return Astronauts to the moon in the next 5 years, and the role of software in achieving the ambitious mission objectives has expanded dramatically in the last few decades. This presentation is the story of how the Independent Verification and Validation team for Orion adapted to the Agile approach that the Orion Program was using to develop the flight software. Consider attending this session if you are working with software developers utilizing Agile development approaches, or are interested in learning about Agile and Lean principles that could help improve communication within your own team.

Smith, Justin↗