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NASA NTRS2011

Ares I-X First Flight Loss of Vehicle Probability Analysis

As part of the Constellation (Cx) Program development effort, several test flights were planned to prove concepts and operational capabilities of the new vehicles being developed. The first test, involving the Eastern Test Range, is the Ares I-X launched in 2009. As part of this test, the risk to the general public was addressed to ensure it is within Air Force requirements. This paper describes the methodology used to develop first flight estimates of overall loss of vehicle (LOV) failure probability, specifically for the Ares I-X. The method described in this report starts with the Air Force s generic failure probability estimate for first flight and adjusts the value based on the complexity of the vehicle as compared to the complexity of a generic vehicle. The results estimate a 1 in 9 probability of failure. The paper also describes traditional PRA methods used in this assessment, which were then combined with the updated first flight risk methodology to generate inputs required by the malfunction turn analysis to support estimate of casualty (Ec) calculations as part of the Final Flight Data Package (FFDP) delivered to the Eastern Range for Final Flight Plan Approval.

Bigler, Mark A.↗
NASA NTRS2011

Aerodynamic Analyses and Database Development for Lift-Off/Transition and First Stage Ascent of the Ares I A106 Vehicle

NASA Langley Research Center, in partnership with NASA Marshall Space Flight Center and NASA Ames Research Center, was involved in the aerodynamic analyses, testing, and database development for the Ares I A106 crew launch vehicle in support of the Ares Design and Analysis Cycle. This paper discusses the development of lift-off/transition and ascent databases. The lift-off/transition database was developed using data from tests on a 1.75% scale model of the A106 configuration in the NASA Langley 14x22 Subsonic Wind Tunnel. The power-off ascent database was developed using test data on a 1% A106 scale model from two different facilities, the Boeing Polysonic Wind Tunnel and the NASA Langley Unitary Plan Wind Tunnel. The ascent database was adjusted for differences in wind tunnel and flight Reynolds numbers using USM3D CFD code. The aerodynamic jet interaction effects due to first stage roll control system were modeled using USM3D and OVERFLOW CFD codes.

Pamadi, Bandu N.↗
NASA NTRS2008

Modeling the Risk of Fire/Explosion Due to Oxidizer/Fuel Leaks in the Ares I Interstage

A significant flight hazard associated with liquid propellants, such as those used in the upper stage of NASA's new Ares I launch vehicle, is the possibility of leakage of hazardous fluids resulting in a catastrophic fire/explosion. The enclosed and vented interstage of the Ares I contains numerous oxidizer and fuel supply lines as well as ignition sources. The potential for fire/explosion due to leaks during ascent depends on the relative concentrations of hazardous and inert fluids within the interstage along with other variables such as pressure, temperature, leak rates, and fluid outgasing rates. This analysis improves on previous NASA Probabilistic Risk Assessment (PRA) estimates of the probability of deflagration, in which many of the variables pertinent to the problem were not explicitly modeled as a function of time. This paper presents the modeling methodology developed to analyze these risks.

Ring, Robert W.↗
NASA NTRS2011

Generation of the Ares I-X Flight Test Vehicle Aerodynamic Data Book and Comparison To Flight

A 3.5-year effort to characterize the aerodynamic behavior of the Ares I-X Flight Test Vehicle (AIX FTV) is described in this paper. The AIX FTV was designed to be representative of the Ares I Crew Launch Vehicle (CLV). While there are several differences in the outer mold line from the current revision of the CLV, the overall length, mass distribution, and flight systems of the two vehicles are very similar. This paper briefly touches on each of the aerodynamic databases developed in the program, describing the methodology employed, experimental and computational contributions to the generation of the databases, and how well the databases and underlying computations compare to actual flight test results.

Bauer, Steven X.↗
NASA NTRS2011

Ares I-X Range Safety Simulation Verification and Analysis Independent Validation and Verification

NASA s Ares I-X vehicle launched on a suborbital test flight from the Eastern Range in Florida on October 28, 2009. To obtain approval for launch, a range safety final flight data package was generated to meet the data requirements defined in the Air Force Space Command Manual 91-710 Volume 2. The delivery included products such as a nominal trajectory, trajectory envelopes, stage disposal data and footprints, and a malfunction turn analysis. The Air Force s 45th Space Wing uses these products to ensure public and launch area safety. Due to the criticality of these data, an independent validation and verification effort was undertaken to ensure data quality and adherence to requirements. As a result, the product package was delivered with the confidence that independent organizations using separate simulation software generated data to meet the range requirements and yielded consistent results. This document captures Ares I-X final flight data package verification and validation analysis, including the methodology used to validate and verify simulation inputs, execution, and results and presents lessons learned during the process

Merry, Carl M.↗
NASA NTRS2011

Ares I-X Best Estimated Trajectory Analysis and Results

The Ares I-X trajectory reconstruction produced best estimated trajectories of the flight test vehicle ascent through stage separation, and of the first and upper stage entries after separation. The trajectory reconstruction process combines on-board, ground-based, and atmospheric measurements to produce the trajectory estimates. The Ares I-X vehicle had a number of on-board and ground based sensors that were available, including inertial measurement units, radar, air-data, and weather balloons. However, due to problems with calibrations and/or data, not all of the sensor data were used. The trajectory estimate was generated using an Iterative Extended Kalman Filter algorithm, which is an industry standard processing algorithm for filtering and estimation applications. This paper describes the methodology and results of the trajectory reconstruction process, including flight data preprocessing and input uncertainties, trajectory estimation algorithms, output transformations, and comparisons with preflight predictions.

Karlgaard, Christopher D.↗
NASA NTRS2011

Preliminary Performance of Lithium-ion Cell Designs for Ares I Upper Stage Applications

NASA's Ares I Crew Launch Vehicle (CLV) baselined lithium-ion technology for the Upper Stage (US). Under this effort, the NASA Glenn Research Center investigated three different aerospace lithium-ion cell suppliers to assess the performance of the various lithium-ion cell designs under acceptance and characterization testing. This paper describes the overall testing approaches associated with lithium-ion cells, their ampere-hour capacity as a function of temperature and discharge rates, as well as their performance limitations for use on the Ares I US vehicle.

Miller, Thomas B.↗
NASA NTRS2011

Error Estimate of the Ares I Vehicle Longitudinal Aerodynamic Characteristics Based on Turbulent Navier-Stokes Analysis

Numerical predictions of the longitudinal aerodynamic characteristics for the Ares I class of vehicles, along with the associated error estimate derived from an iterative convergence grid refinement, are presented. Computational results are based on the unstructured grid, Reynolds-averaged Navier-Stokes flow solver USM3D, with an assumption that the flow is fully turbulent over the entire vehicle. This effort was designed to complement the prior computational activities conducted over the past five years in support of the Ares I Project with the emphasis on the vehicle s last design cycle designated as the A106 configuration. Due to a lack of flight data for this particular design s outer mold line, the initial vehicle s aerodynamic predictions and the associated error estimates were first assessed and validated against the available experimental data at representative wind tunnel flow conditions pertinent to the ascent phase of the trajectory without including any propulsion effects. Subsequently, the established procedures were then applied to obtain the longitudinal aerodynamic predictions at the selected flight flow conditions. Sample computed results and the correlations with the experimental measurements are presented. In addition, the present analysis includes the relevant data to highlight the balance between the prediction accuracy against the grid size and, thus, the corresponding computer resource requirements for the computations at both wind tunnel and flight flow conditions. NOTE: Some details have been removed from selected plots and figures in compliance with the sensitive but unclassified (SBU) restrictions. However, the content still conveys the merits of the technical approach and the relevant results.

Aerodynamic characteristics↗
NASA NTRS2011

Ares I-X Flight Test Validation of Control Design Tools in the Frequency-Domain

A major motivation of the Ares I-X flight test program was to Design for Data, in order to maximize the usefulness of the data recorded in support of Ares I modeling and validation of design and analysis tools. The Design for Data effort was intended to enable good post-flight characterizations of the flight control system, the vehicle structural dynamics, and also the aerodynamic characteristics of the vehicle. To extract the necessary data from the system during flight, a set of small predetermined Programmed Test Inputs (PTIs) was injected directly into the TVC signal. These PTIs were designed to excite the necessary vehicle dynamics while exhibiting a minimal impact on loads. The method is similar to common approaches in aircraft flight test programs, but with unique launch vehicle challenges due to rapidly changing states, short duration of flight, a tight flight envelope, and an inability to repeat any test. This paper documents the validation effort of the stability analysis tools to the flight data which was performed by comparing the post-flight calculated frequency response of the vehicle to the frequency response calculated by the stability analysis tools used to design and analyze the preflight models during the control design effort. The comparison between flight day frequency response and stability tool analysis for flight of the simulated vehicle shows good agreement and provides a high level of confidence in the stability analysis tools for use in any future program. This is true for both a nominal model as well as for dispersed analysis, which shows that the flight day frequency response is enveloped by the vehicle s preflight uncertainty models.

Johnson, Matthew↗
NASA NTRS2011

Ares I-X Ascent Base Environments

Plume induced base heating environments were measured during the flight of the NASA Constellation Ares I-X developmental launch vehicle, successfully flown on October 28, 2009. The Ares IX first stage is a four segment Space Shuttle derived booster with base consisting of a flared aft skirt, deceleration and tumble motors, and a thermal curtain surrounding the first stage 7.2 area ratio nozzle. Developmental Flight Instrumentation (DFI) consisted of radiometers, calorimeters, pressure transducers and gas temperature probes installed on the aft skirt and nozzle to measure the base environments. In addition, thermocouples were also installed between the layers of the flexible thermal curtain to provide insight into the curtain response to the base environments and to assist in understanding curtain failure during reentry. Plume radiation environment predictions were generated by the Reverse Monte Carlo (RMC) code and the convective base heating predictions utilized heritage MSFC empirical methods. These predictions were compared to the DFI data and results from the flight videography. Radiation predictions agreed with the flight measured data early in flight but gauge failures prevented high altitude comparisons. The convective environment comparisons demonstrated the need to improve the prediction methodology; particularly for low altitude, local plume recirculation. The convective comparisons showed relatively good agreement at altitudes greater than 50,000 feet.

Mobley, B. L.↗
NASA NTRS2011

Ares I-X Best Estimated Trajectory and Comparison with Pre-Flight Predictions

The Ares I-X trajectory reconstruction produced best estimated trajectories of the flight test vehicle ascent through stage separation, and of the first and upper stage entries after separation. The trajectory reconstruction process combines on-board, ground-based, and atmospheric measurements to produce the trajectory estimates. The Ares I-X vehicle had a number of on-board and ground based sensors that were available, including inertial measurement units, radar, air- data, and weather balloons. However, due to problems with calibrations and/or data, not all of the sensor data were used. The trajectory estimate was generated using an Iterative Extended Kalman Filter algorithm, which is an industry standard processing algorithm for filtering and estimation applications. This paper describes the methodology and results of the trajectory reconstruction process, including flight data preprocessing and input uncertainties, trajectory estimation algorithms, output transformations, and comparisons with preflight predictions.

Karlgaard, Christopher D.↗
NASA NTRS2011

Seal Joint Analysis and Design for the Ares-I Upper Stage LOX Tank

The sealing capability of the Ares-I Upper Stage liquid oxygen tank-to-sump joint is assessed by analyzing the deflections of the joint components. Analyses are performed using three-dimensional symmetric wedge finite element models and the ABAQUS commercial finite element software. For the pressure loads and feedline interface loads, the analyses employ a mixed factor of safety approach to comply with the Constellation Program factor of safety requirements. Naflex pressure-assisted seals are considered first because they have been used successfully in similar seal joints in the Space Shuttle External Tank. For the baseline sump seal joint configuration with a Naflex seal, the predicted joint opening greatly exceeds the seal design specification. Three redesign options of the joint that maintain the use of a Naflex seal are studied. The joint openings for the redesigned seal joints show improvement over the baseline configuration; however, these joint openings still exceed the seal design specification. RACO pressure-assisted seals are considered next because they are known to also be used on the Space Shuttle External Tank, and the joint opening allowable is much larger than the specification for the Naflex seals. The finite element models for the RACO seal analyses are created by modifying the models that were used for the Naflex seal analyses. The analyses show that the RACO seal may provide sufficient sealing capability for the sump seal joint. The results provide reasonable data to recommend the design change and plan a testing program to determine the capability of RACO seals in the Ares-I Upper Stage liquid oxygen tank sump seal joint.

Phillips, Dawn R.↗
NASA NTRS2007

KSC Engineering Academy (KEA): Ares 1-X Overview

The presentation provides an overview of the ARES 1-X program. Videos include avionics ATVC actuator testing, GS damper retractor, GS vortex shedding, RoCS hot fire at WSTF, RoCS Peacekeeper tests, RoCS installation, thrust OSC, amd Ares 1-X fly through.

Ess, Bob↗
NASA NTRS2011

Simulation of Acoustics for Ares I Scale Model Acoustic Tests

The Ares I Scale Model Acoustics Test (ASMAT) is a series of live-fire tests of scaled rocket motors meant to simulate the conditions of the Ares I launch configuration. These tests have provided a well documented set of high fidelity acoustic measurements useful for validation including data taken over a range of test conditions and containing phenomena like Ignition Over-Pressure and water suppression of acoustics. To take advantage of this data, a digital representation of the ASMAT test setup has been constructed and test firings of the motor have been simulated using the Loci/CHEM computational fluid dynamics software. Results from ASMAT simulations with the rocket in both held down and elevated configurations, as well as with and without water suppression have been compared to acoustic data collected from similar live-fire tests. Results of acoustic comparisons have shown good correlation with the amplitude and temporal shape of pressure features and reasonable spectral accuracy up to approximately 1000 Hz. Major plume and acoustic features have been well captured including the plume shock structure, the igniter pulse transient, and the ignition overpressure.

Putnam, Gabriel↗
NASA NTRS2011

Ares I Scale Model Acoustic Tests Instrumentation for Acoustic and Pressure Measurements

The Ares I Scale Model Acoustic Test (ASMAT) was a development test performed at the Marshall Space Flight Center (MSFC) East Test Area (ETA) Test Stand 116. The test article included a 5% scale Ares I vehicle model and tower mounted on the Mobile Launcher. Acoustic and pressure data were measured by approximately 200 instruments located throughout the test article. There were four primary ASMAT instrument suites: ignition overpressure (IOP), lift-off acoustics (LOA), ground acoustics (GA), and spatial correlation (SC). Each instrumentation suite incorporated different sensor models which were selected based upon measurement requirements. These requirements included the type of measurement, exposure to the environment, instrumentation check-outs and data acquisition. The sensors were attached to the test article using different mounts and brackets dependent upon the location of the sensor. This presentation addresses the observed effect of the sensors and mounts on the acoustic and pressure measurements.

Vargas, Magda B.↗
NASA NTRS2011

Ares I Scale Model Acoustic Test Liftoff Acoustic Results and Comparisons

Conclusions: Ares I-X flight data validated the ASMAT LOA results. Ares I Liftoff acoustic environments were verified with scale model test results. Results showed that data book environments were under-conservative for Frustum (Zone 5). Recommendations: Data book environments can be updated with scale model test and flight data. Subscale acoustic model testing useful for future vehicle environment assessments.

Counter, Doug↗
NASA NTRS2011

Ares I Scale Model Acoustic Test Instrumentation for Acoustic and Pressure Measurements

Ares I Scale Model Acoustic Test (ASMAT) is a 5% scale model test of the Ares I vehicle, launch pad and support structures conducted at MSFC to verify acoustic and ignition environments and evaluate water suppression systems Test design considerations 5% measurements must be scaled to full scale requiring high frequency measurements Users had different frequencies of interest Acoustics: 200 - 2,000 Hz full scale equals 4,000 - 40,000 Hz model scale Ignition Transient: 0 - 100 Hz full scale equals 0 - 2,000 Hz model scale Environment exposure Weather exposure: heat, humidity, thunderstorms, rain, cold and snow Test environments: Plume impingement heat and pressure, and water deluge impingement Several types of sensors were used to measure the environments Different instrument mounts were used according to the location and exposure to the environment This presentation addresses the observed effects of the selected sensors and mount design on the acoustic and pressure measurements

Vargas, Magda B.↗
NASA NTRS2011

Validation and Simulation of Ares I Scale Model Acoustic Test - 2 - Simulations at 5 Foot Elevation for Evaluation of Launch Mount Effects

The Ares I Scale Model Acoustics Test (ASMAT) is a series of live-fire tests of scaled rocket motors meant to simulate the conditions of the Ares I launch configuration. These tests have provided a well documented set of high fidelity measurements useful for validation including data taken over a range of test conditions and containing phenomena like Ignition Over-Pressure and water suppression of acoustics. Expanding from initial simulations of the ASMAT setup in a held down configuration, simulations have been performed using the Loci/CHEM computational fluid dynamics software for ASMAT tests of the vehicle at 5 ft. elevation (100 ft. real vehicle elevation) with worst case drift in the direction of the launch tower. These tests have been performed without water suppression and have compared the acoustic emissions for launch structures with and without launch mounts. In addition, simulation results have also been compared to acoustic and imagery data collected from similar live-fire tests to assess the accuracy of the simulations. Simulations have shown a marked change in the pattern of emissions after removal of the launch mount with a reduction in the overall acoustic environment experienced by the vehicle and the formation of highly directed acoustic waves moving across the platform deck. Comparisons of simulation results to live-fire test data showed good amplitude and temporal correlation and imagery comparisons over the visible and infrared wavelengths showed qualitative capture of all plume and pressure wave evolution features.

Strutzenberg, Louise L.↗