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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Advanced Lightweight Polymeric Foam Thermal Protection for Space Launch Vehicles

Lightweight thermal protective materials are essential for temperature regulation during ascent of space launch vehicles, especially for expendable launch vehicles and cryogenic propellant tanks. Among the lightest thermal protective materials commonly in use is polymeric foam, in the form of pour foam or spray-on foam insulation (SOFI). Foam processing is rapid, can accommodate large-scale or small-scale challenging geometries easily, and can be used in a climate controlled or non-climate-controlled setting. Application systems can be fixed or portable. Use-temperatures of foam range from cryogenic to those that will ablate the material.

TPS↗
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 NTRS2018

Estimating Software Reliability for Space Launch Vehicles in Probabilistic Risk Assessment (PRA)

It is acutely recognized in the Probabilistic Risk Assessment (PRA) field that software plays a defining role in overall system reliability for all modern systems across a wide variety of industries. Regardless of whether the software is embedded firmware for working components or elements, part of a Human-Machine-Interface, or automated command and control logic, the success of the software to fulfill its function under nominal and off-nominal environments will be a dominant contributor to system reliability. It is also recognized that software reliability prediction and estimation is one of the more challenging and questionable aspects of any PRA or system analyses due to the nature of software and its integration with physics based systems. Irrespective of this dichotomy, any incorporation of software reliability methods requires that the contributions are accountable, quantitative, and tractable. This paper provides a brief overview of software reliability methods, establishes some minimum requirements that the methods should incorporate for completeness, and provides a logic structure for applying software reliability. Model resolution will be discussed that supports current testing plans and trade studies. We will provide initial recommendations for use in the National Aeronautics and Space Administration (NASA) PRA and present a future dynamic option for software and PRA. Space Launch Vehicle software is recognized to be reliable in static conditions, yet relatively vulnerable to a set of failure modes in changing environments/flight phases. Two quantitative methods were chosen to incorporate software reliability into a Space Launch Vehicle PRA accounting for phase adjustments. One method predicts latent software failure using statistical methods, and the second provides estimates of coding errors and software operating system failures based on test and historical data. Software uncertainty will also be discussed. It is determined that recommendations for PRA software reliability should be modeled at the software module level where multiple software components compose a module and combinations of the software architecture can lead to a functional failure.

Steven D. Novack↗
NASA NTRS2018

Estimating Software Reliability for Space Launch Vehicles in Probabilistic Risk Assessment (PRA)

It is acutely recognized in the Probabilistic Risk assessment (PRA) field that software plays a defining role in overall system reliability for all modern systems across a wide variety of industries. Regardless if the software is embedded firmware for working components or elements, part of a Human-Machine-Interface, or automated command and control logic, the success of the software to fulfill its function under nominal and off-nominal environments will be a dominant contributor to system reliability. It is also recognized that software reliability prediction and estimation is one of the more challenging and questionable aspects of any PRA or system analyses due to the nature of software and its integration with physics based systems. Irrespective of this dichotomy, any incorporation of software reliability methods requires that the contributions are accountable, quantitative, and tractable. This paper provides a brief overview of software reliability methods, establishes some minimum requirements that the methods should incorporate for completeness, and provides a logic structure for applying software reliability. Model resolution will be discussed that supports current testing plans and trade studies. We will provide initial recommendations for use in the NASA PRA and present a future dynamic option for software and PRA. Space Launch Vehicle Software is recognized to be reliable in static conditions, yet relatively vulnerable to a set of failure modes in changing environments/flight phases. Two quantitative methods were chosen to incorporate software reliability into a Space Launch Vehicle PRA accounting for phase adjustments. One method predicts latent software failure using statistical methods, and the second provides estimates of coding errors and software operating system failures based on test and historical data, respectively. Software uncertainty will also be discussed. We determined that recommendations for PRA software reliability should be modeled at the software module level where multiple software components compose a module and combinations of the software architecture can lead to a functional failure.

Novack, Steven↗
NASA NTRS2008

L1 Adaptive Control Law for Flexible Space Launch Vehicle and Proposed Plan for Flight Test Validation

This paper explores application of the L1 adaptive control architecture to a generic flexible Crew Launch Vehicle (CLV). Adaptive control has the potential to improve performance and enhance safety of space vehicles that often operate in very unforgiving and occasionally highly uncertain environments. NASA s development of the next generation space launch vehicles presents an opportunity for adaptive control to contribute to improved performance of this statically unstable vehicle with low damping and low bending frequency flexible dynamics. In this paper, we consider the L1 adaptive output feedback controller to control the low frequency structural modes and propose steps to validate the adaptive controller performance utilizing one of the experimental test flights for the CLV Ares-I Program.

Kharisov, Evgeny↗
NASA NTRS2017

Analysis of Rawinsonde Spatial Separation for Space Launch Vehicle Applications at the Eastern Range

Spatial separation of HR rawinsonde data is directly correlated with climatological tropospheric wind environment over ER. Stronger winds in the winter result in further downrange drift. Lighter winds in the summer result in the less horizontal drift during ascent. Maximum downrange distance can exceed 200 km during winter months. Data could misrepresent the environment the vehicle will experience during ascent. PRESTO uses all available data sources to produce the best representative, vertically complete atmosphere for launch vehicle DOL operations. Capability planned for use by NASA Space Launch System vehicle's first flight scheduled for Fall 2018.

Decker, Ryan K.↗
NASA NTRS2019

A Comparison of Boundary Layer Wind Profilers for Use with Space Launch Vehicles

The United States Air Force (USAF) operates two space launch ranges, the Eastern Range (ER) and the Western Range (WR). The ER is primarily located at the Cape Canaveral Air Force Station (CCAFS) and the WR is located at the Vandenberg Air Force Base (VAFB). Multiple systems are used to measure the atmosphere at both ranges, including a suite of 915-Mhz (megahertz) Doppler Radar Wind Profilers (DRWP). The 915-MHz DRWPs are used to measure winds in the lowest few kilometers of the atmosphere, primarily in the boundary layer. Boundary layer winds are important during launch, and observations of such can be used as input to toxic dispersion and low-level abort trajectory models. However, these 915-MHz systems are nearing the end of their service life and need to be replaced by systems with similar, or greater, capabilities. The USAF funded evaluations of two systems: a 449-MHz DRWP and a Lidar. Both systems were stationed at each range for separate periods of approximately three months from November 2017 through May 2018. The USAF also funded NASA’s Marshall Space Flight Center (MSFC) Natural Environments Branch (NE) to evaluate wind output from the two systems. MSFC NE conducted analysis to demonstrate the system’s wind accuracy relative to measurements from the Automated Meteorological Profiling System (AMPS) (Divers et al., 2000), data availability, and Effective Vertical Resolution (EVR).

Orcutt, John M.↗
NASA NTRS1993

Demonstration of the Dynamic Flowgraph Methodology using the Titan 2 Space Launch Vehicle Digital Flight Control System

Dynamic Flowgraph Methodology (DFM) is a new approach developed to integrate the modeling and analysis of the hardware and software components of an embedded system. The objective is to complement the traditional approaches which generally follow the philosophy of separating out the hardware and software portions of the assurance analysis. In this paper, the DFM approach is demonstrated using the Titan 2 Space Launch Vehicle Digital Flight Control System. The hardware and software portions of this embedded system are modeled in an integrated framework. In addition, the time dependent behavior and the switching logic can be captured by this DFM model. In the modeling process, it is found that constructing decision tables for software subroutines is very time consuming. A possible solution is suggested. This approach makes use of a well-known numerical method, the Newton-Raphson method, to solve the equations implemented in the subroutines in reverse. Convergence can be achieved in a few steps.

Yau, M.↗
NASA NTRS2019

Laboratory Scale Testing of Ignition Overpressure for Space Vehicle Launch Pad Environments

A scale model of a NASA representative space vehicle is used to develop a refined estimate of the transient pressure loads that are expected to form at the base of the vehicle in the event of a vapor cloud explosion. Flammable vapor clouds are known to form prior to engine startup due to the significant amount of unburned hydrogen that is ejected from the combustion chamber. In the event of a vapor cloud explosion, the vehicle and payload must be able to withstand the resulting overpressure waves. The study comprises an array of pressure sensors located along the base heat shield of the scale model space vehicle as well as the interior wall and throat plug plane of the solid rocket booster. A spark source generator is used to simulate the overpressure wave produced by a vapor cloud explosion while measurements are acquired with and without the effect of a mobile launcher. Time- resolved schlieren images of the simulated vapor cloud explosion reveal the path and impact of both the initial wave and several reflected waves on the various components at the base of the space vehicle. In some instances, the reflected waves superpose to create waves that are higher in amplitude than the initial overpressure wave. A time frequency analysis of the pressure waveforms measured inside the solid rocket booster reveal a ring down tone corresponding to a standing wave that is four times the length of the nozzle.

Tinney, Charles E.↗
NASA NTRS2019

Development of Composite Sandwich Bonded Longitudinal Joints for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. The paper includes details of the design, analysis, materials, manufacturing, and testing of sub-element joint test articles to test the capability of the joint design. The test results show that the composite longitudinal bonded joint design significantly exceeds the design loads with a 2.0 factor of safety. Analysis pre-test failure predictions for all sub-element bonded joint test coupons were all within 10% of the average test coupon failure load. This testing and analysis provides confidence in the potential use of composite bonded joints for future launch vehicle structures.

Segal, Kenneth N.↗
NASA NTRSDate not supplied

Testing and Analysis Correlation of a Large-Scale Composite Sandwich Longitudinal Bonded Joint for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. This paper reports on the large-scale longitudinal bonded joint test articles that were fabricated and tested under axial compressive loading conditions to test the capability of the bonded joint design for buckling and joint failure. Test and analysis correlation of an as-manufactured undamaged longitudinal bonded joint panel are presented in the paper for tests to the onset of buckling and panel failure. Analysis predictions for buckling initiation and panel failure were both within 10% of the longitudinal bonded joint panel test results. This testing and analysis provide confidence in the potential use of composite bonded joints for future launch vehicle structures.

David W Sleight↗
NASA NTRSDate not supplied

An Overview of the Meteorological Instrumentation Utilized for the Design and Operations of Space Launch Vehicles

One of the first hurdles a space vehicle must overcome is the ability to successfully traverse Earth’s atmosphere. In order to achieve this goal, there must exist both climatological and real-time atmospheric data from the surface to the Karman line. The Natural Environments Branch at the National Aeronautics and Space Administration’s Marshall Space Flight Center utilizes both traditional and specialized meteorological instrumentation to aide in both the design and operations of launch vehicles. Weather balloons measuring thermodynamic and wind data from 0 - 70 kft are an example of the more traditional instrumentation. While the Tropospheric Doppler Radar Weather Profiler that measures winds from roughly 5 kft – 60 kft every five minutes is an example of a more specialized instrument. Other instruments include: 915 MHz Doppler Radar Wind Profilers, rain gauges, meteorological towers, lightning detection networks, Automated Weather Observing System stations, Mobile Launcher weather stations, and more. This presentation will give a high-level overview of which instruments are utilized, how the data are acquired, and how the data are ultimately used in design and/or operations.

Nathan L. Curtis↗
NASA NTRS2015

Common Cause Failure Modeling in Space Launch Vehicles

Common Cause Failures (CCFs) are a known and documented phenomenon that defeats system redundancy. CCFs are a set of dependent type of failures that can be caused for example by system environments, manufacturing, transportation, storage, maintenance, and assembly. Since there are many factors that contribute to CCFs, they can be reduced, but are difficult to eliminate entirely. Furthermore, failure databases sometimes fail to differentiate between independent and dependent CCF. Because common cause failure data is limited in the aerospace industry, the Probabilistic Risk Assessment (PRA) Team at Bastion Technology Inc. is estimating CCF risk using generic data collected by the Nuclear Regulatory Commission (NRC). Consequently, common cause risk estimates based on this database, when applied to other industry applications, are highly uncertain. Therefore, it is important to account for a range of values for independent and CCF risk and to communicate the uncertainty to decision makers. There is an existing methodology for reducing CCF risk during design, which includes a checklist of 40+ factors grouped into eight categories. Using this checklist, an approach to produce a beta factor estimate is being investigated that quantitatively relates these factors. In this example, the checklist will be tailored to space launch vehicles, a quantitative approach will be described, and an example of the method will be presented.

Hark, Frank↗
NASA NTRSDate not supplied

A Modern Load Relief Guidance Scheme for Space Launch Vehicles

Launch vehicle load relief algorithms are concerned with realizing a reduction of transient bending moments near maximum dynamic pressure. Traditional approaches to load relief typically use inner-loop acceleration feedback to reduce the wind-induced angle of attack. When implemented in the inner loop, load relief bandwidth is necessarily limited by the achievable stability margins, and when acceleration feedback is employed, by the uncertainty associated with structural modes that couple with the body-mounted accelerometer. The structure of inner loop load relief increases the dimensionality of the flight control gain and filter optimization problem. Most importantly, classical load relief laws do not take advantage of high-rate and high-accuracy GPS-aided inertial velocity data that is readily available from modern strap down IMUs. In this paper, a novel load relief guidance scheme is described that uses direct angle-of-attack feedback in a clever mechanization. The steering commands are determined by examining the wind-perturbed dynamics of a launch vehicle with respect to a gravity turn ascent trajectory. An angle of attack estimate is derived from GPS-aided inertial data and pre-launch range wind measurements, and it is shown that a reduction worst-case rigid-body loads can be realized without requiring air data. The algorithm also includes a high-rate navigation data preprocessing scheme that operates directly on the IMU delta-theta and delta-velocity measurements in order to produce a filtered acceleration estimate at the vehicle center of mass. The outer-loop guidance scheme simplifies the design process for the classical inner-loop autopilot. Algorithm performance is demonstrated using Monte Carlo analysis of a representative liquid booster in a production high fidelity launch vehicle simulation.

NESC↗
NASA NTRS2004

High Temperature Propulsion System Structural Seals for Future Space Launch Vehicles

High temperature, dynamic structural seals are required in advanced hypersonic engines to seal the perimeters of movable engine ramps for efficient, safe operation in high heat flux environments at temperatures from 2000 to 2500 F. NASA GRC became involved in the development of high temperature structural seals in the late 1980 s and early 1990 s during the National Aerospace Plane (NASP) program. Researchers at GRC carried out an in-house program to develop seals for the NASP hypersonic engine and oversaw industry efforts for airframe and propulsion system seal development for this vehicle. The figure shows one of the seal locations in the NASP engine. Seals were needed along the edges of movable panels in the engine to seal gaps between the panels and adjacent engine sidewalls. Seals developed during the NASP program met many requirements but fell short of leakage, durability, and resiliency goals. Due to program termination the seals could not be adequately matured. To overcome these shortfalls, GRC is currently developing advanced seals and seal preloading devices for the hypersonic engines of future space vehicles as part of NASA s Next Generation Launch Technology (NGLT) program.

Dunlap, Patrick H., Jr.↗
NASA NTRS1998

Friction Plug Welding of 2195 Al-Cu-Li for Manned Space Launch Vehicles

Friction Plug Welding (FPW) is currently being studied for use on the Space Transportation System's Super Light weight External Tank. This process has demonstrated the potential to solve on of Al-Li 2195's most challenging aspects repair welding. The current weld repair process is successful, but is labor intensive and inconsistent. Technology advances in FPW and tooling designs will be presented. The results of plug welding optimization, production implementation, considerations and cost benefit analysis are discussed. Among the tests to be discussed are tensile, surface crack tension, simulated service, liquid oxygen compatibility results and methods of repairing plug repairs. Tool design, computerized process control equipment and database record retention and analyses may also be addressed.

Takeshita, Riki P.↗
NASA NTRS1995

Heavy-lift vehicle-launched Space Station method and apparatus

Methods and apparatus are provided for a single heavy-lift launch to place a complete, operational space station on-orbit. A payload including the space station takes the place of a shuttle orbiter using the launch vehicle of the shuttle orbiter. The payload includes a forward shroud, a core module, a propulsion module, and a transition module between the core module and the propulsion module. The essential subsystems are preintegrated and verified on Earth. The core module provides means for attaching international modules with minimum impact to the overall design. The space station includes six control moment gyros for selectably operating in either LVLH (local-vertical local-horizontal) or SI (solar inertial) flight modes.

Wade, Donald C.↗
NASA NTRS1993

Heavy-lift vehicle-launched Space Station method and apparatus

Methods and apparatus are provided for a single heavylift launch to place a complete, operational space station on-orbit. A payload including the space station takes the place of a Shuttle Orbiter using the launch vehicle of the Shuttle Orbiter. The payload includes a forward shroud, a core module, a propulsion module, and a transition module between the core module and the propulsion module. The essential subsystems are pre-integrated and verified on Earth. The core module provides means for attaching international modules with minimum impact to the overall design. The space station includes six control moment gyros for selectably operating in either LVLH (local-vertical local-horizontal) or SI (solar inertial) flight modes.

Wade, Donald C.↗