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Advanced fabrication technology for high speed aircraft structures

An overview of the development of the weld-brazing process for fabricating Ti-6Al-4V skin-stiffened panels, a brazing process for fabricating Bsc/Al titanium honeycomb core panels, and the enhanced diffusion bonding (EDB) process for fabricating Ti-14Al-21Nb titanium aluminide structural elements are presented. Data presented include the shear strengths of full-scale weldbrazed Ti-6Al-4V skin stiffened and Bsc/Al titanium honeycomb core sandwich panels designed to meet the requirements of an upper wing panel on the NASA YF-12. These results verified that the materials, fabrication processes, and structural concepts were qualified for Mach 3 flight. Shear strengths of each of the panel concepts following flight service evaluation are also reported. Comparisons made with the cost and weight of the original wing panel indicated that the weldbrazed titanium panels resulted in a 15-20 percent cost savings and the brazed Bsc/Al panel showed a 30 percent weight savings. It was also shown that the strengths of the EDB joints were sufficient to develop stresses in the Ti-14Al-21Nb face sheets of the sandwich structure which were above the yield strength of the material.

Bales, T. T.↗

NASA's EOSDIS, Trust and Certification

NASA's Earth Observing System Data and Information System (EOSDIS) has been in operation since August 1994, managing most of NASA's Earth science data from satellites, airborne sensors, filed campaigns and other activities. Having been designated by the Federal Government as a project responsible for production, archiving and distribution of these data through its Distributed Active Archive Centers (DAACs), the Earth Science Data and Information System Project (ESDIS) is responsible for EOSDIS, and is legally bound by the Office of Management and Budgets circular A-130, the Federal Records Act. It must follow the regulations of the National Institute of Standards and Technologies (NIST) and National Archive and Records Administration (NARA). It must also follow the NASA Procedural Requirement 7120.5 (NASA Space Flight Program and Project Management). All these ensure that the data centers managed by ESDIS are trustworthy from the point of view of efficient and effective operations as well as preservation of valuable data from NASA's missions. Additional factors contributing to this trust are an extensive set of internal and external reviews throughout the history of EOSDIS starting in the early 1990s. Many of these reviews have involved external groups of scientific and technological experts. Also, independent annual surveys of user satisfaction that measure and publish the American Customer Satisfaction Index (ACSI), where EOSDIS has scored consistently high marks since 2004, provide an additional measure of trustworthiness. In addition, through an effort initiated in 2012 at the request of NASA HQ, the ESDIS Project and 10 of 12 DAACs have been certified by the International Council for Science (ICSU) World Data System (WDS) and are members of the ICSUWDS. This presentation addresses questions such as pros and cons of the certification process, key outcomes and next steps regarding certification. Recently, the ICSUWDS and Data Seal of Approval (DSA) organizations merged their Core Trustworthy Data Repositories Requirements and require that members be recertified every three years. Given the rigor with which NASA manages the ESDIS Project and the DAACs, the recertification through WDSDSA, while involving some additional work, is a relatively simple process.

Certification↗

Enhancing the NASA Expendable Launch Vehicle Payload Safety Review Process Through Program Activities

The safety review process for NASA spacecraft flown on Expendable Launch Vehicles (ELVs) has been guided by NASA-STD 8719.8, Expendable Launch Vehicle Payload Safety Review Process Standard. The standard focused primarily on the safety approval required to begin pre-launch processing at the launch site. Subsequent changes in the contractual, technical, and operational aspects of payload processing, combined with lessons-learned supported a need for the reassessment of the standard. This has resulted in the formation of a NASA ELV Payload Safety Program. This program has been working to address the programmatic issues that will enhance and supplement the existing process, while continuing to ensure the safety of ELV payload activities.

Palo, Thomas E.↗

Constraint-based scheduling

The GERRY scheduling system developed by NASA Ames with assistance from the Lockheed Space Operations Company, and the Lockheed Artificial Intelligence Center, uses a method called constraint based iterative repair. Using this technique, one encodes both hard rules and preference criteria into data structures called constraints. GERRY repeatedly attempts to improve schedules by seeking repairs for violated constraints. The system provides a general scheduling framework which is being tested on two NASA applications. The larger of the two is the Space Shuttle Ground Processing problem which entails the scheduling of all inspection, repair, and maintenance tasks required to prepare the orbiter for flight. The other application involves power allocations for the NASA Ames wind tunnels. Here the system will be used to schedule wind tunnel tests with the goal of minimizing power costs. In this paper, we describe the GERRY system and its applications to the Space Shuttle problem. We also speculate as to how the system would be used for manufacturing, transportation, and military problems.

Zweben, Monte↗

The Advanced Integration Matrix Project and Analog Sites: Difference or Duplication?

Several project teams have conducted Mars and Lunar mission simulations at analog sites and facilities over the past decade. These projects have a range of scope, participants, and objectives. NASA has provided many of these projects with funding, equipment, and personnel. Despite their variety, a consistent aim of these sites is advancing our capability to return to the Moon or to go to Mars. The Advanced Integration Matrix (AIM) Project was begun in 2002 with a corollary aim: that of advancing the technology needed for long duration human exploration of space. As a new project, it is prudent to ask and answer the question: "What does AIM offer to NASA that is distinct from what current and past analog sites offer?" The price tag for human spaceflight is high enough without needless duplication of efforts. The AIM Project concept is distinct from currently operating terrestrial analogs in three important ways. First, AIM is not strictly an analog site or facility; second, AIM is primarily focused on systems and integration issues; and finally, AIM is organizationally related to NASA s advanced development groups and subject to the rigors of the JSC Engineering Directorate s development process. The successful development of destination-independent, cost-effective, safe, and reliable long duration human exploration systems requires that NASA use both the analog sites and ground-based systems integration efforts. The Advanced Integration Matrix Project will not simply duplicate the former, but will give the agency the capability for the latter.

Wells, Kevin M.↗

Using NASA's Reference Architecture: Comparing Polar and Geostationary Data Processing Systems

The JPSS and GOES-R programs are housed at NASA GSFC and jointly implemented by NASA and NOAA to NOAA requirements. NASA's role in the JPSS Ground System is to develop and deploy the system according to NOAA requirements. NASA's role in the GOES-R ground segment is to provide Systems Engineering expertise and oversight for NOAA's development and deployment of the system. NASA's Earth Science Data Systems Reference Architecture is a document developed by NASA's Earth Science Data Systems Standards Process Group that describes a NASA Earth Observing Mission Ground system as a generic abstraction. The authors work within the respective ground segment projects and are also separately contributors to the Reference Architecture document. Opinions expressed are the author's only and are not NOAA, NASA or the Ground Projects' official positions.

Ullman, Richard↗

The Center Master Plan For NASA Glenn Research Center

The Center Master Plan for NASA Glenn Research Center is a comprehensive survey of NASA Glenn's current facility assets and a vision of how we see the facilities will change over the next 20 years in order to support the changing NASA Mission. This Center Master Plan is a vital management tool used by all organizations for making near term decisions and in future planning. During the summer of 2004, I worked with Joseph Morris, the Chief Architect in the Facilities Division, on beginning this Center Master Planning Process. The previous Master Plan was completed by the Center in 1985 and contained general information on the background of the facility as well as maps detailing environmental and historic records, land use, utilities, etc. The new Master Plan is required for the Center by NASA headquarters and will include similar types of information as used in the past. The new study will provide additional features including showing how individual buildings are linked to the programs and missions that they serve. The Master Plan will show practical future options for the facility s assets with a twenty year look ahead. The Plan will be electronically retrievable so that it becomes a communications tool for Center personnel. A Center Master Plan, although required, is very beneficial to NASA Glenn Research Center in aiding management with the future direction of the campus. Keeping up-to-date information and future plans readily available to all of NASA Glenn will insure that future real property development efficiently and effectively supports the missions camed out and supported by the Center. A Center Master Plan will also facilitate coordination with Center supported programs, stakeholders, and customers. In addition, it will provide a basis for cooperative planning with local and other governmental organizations and ultimately ensure that future budgets include the Center program needs described in the plan. This will ensure that development plans are safe, practical, and cost effective. To properly formulate any future plans, background information and research are required. Before bringing in a consultant to tackle the three year process anticipated to prepare a Center Master Plan, my job was to gather information on different organizations contributions to the NASA mission, their facility needs, consistent trends they observe, etc. I conducted numerous interviews with personnel such as Directorate Representatives, Division Chiefs, Branch Chiefs, System Managers and Building Managers. I documented the information I received from them for future use. I used the information to create various color-coded maps layering the different data. This was done with the ending objective being to collect the information and place it in a database that will be linked with Aperture (a computer program that generates color-coded map layers from database information) and made electronically retrievable to the Planning Consultant, NASA personnel, program stakeholders, and other governmental agencies. My goal this summer was to gather information and ideas appropriate for use in NASA Glenn Research Center s Master Plan and organize them for future application by the Planning Consultant. By the end of the summer, after completion of my goal, I will utilize my knowledge and create an array of preliminary future plans for the facility that can be passed along as a guidance tool.

Bigach, Kristin M.↗

Toward a space materials systems program

A program implementation model is presented which covers the early stages of space material processing and manufacturing. The model includes descriptions of major program elements, development and experiment requirements in space materials processing and manufacturing, and an integration of the model into NASA's long range plans as well as its evolution from present Materials Processing in Space plans.

Vontiesenhausen, G. F.↗

The challenge of the US Space Station

The U.S. Space Station program is described. The objectives of the present national space policy are reviewed. International involvement and commercial use of space are the two strategies involved in the development of the Space Station. The Space Station is to be a multifunctional, modular, permanent facility with manned and unmanned platforms. The functions of the Space Station for space research projects, such as material processing and electrophoresis, are examined. The infrastructure required for commercialization of space is analyzed. NASA's space policy aimed at stimulating space commerce is discussed. NASA's plans to reduce the financial, institutional, and technical risks of space research are studied.

Beggs, J. M.↗

The Hubble Space Telescope optical systems failure report

The findings of the Hubble Space Telescope Optical Systems Board of Investigation are reported. The Board was formed to determine the cause of the flaw in the telescope, how it occurred, and why it was not detected before launch. The Board conducted its investigation to include interviews with personnel involved in the fabrication and test of the telescope, review of documentation, and analysis and test of the equipment used in the fabrication of the telescope's mirrors. The investigation proved that the primary mirror was made in the wrong shape (a 0.4-wave rms wavefront error at 632.8 nm). The primary mirror was manufactured by the Perkin-Elmer Corporation (Hughes Danbury Optical Systems, Inc.). The critical optics used as a template in shaping the mirror, the reflective null corrector (RNC), consisted of two small mirrors and a lens. This unit had been preserved by the manufacturer exactly as it was during the manufacture of the mirror. When the Board measured the RNC, the lens was incorrectly spaced from the mirrors. Calculations of the effect of such displacement on the primary mirror show that the measured amount, 1.3 mm, accounts in detail for the amount and character of the observed image blurring. No verification of the reflective null corrector's dimensions was carried out by Perkin-Elmer after the original assembly. There were, however, clear indications of the problem from auxiliary optical tests made at the time. A special optical unit called an inverse null corrector, designed to mimic the reflection from a perfect primary mirror, was built and used to align the apparatus; when so used, it clearly showed the error in the reflective null corrector. A second null corrector was used to measure the vertex radius of the finished primary mirror. It, too, clearly showed the error in the primary mirror. Both indicators of error were discounted at the time as being themselves flawed. The Perkin-Elmer plan for fabricating the primary mirror placed complete reliance on the reflective null corrector as the only test to be used in both manufacturing and verifying the mirror's surface with the required precision. This methodology should have alerted NASA management to the fragility of the process and the possibility of gross error. Such errors had been seen in other telescope programs, yet no independent tests were planned, although some simple tests to protect against major error were considered and rejected. During the critical time period, there was great concern about cost and schedule, which further inhibited consideration of independent tests.

Source record↗

Reduction of solar vector magnetograph data using a microMSP array processor

The processing of raw data obtained by the solar vector magnetograph at NASA-Marshall requires extensive arithmetic operations on large arrays of real numbers. The objectives of this summer faculty fellowship study are to: (1) learn the programming language of the MicroMSP Array Processor and adapt some existing data reduction routines to exploit its capabilities; and (2) identify other applications and/or existing programs which lend themselves to array processor utilization which can be developed by undergraduate student programmers under the provisions of project JOVE.

Kineke, Jack↗

Life Cycle Systems Engineering Approach to NASA's 2nd Generation Reusable Launch Vehicle

The overall goal of the 2nd Generation RLV Program is to substantially reduce technical and business risks associated with developing a new class of reusable launch vehicles. NASA's specific goals are to improve the safety of a 2nd- generation system by 2 orders of magnitude - equivalent to a crew risk of 1 -in- 10,000 missions - and decrease the cost tenfold, to approximately $1,000 per pound of payload launched. Architecture definition is being conducted in parallel with the maturating of key technologies specifically identified to improve safety and reliability, while reducing operational costs. An architecture broadly includes an Earth-to-orbit reusable launch vehicle, on-orbit transfer vehicles and upper stages, mission planning, ground and flight operations, and support infrastructure, both on the ground and in orbit. The systems engineering approach ensures that the technologies developed - such as lightweight structures, long-life rocket engines, reliable crew escape, and robust thermal protection systems - will synergistically integrate into the optimum vehicle. Given a candidate architecture that possesses credible physical processes and realistic technology assumptions, the next set of analyses address the system's functionality across the spread of operational scenarios characterized by the design reference missions. The safety/reliability and cost/economics associated with operating the system will also be modeled and analyzed to answer the questions "How safe is it?" and "How much will it cost to acquire and operate?" The systems engineering review process factors in comprehensive budget estimates, detailed project schedules, and business and performance plans, against the goals of safety, reliability, and cost, in addition to overall technical feasibility. This approach forms the basis for investment decisions in the 2nd Generation RLV Program's risk-reduction activities. Through this process, NASA will continually refine its specialized needs and identify where Defense and commercial requirements overlap those of civil missions.

Thomas, Dale↗

Systems Engineering Approach to Technology Integration for NASA's 2nd Generation Reusable Launch Vehicle

The overall goal of the 2nd Generation RLV Program is to substantially reduce technical and business risks associated with developing a new class of reusable launch vehicles. NASA's specific goals are to improve the safety of a 2nd generation system by 2 orders of magnitude - equivalent to a crew risk of 1-in-10,000 missions - and decrease the cost tenfold, to approximately $1,000 per pound of payload launched. Architecture definition is being conducted in parallel with the maturating of key technologies specifically identified to improve safety and reliability, while reducing operational costs. An architecture broadly includes an Earth-to-orbit reusable launch vehicle, on-orbit transfer vehicles and upper stages, mission planning, ground and flight operations, and support infrastructure, both on the ground and in orbit. The systems engineering approach ensures that the technologies developed - such as lightweight structures, long-life rocket engines, reliable crew escape, and robust thermal protection systems - will synergistically integrate into the optimum vehicle. To best direct technology development decisions, analytical models are employed to accurately predict the benefits of each technology toward potential space transportation architectures as well as the risks associated with each technology. Rigorous systems analysis provides the foundation for assessing progress toward safety and cost goals. The systems engineering review process factors in comprehensive budget estimates, detailed project schedules, and business and performance plans, against the goals of safety, reliability, and cost, in addition to overall technical feasibility. This approach forms the basis for investment decisions in the 2nd Generation RLV Program's risk-reduction activities. Through this process, NASA will continually refine its specialized needs and identify where Defense and commercial requirements overlap those of civil missions.

Thomas, Dale↗

Systems Engineering Approach to Technology Integration for NASA's 2nd Generation Reusable Launch Vehicle

The overall goal of the 2nd Generation RLV Program is to substantially reduce technical and business risks associated with developing a new class of reusable launch vehicles. NASA's specific goals are to improve the safety of a 2nd-generation system by 2 orders of magnitude - equivalent to a crew risk of 1-in-10,000 missions - and decrease the cost tenfold, to approximately $1,000 per pound of payload launched. Architecture definition is being conducted in parallel with the maturating of key technologies specifically identified to improve safety and reliability, while reducing operational costs. An architecture broadly includes an Earth-to-orbit reusable launch vehicle, on-orbit transfer vehicles and upper stages, mission planning, ground and flight operations, and support infrastructure, both on the ground and in orbit. The systems engineering approach ensures that the technologies developed - such as lightweight structures, long-life rocket engines, reliable crew escape, and robust thermal protection systems - will synergistically integrate into the optimum vehicle. To best direct technology development decisions, analytical models are employed to accurately predict the benefits of each technology toward potential space transportation architectures as well as the risks associated with each technology. Rigorous systems analysis provides the foundation for assessing progress toward safety and cost goals. The systems engineering review process factors in comprehensive budget estimates, detailed project schedules, and business and performance plans, against the goals of safety, reliability, and cost, in addition to overall technical feasibility. This approach forms the basis for investment decisions in the 2nd Generation RLV Program's risk-reduction activities. Through this process, NASA will continually refine its specialized needs and identify where Defense and commercial requirements overlap those of civil missions.

Thomas, Dale↗

How to Do Science From an Engineering Organization

MSFC's Space Environments Team performs engineering support for a number of NASA spaceflight projects by defining the space environment, developing design requirements, supporting the design process, and supporting operations. Examples of this type of support are given including meteoroid environment work for the Jovian Icy Moon Orbiter mission, ionizing radiation support for the Chandra X-Ray Observatory, and astronomicaVgeophysica1 observation planning for International Space Station.

Suggs, Robert M.↗

Software Tools to Support the Assessment of System Health

This presentation provides an overview of three software tools that were developed by the NASA Glenn Research Center to support the assessment of system health: the Propulsion Diagnostic Method Evaluation Strategy (ProDIMES), the Systematic Sensor Selection Strategy (S4), and the Extended Testability Analysis (ETA) tool. Originally developed to support specific NASA projects in aeronautics and space, these software tools are currently available to U.S. citizens through the NASA Glenn Software Catalog. The ProDiMES software tool was developed to support a uniform comparison of propulsion gas path diagnostic methods. Methods published in the open literature are typically applied to dissimilar platforms with different levels of complexity. They often address different diagnostic problems and use inconsistent metrics for evaluating performance. As a result, it is difficult to perform a one ]to ]one comparison of the various diagnostic methods. ProDIMES solves this problem by serving as a theme problem to aid in propulsion gas path diagnostic technology development and evaluation. The overall goal is to provide a tool that will serve as an industry standard, and will truly facilitate the development and evaluation of significant Engine Health Management (EHM) capabilities. ProDiMES has been developed under a collaborative project of The Technical Cooperation Program (TTCP) based on feedback provided by individuals within the aircraft engine health management community. The S4 software tool provides a framework that supports the optimal selection of sensors for health management assessments. S4 is structured to accommodate user ]defined applications, diagnostic systems, search techniques, and system requirements/constraints. One or more sensor suites that maximize this performance while meeting other user ]defined system requirements that are presumed to exist. S4 provides a systematic approach for evaluating combinations of sensors to determine the set or sets of sensors that optimally meet the performance goals and the constraints. It identifies optimal sensor suite solutions by utilizing a merit (i.e., cost) function with one of several available optimization approaches. As part of its analysis, S4 can expose fault conditions that are difficult to diagnose due to an incomplete diagnostic philosophy and/or a lack of sensors. S4 was originally developed and applied to liquid rocket engines. It was subsequently used to study the optimized selection of sensors for a simulation ]based aircraft engine diagnostic system. The ETA Tool is a software ]based analysis tool that augments the testability analysis and reporting capabilities of a commercial ]off ]the ]shelf (COTS) package. An initial diagnostic assessment is performed by the COTS software using a user ]developed, qualitative, directed ]graph model of the system being analyzed. The ETA Tool accesses system design information captured within the model and the associated testability analysis output to create a series of six reports for various system engineering needs. These reports are highlighted in the presentation. The ETA Tool was developed by NASA to support the verification of fault management requirements early in the Launch Vehicle process. Due to their early development during the design process, the TEAMS ]based diagnostic model and the ETA Tool were able to positively influence the system design by highlighting gaps in failure detection, fault isolation, and failure recovery.

Melcher, Kevin J.↗

Expert systems for superalloy studies

There are many areas in science and engineering which require knowledge of an extremely complex foundation of experimental results in order to design methodologies for developing new materials or products. Superalloys are an area which fit well into this discussion in the sense that they are complex combinations of elements which exhibit certain characteristics. Obviously the use of superalloys in high performance, high temperature systems such as the Space Shuttle Main Engine is of interest to NASA. The superalloy manufacturing process is complex and the implementation of an expert system within the design process requires some thought as to how and where it should be implemented. A major motivation is to develop a methodology to assist metallurgists in the design of superalloy materials using current expert systems technology. Hydrogen embrittlement is disasterous to rocket engines and the heuristics can be very complex. Attacking this problem as one module in the overall design process represents a significant step forward. In order to describe the objectives of the first phase implementation, the expert system was designated Hydrogen Environment Embrittlement Expert System (HEEES).

Workman, Gary L.↗

Parallelization and Visual Analysis of Multidimensional Fields: Application to Ozone Production, Destruction, and Transport in Three Dimensions

The three-dimensional, spectral transport model used in the current project was first successfully integrated over climatological time scales by Dr. Guang Ping Lou for the simulation of atmospheric N2O using the United Kingdom Meteorological Office (UKMO) 4-dimensional, assimilated wind and temperature data set. A non-parallel, FORTRAN version of this integration using a fairly simple N2O chemistry package containing only photo-chemical reactions was used to verify our initial parallel model results. The integrations reproduced the gross features of the observed stratospheric climatological N2O distributions but also simulated the structure of the stratospheric Antarctic vortex and its evolution. Subsequently, Dr. Thomas Kindler, who produced much of the parallel version of our model, enlarged the N2O model chemistry package to include N2O reactions involving O(D-1) and also introduced assimilated wind data from NASA as well as UKMO. Initially, transport calculations without chemistry were run using Carbon-14 as a non-reactive tracer gas with the result that large differences in the transport properties of the two assimilated wind data sets were apparent from the resultant Carbon-14 distributions. Subsequent calculations for N2O, including its chemistry, with the two input winds data sets with verification from UARS satellite observations have refined the transport differences between the two such that the model's steering capabilities could be used to infer the correct climatological vertical velocity fields required to support the N2O observations. During this process, it was also discovered that both the NASA and the UKMO data contained spurious values in some of the higher frequency wave components, leading to incorrect local transport calculations and ultimately affecting the large scale properties of the model's N2O distributions, particularly at tropical latitudes. Subsequent model runs with wind data that had been filtered to remove some of the high frequency components produced much more realistic N2O distributions. During the past few months, the UKMO wind data base for a complete two-year period was processed into spectral form for model use. This new version of the input transport data base now includes complete temperature fields as well as the necessary wind data. This was done to facilitate advanced chemical calculations in the parallel model which often depend upon temperature. Additional UKMO data is being added as it becomes available.

Schwan, Karsten↗