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NASA NTRSDate not supplied

NASA’s Space Launch System: Comprehensive Test Program Leads to Mission Success during Artemis I Flight Test

NASA’s SLS (Space Launch System) rocket had a successful first launch on Nov. 16, 2022, sending an uncrewed Orion spacecraft to the Moon on the agency’s Artemis I mission. Ten 6U CubeSats were also deployed from SLS during the mission. Orbital insertion parameters, including insertion velocity and altitude, were within hundredths and tenths of a percent from predicted values, corroborating data collected from the individual elements that showed similar performance accuracy. While launch remains the main test – and Artemis I was a true test flight – to collect data, confirm and refine computer models, and validate hardware test data, multiple test programs led up to the first flight and enabled the historic launch. Additionally, SLS was designed from the beginning to be a crew-rated launch vehicle, and teams put the astronauts who will fly on it at the forefront of the development process. This paper and presentation will cover the SLS design and development programs that led to the successful Artemis I mission, and which have set the stage to send the first astronauts back to cislunar space since the Apollo 17 crew in 1972.

John Honeycutt↗
NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.

Michael W Lee↗
NASA NTRSDate not supplied

Development of Aerodynamic Loads Databases for the Space Launch System Booster Separation Event

Booster separation is a mission-critical event within the orbital ascent of the Space Launch System (SLS). The complexity of the engine plume-affected, multibody, supersonic aerodynamics is compounded by the large span of the likely trajectory space. Characterization of the multiple input, multiple output system requires a combination of wind tunnel testing and computational simulation, but additional data processing is also required before the sparse, high-fidelity data can be fused into a continuous database with acceptable uncertainty quantification. This paper outlines the state of this approach as it has been applied to the most recent SLS booster separation aerodynamic loads database: that of the Artemis II launch vehicle.

Michael Lee↗
NASA NTRS2016

NASA's Space Launch System: Developing the World's Most Powerful Solid Booster

NASA's Journey to Mars has begun. Indicative of that challenge, this will be a multi-decadal effort requiring the development of technology, operational capability, and experience. The first steps are under way with more than 15 years of continuous human operations aboard the International Space Station (ISS) and development of commercial cargo and crew transportation capabilities. NASA is making progress on the transportation required for deep space exploration - the Orion crew spacecraft and the Space Launch System (SLS) heavy-lift rocket that will launch Orion and large components such as in-space stages, habitat modules, landers, and other hardware necessary for deep-space operations. SLS is a key enabling capability and is designed to evolve with mission requirements. The initial configuration of SLS - Block 1 - will be capable of launching more than 70 metric tons (t) of payload into low Earth orbit, greater mass than any other launch vehicle in existence. By enhancing the propulsion elements and larger payload fairings, future SLS variants will launch 130 t into space, an unprecedented capability that simplifies hardware design and in-space operations, reduces travel times, and enhances the odds of mission success. SLS will be powered by four liquid fuel RS-25 engines and two solid propellant five-segment boosters, both based on space shuttle technologies. This paper will focus on development of the booster, which will provide more than 75 percent of total vehicle thrust at liftoff. Each booster is more than 17 stories tall, 3.6 meters (m) in diameter and weighs 725,000 kilograms (kg). While the SLS booster appears similar to the shuttle booster, it incorporates several changes. The additional propellant segment provides additional booster performance. Parachutes and other hardware associated with recovery operations have been deleted and the booster designated as expendable for affordability reasons. The new motor incorporates new avionics, new propellant grain, asbestos-free case insulation, a redesigned nozzle, streamlined manufacturing processes, and new inspection techniques. New materials and processes provide improved performance, safety, and affordability but also have led to challenges for the government/industry development team. The team completed its first full-size qualification motor test firing in early 2015. The second is scheduled for mid-2016. This paper will discuss booster accomplishments to date, as well as challenges and milestones ahead.

Priskos, Alex↗
NASA NTRS1992

In-flight Evaluation of Aerodynamic Predictions of an Air-launched Space Booster

Several analytical aerodynamic design tools that were applied to the Pegasus (registered trademark) air-launched space booster were evaluated using flight measurements. The study was limited to existing codes and was conducted with limited computational resources. The flight instrumentation was constrained to have minimal impact on the primary Pegasus missions. Where appropriate, the flight measurements were compared with computational data. Aerodynamic performance and trim data from the first two flights were correlated with predictions. Local measurements in the wing and wing-body interference region were correlated with analytical data. This complex flow region includes the effect of aerothermal heating magnification caused by the presence of a corner vortex and interaction of the wing leading edge shock and fuselage boundary layer. The operation of the first two missions indicates that the aerodynamic design approach for Pegasus was adequate, and data show that acceptable margins were available. Additionally, the correlations provide insight into the capabilities of these analytical tools for more complex vehicles in which the design margins may be more stringent.

Curry, Robert E.↗
NASA NTRS2003

Advanced Control Surface Seal Development at NASA GRC for Future Space Launch Vehicles

NASA s Glenn Research Center (GRC) is developing advanced control surface seal technologies for future space launch vehicles as part of the Next Generation Launch Technology project (NGLT). New resilient seal designs are currently being fabricated and high temperature seal preloading devices are being developed as a means of improving seal resiliency. GRC has designed several new test rigs to simulate the temperatures, pressures, and scrubbing conditions that seals would have to endure during service. A hot compression test rig and hot scrub test rig have been developed to perform tests at temperatures up to 3000 F. Another new test rig allows simultaneous seal flow and scrub tests at room temperature to evaluate changes in seal performance with scrubbing. These test rigs will be used to evaluate the new seal designs. The group is also performing tests on advanced TPS seal concepts for Boeing using these new test facilities.

Dunlap, Patrick H., Jr.↗
NASA NTRS2013

Space Launch System Advanced Development Office, FY 2013 Annual Report

The Advanced Development Office (ADO), part of the Space Launch System (SLS) program, provides SLS with the advanced development needed to evolve the vehicle from an initial Block 1 payload capability of 70 metric tons (t) to an eventual capability Block 2 of 130 t, with intermediary evolution options possible. ADO takes existing technologies and matures them to the point that insertion into the mainline program minimizes risk. The ADO portfolio of tasks covers a broad range of technical developmental activities. The ADO portfolio supports the development of advanced boosters, upper stages, and other advanced development activities benefiting the SLS program. A total of 34 separate tasks were funded by ADO in FY 2013.

Crumbly, C. M.↗
NASA NTRS2018

Methodologies for Verification and Validation of Space Launch System (SLS) Structural Dynamic Models

Responses to challenges associated with verification and validation (V&V) of Space Launch System (SLS) structural dynamics models are presented in this paper. Four methodologies addressing specific requirements for V&V are discussed. (1) Residual Mode Augmentation (RMA), which has gained acceptance by various principals in the NASA community, defines efficient and accurate FEM modal sensitivity models that are useful in test-analysis correlation and reconciliation and parametric uncertainty studies. (2) Modified Guyan Reduction (MGR) and Harmonic Reduction (HR, introduced in 1976), developed to remedy difficulties encountered with the widely used Classical Guyan Reduction (CGR) method, are presented. MGR and HR are particularly relevant for estimation of "body dominant" target modes of shell-type SLS assemblies that have numerous "body", "breathing" and local component constituents. Realities associated with configuration features and "imperfections" cause "body" and "breathing" mode characteristics to mix resulting in a lack of clarity in the understanding and correlation of FEM- and test-derived modal data. (3) Mode Consolidation (MC) is a newly introduced procedure designed to effectively "de-feature" FEM and experimental modes of detailed structural shell assemblies for unambiguous estimation of "body" dominant target modes. Finally, (4) Experimental Mode Verification (EMV) is a procedure that addresses ambiguities associated with experimental modal analysis of complex structural systems. Specifically, EMV directly separates well-defined modal data from spurious and poorly excited modal data employing newly introduced graphical and coherence metrics.

Coppolino, Robert N.↗
NASA NTRSDate not supplied

A Flexible Multibody Approach to Space Launch System Liftoff Pad Separation with Umbilical Disconnect

A flexible multibody dynamic framework is applied to the Space Launch System (SLS) liftoff Coupled Loads Analysis (CLA), enabling computational efficiencies and systematic inclusion of components and various nonlinearities. The objective of this work is to simulate the SLS liftoff transient pad separation event inclusive of umbilical disconnects. The vehicle stacking preloads and cryogenically induced preloads, due to the fueling of the Core Stage (CS), are integrated via specialized deformed coupling procedure to ensure full capture of the liftoff transient event. The Vehicle Stabilizer System (VSS) hydraulic struts are nonlinear and provide amplitude dependent damping, significantly contributing to the liftoff transient event. Ground Extensible Columns (EC) provide additional stiffness and preloads on the Mobile Launcher (ML), also significantly contributing to the liftoff transient. An advanced Henkel-Mar algorithm, with separation and re-contact, thus tracking the potential post separation re-contact between the booster aft skirt and ML, the umbilicals and vehicle, and ground EC separation. For this system level nonlinear dynamic simulation, the flexible multibody framework provides a systematic approach for the addition of component specific algorithms to enforce nonlinearities. This multibody framework is similar to an object-oriented programming language integrating classes of associated subroutines. As such, the complexities associated with the nonlinear CLA are greatly reduced, facilitating simplified bookkeeping as well as accelerating the execution of the nonlinear time-domain simulations.

Joel W Sills Jr.↗
NASA NTRSDate not supplied

A Flexible Multibody Approach to Space Launch System Liftoff Pad Separation with Umbilical Disconnect

A flexible multibody dynamic framework is applied to the Space Launch System(SLS)liftoff Coupled Loads Analysis(CLA), enabling computational efficiencies and systematic inclusion of component nonlinearities. This work simulates the SLS liftoff transient pad separation event inclusive of umbilical disconnects and preload strain energy release (twang). For this system level nonlinear dynamic simulation, the flexible multibody framework provides a systematic approach for the addition of component specific algorithms to enforce the subject nonlinearities. As such, the complexities associated with the nonlinear CLA are greatly reduced, facilitating simplified bookkeeping as well as accelerating the execution of the nonlinear time-domain simulations.

Joel W Sills↗
NASA NTRS2019

CHANGO: A Software Tool for Boost Stage Guidance of the Space Launch System Exploration Mission 1

The Day of Launch Initiation Load Update (DOLILU) System is the means by which the Space Launch System (SLS) Vehicle trajectory is designed, verified, and uploaded on the Day of Launch (DOL) in order to ensure a safe flight. Launch vehicles are designed to fly down a narrow angle of attack and sideslip angle corridor in order to keep them within structural load limits. The angle of attack and sideslip angle response to the launch vehicle experiences can vary significantly based upon the winds experienced on the DOL. SLS Boost Stage flight employs an open-loop guidance scheme through Solid Rocket Booster (SRB) separation. In the SLS open-loop scheme, the vehicle will fly a prescribed set of attitudes as a function of the change in altitude since launch. This set of reference attitude values and corresponding altitude reference independent values are designed with ground software using winds measured on the DOL with the goal of minimizing angle of attack and sideslip angle, thereby minimizing related ascent integrated vehicle structural loads. The table of Boost Stage attitude commands as a function of altitude gained since launch is called the chi table. A software tool called CHANGO (Chi Angle Optimizer) designs the Boost Stage chi table which is uploaded to the vehicle’s flight computer and used during ascent by the flight software (FSW). The wind and atmospheric conditions are measured prior to launch and pre-processed to become input to the CHANGO software along with a set of parameters developed in advance of the DOL. CHANGO’s target set consists of the heading and altitude rate at SRB separation determined well before launch by the Program to Optimize Simulated Trajectories (POST). CHANGO consists of a simplified three degree-of-freedom (3-DOF) simulation representing the SLS launch configuration. In general, the launch azimuth is strongly correlated with the heading at SRB separation, and the initial pitchover rate is strongly correlated with the altitude rate at SRB separation. CHANGO uses an adaptation of Powell’s method to vary the initial pitchover rate and launch azimuth to solve a 2-dimentional minimization problem. CHANGO’s trajectory simulation is phase-based, with flight events separating the phases. Each flight phase has different attitude alignment logic. CHANGO’s 3-DOF simulation starts when the vehicle’s thrust-to-weight ratio equals one, and ends at a pre-calculated SRB separation time.

Ahmad, Naeem↗
NASA NTRS2016

Space Launch System Booster Separation Aerodynamic Database Development and Uncertainty Quantification

The development of the aerodynamic database for the Space Launch System (SLS) booster separation environment has presented many challenges because of the complex physics of the ow around three independent bodies due to proximity e ects and jet inter- actions from the booster separation motors and the core stage engines. This aerodynamic environment is dicult to simulate in a wind tunnel experiment and also dicult to simu- late with computational uid dynamics. The database is further complicated by the high dimensionality of the independent variable space, which includes the orientation of the core stage, the relative positions and orientations of the solid rocket boosters, and the thrust lev- els of the various engines. Moreover, the clearance between the core stage and the boosters during the separation event is sensitive to the aerodynamic uncertainties of the database. This paper will present the development process for Version 3 of the SLS booster separa- tion aerodynamic database and the statistics-based uncertainty quanti cation process for the database.

Chan, David T.↗
NASA NTRS2021

Damage Tolerance of Candidate Sandwich Structure for the Space Launch System (SLS) Payload Adapter Fitting (PAF)

This Technical Memorandum presents results from a damage tolerance study undertaken in support of the payload adapter fitting (PAF) for the Space Launch System (SLS) program at NASA’s Marshall Space Flight Center (MSFC). The study consisted of determining the compression-after-impact (CAI) strength of candidate carbon/epoxy face sheet sandwich structure that has been identified for potential use to manufacture the PAF hardware. Two types of core material that have been considered for use on the PAF structure were used in this study. One was an aluminum honeycomb and the other was a Rohacell foam. Levels of barely visible impact damage (BVID) were determined for the types of sandwich structure tested in this study and this level of damage was used for CAI strength testing. It was found that the honeycomb core sandwich structure failed by face sheet failure and the foam core sandwich structure failed by core shear failure. CAI strength values were normalized by weight of the sandwich structure since lower mass is desirable for this structure.

sandwich structure↗
NASA NTRS2006

Trade Studies of Space Launch Architectures using Modular Probabilistic Risk Analysis

A top-down risk assessment in the early phases of space exploration architecture development can provide understanding and intuition of the potential risks associated with new designs and technologies. In this approach, risk analysts draw from their past experience and the heritage of similar existing systems as a source for reliability data. This top-down approach captures the complex interactions of the risk driving parts of the integrated system without requiring detailed knowledge of the parts themselves, which is often unavailable in the early design stages. Traditional probabilistic risk analysis (PRA) technologies, however, suffer several drawbacks that limit their timely application to complex technology development programs. The most restrictive of these is a dependence on static planning scenarios, expressed through fault and event trees. Fault trees incorporating comprehensive mission scenarios are routinely constructed for complex space systems, and several commercial software products are available for evaluating fault statistics. These static representations cannot capture the dynamic behavior of system failures without substantial modification of the initial tree. Consequently, the development of dynamic models using fault tree analysis has been an active area of research in recent years. This paper discusses the implementation and demonstration of dynamic, modular scenario modeling for integration of subsystem fault evaluation modules using the Space Architecture Failure Evaluation (SAFE) tool. SAFE is a C++ code that was originally developed to support NASA s Space Launch Initiative. It provides a flexible framework for system architecture definition and trade studies. SAFE supports extensible modeling of dynamic, time-dependent risk drivers of the system and functions at the level of fidelity for which design and failure data exists. The approach is scalable, allowing inclusion of additional information as detailed data becomes available. The tool performs a Monte Carlo analysis to provide statistical estimates. Example results of an architecture system reliability study are summarized for an exploration system concept using heritage data from liquid-fueled expendable Saturn V/Apollo launch vehicles.

Mathias, Donovan L.↗
NASA NTRS2015

CFD Simulations of the Space Launch System Ascent Aerodynamics and Booster Separation

This paper presents details of Computational Fluid Dynamic modeling of the Space Launch System during ascent. The primary focus of the paper is the flow simulation of the vehicle during ascent using the Overflow Navier-Stokes code. Computations of 739 first-stage flight conditions covering a range of Mach numbers, angles of attack, and roll angles were computed. The overset grid system contained 375 million grid points, and over 28 mil- lion CPU hours were used in the simulations. The simulations were run on the Pleiades supercomputer at the NASA Advanced Supercomputer Center at Ames Research Center. The data products from this work include integrated line-loads, surface pressure coefficients, venting pressures, and protuberance air-loads. Detailed comparisons were made of the aerodynamic performance predicted by Overflow and the wind-tunnel derived aero- dynamic database. A small number of the cases were run with two different turbulence models and with two differencing schemes. These results were used to quantify the sensitivity to the choice of the turbulence model and to the differencing scheme. The paper also introduces an effort to use the inviscid, unstructured Cartesian solver Cart3D to compute the aerodynamics during booster separation. Adaptive mesh refinement is being used to enable accurate simulations of sixteen booster-separation-motor plumes. The use of this tool is explored in preparation for building a booster-separation aerodynamic database.

Ascent Aerodynamics↗
NASA NTRSDate not supplied

Informing the Space Launch System Booster Separation Initial CFD Run Matrix with Observed Parametric Sensitivity

It currently requires significant computational cost to simulate the flow physics of the booster separation event on the Space Launch System. This comes from the large parametric space in which the event occurs, as pre-separation flight conditions and separated booster core-relative trajectories can vary. Functionally removing the risk of core-booster collision mandates careful assessment of the fluid dynamics in terms of several trajectory parameters. However, simulating the entire trajectory envelope is computationally intractable given the high parametric dimension. In order to reduce the uncertainty in the resulting low-parametric-resolution aerodynamic booster separation database, a data-driven approach was developed to select which breakpoints should be studied by simulations and experiments and which should be relegated to a regression-based interpolation procedure. This technique works by simulating cases where the flow physics are most sensitive to changes in the parameters and leaving the less parametrically sensitive regions for interpolation. The result is a booster separation run matrix whose computational cost is comparable to that of previous database generations but has lower interpolation errors.

SLS↗
NASA NTRSDate not supplied

Informing the Space Launch System Booster Separation Initial CFD Run Matrix with Observed Parametric Sensitivity

It currently requires significant computational cost to simulate the flow physics of the booster separation event on the Space Launch System. This comes from the large parametric space in which the event occurs, as pre-separation flight conditions and separated booster core-relative trajectories can vary. Functionally removing the risk of core-booster collision mandates careful assessment of the fluid dynamics in terms of several trajectory parameters. However, simulating the entire trajectory envelope is computationally intractable given the high parametric dimension. In order to reduce the uncertainty in the resulting low-parametric-resolution aerodynamic booster separation database, a data-driven approach was developed to select which breakpoints should be studied by simulations and experiments and which should be relegated to a regression-based interpolation procedure. This technique works by simulating cases where the flow physics are most sensitive to changes in the parameters and leaving the less parametrically sensitive regions for interpolation. The result is a booster separation run matrix whose computational cost is comparable to that of previous database generations but has lower interpolation errors.

SLS↗