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Developments on Low Cost Manufacturing Methods for Cylindrical Launch Vehicle Structures

Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.

Martin Stachulla

Computer-aided design of large-scale integrated circuits - A concept

Circuit design and mask development sequence are improved by using general purpose computer with interactive graphics capability establishing efficient two way communications link between design engineer and system. Interactive graphics capability places design engineer in direct control of circuit development.

Schansman, T. T.

Flat-plate solar array progress and plans

The emphasis of the Flat-plate Solar Array Project has been shifted from price goals and commercial development toward longer-term, higher risk, higher-potential-payoff opportunities. The revised objectives, status, and plans of the project are presented and technical progress is noted in the areas of: large-area sheet formation; silicon feedstock refinement; flat-plate module process sequence development; and engineering and environmental testing.

Callaghan, W. T.

MPST Software: grl_suppdoc

Due to the nature of the GRAIL mission, the GRAIL Mission Planning and Sequence Team (MPST) is required to generate ground and uplink products faster than ever done before. The existing correct_transmitter_min_dur tool that provides a similar function to grl_suppdoc lacks the ability to operate accurately or quickly enough to support the rapid turnaround required of the GRAIL MPST. The GRAIL MPST was required to build this new tool to facilitate the ground and uplink generation processes to meet a tight sequence development timeline. The grl_suppdoc tool enables the GRAIL MPST to generate automatically Deep Space Network (DSN) transmitter suppressions based on short uplinks that are found in the ground/modeled Predicted Events File (PEF). The grl_suppdoc script automatically generates applicable DSN uplink suppressions in the form of a Spacecraft Activity Sequence File (SASF) to protect the GRAIL project from short DSN uplink windows, which can be cause for operator error at the DSN antennas. Currently, no software exists that provides this functionality at the efficiency required for GRAIL sequence team operations. Compared to a manual process, this script reduces human error and saves considerable man-hours by automating and streamlining the mission planning and sequencing task for the GRAIL mission.

Call, Jared A.

Sources, Sinks, and the Distribution of OH in the Lower Stratosphere

Extensive measurement campaigns by the NASA ER-2 research aircraft have obtained a nearly pole-to-pole database of the species that control HOx (OH + HO2) chemistry. The wide dynamic range of these in situ measurements provides an opportunity to demonstrate empirically the mechanisms that control the HOx system. Measurements in the lower stratosphere show a remarkably tight correlation of OH concentration with the solar zenith angle (SZA). This correlation is nearly invariant over latitudes ranging from 70 S to 90 N and all seasons. An analysis of the production and loss of HOx in terms of the rate determining steps of reaction sequences developed by Johnston and Podolske and Johnston and Kinnison is used to clarify the behavior of the system and to directly test our understanding of the system with observations. Calculations using in situ measurements show that the production rate of HOx is proportional to O3 and ultraviolet radiation flux. The loss rate is proportional to the concentration and the partitioning of NOy (reactive nitrogen) and the concentration of HO2. In the absence of heterogeneous reactions, the partitioning of NOy is controlled by O3 and NOx and the concentration of HO2 is controlled by NOy and O3, so that the removal rate of OH is buffered against changes in the correlation of O3 and NOy. The heterogeneous conversion of NO2 to HNO3 is not an important net source of HO, because production and removal sequences are nearly balanced. Changes in NOy partitioning resulting from heterogeneous chemistry have a large effect on the loss rates of HOx, but little or no impact on the measured abundance of OH. The enhanced loss rates at high NO2/HNO3 are offset in the data set examined here by enhanced production rates resulting from increased photolysis rates resulting from the decreased O3 column above the ER-2.

Hanisco, T. F.

Development of Low-Noise High Value Chromium Silicide Resistors for Cryogenic Detector Applications

Extremely high sensitivity detectors, such as silicon bolometers are required in many NASA missions for detection of photons from the x-ray to the far infrared regions. Typically, these detectors are cooled to well below the liquid helium (LHe) temperature (4.2 K) to achieve the maximum detection performance. As photoconductors, they are generally operated with a load resistor and a pre-set bias voltage, which is then coupled to the input gate of a source-follower Field Effect Transistor (FET) circuit. It is imperative that the detector system signal to noise performance be limited by the noise of the detector and not by the noise of the external components. The load resistor value is selected to optimize the detector performance. These two criteria tend to be contradictory in that these detectors require load resistors in the hundreds of megaohms, which leads to a higher Johnson noise. Additionally, the physical size of the resistor must be small for device integration as required by such missions as the NASA High Resolution Airborne Wide-Band Camera (HAWC) instrument and the Submillimeter High Angular Resolution Camera (SHARC) for the Caltech Submillimeter Observatory (CSO). We have designed, fabricated and characterized thin film resistors using a CrSi/TiW/Al metal system on optical quality quartz substrates. The resistor values range from 100 megaohms to over 650 megaohms and are Johnson noise limited at LHe temperatures. The resistor film is sputtered with a sheet resistance ranging from 300 ohms to 1600 ohms and the processing sequence developed for these devices allows for chemically fine tuning the sheet resistance in-situ. The wafer fabrication process was of sufficiently high yield (>80%) providing clusters of good resistors for integrated multiple detector channels, a very important feature in the assembly of these two instruments.

Jhabvala, Murzy

The Viking decelerator system - An overview.

The Viking mission to place an instrumented lander on Mars in 1976 includes an aerodynamic decelerator as part of the landing sequence. Development of the decelerator, a single-stage mortared disk-gap-band parachute, began in 1965 for the Voyager project and culminated in the flight qualification of the decelerator system for the Viking mission in 1972. This paper summarizes the research, development, and qualification effort. The special operating conditions and the constraints imposed by the Viking mission and the Mars atmosphere, their effects on the decelerator system, and the solution of the resulting technical problems are briefly described.

Gillis, C. L.

Centaur propellant acquisition system study

A study was performed to determine the desirability of replacing the hydrogen peroxide settling system on the Centaur D-1S with a capillary acquisition system. A comprehensive screening was performed to select the most promising capillary device fluid acquisition, thermal conditioning, and fabrication techniques. Refillable start baskets and bypass feed start tanks were selected for detailed design. Critical analysis areas were settling and refilling, start sequence development with an initially dry boost pump, and cooling the fluid delivered to the boost pump in order to provide necessary net position suction head (NPSH). Design drawings were prepared for the start basket and start tank concepts for both LO2 and LH2 tanks. System comparisons indicated that the start baskets using wicking for thermal conditioning, and thermal subcooling for boost pump NPSH, are the most desirable systems for future development.

Blatt, M. H.

Centaur propellant acquisition system

The desirability of replacing the hydrogen peroxide settling system of the Centaur D-1S with a capillary acquisition system was evaluated. A comprehensive screening was performed to select the most promising capillary device fluid acquisition, thermal conditioning, and fabrication techniques. Refillable start baskets and bypass feed start tanks were selected for detailed design. Critical analysis areas were settling and refilling, start sequence development with an initially dry boost pump, and cooling the fluid delivered to the boost pump to provide the necessary net positive suction head (NPSH). Design drawings were prepared for start basket and start tank concepts for both the liquid oxygen and liquid hydrogen tanks. System comparisons indicated that the start baskets using wicking flow for thermal conditioning, and thermal subcooling for providing boost pump NPSH, are the most desirable systems for future Centaur acquisition system development.

Blatt, M. H.

Flat-plate solar array progress and plans

The Flat-Plate Solar Array Project (FSA), sponsored by the U.S. Department of Energy (DOE) and managed by the Jet Propulsion Laboratory (JPL), has achieved progress in a broad range of technical activities since that reported at the Fourth European Communities Conference. A particularly important analysis has been completed recently which confirms the adoption into practice by the U.S. Photovoltaic (PV Industry, of all the low-cost module technology elements proposed at the 16th Project Integration Meeting for a $2.80/Wp (1980 U.S. Dollars) design approach in the fall of 1980. This work presents along with a projection, using the same techniques, for what is believed to be a very credible ribbon-based module design for less that $0.55/Wp (1980 U.S. Dollars). Other areas to be reported upon include low-cost Si feedstock refinement; ribbon growth; process sequence development for cells; environmental isolation; engineering science investigations; and module testing progress.

Callaghan, W. T.

On recent advances and future research directions for computational fluid dynamics

This paper highlights some recent accomplishments regarding CFD numerical algorithm constructions for generation of discrete approximate solutions to classes of Reynolds-averaged Navier-Stokes equations. Following an overview of turbulent closure modeling, and development of appropriate conservation law systems, a Taylor weak-statement semi-discrete approximate solution algorithm is developed. Various forms for completion to the final linear algebra statement are cited, as are a range of candidate numerical linear algebra solution procedures. This development sequence emphasizes the key building blocks of a CFD RNS algorithm, including solution trial and test spaces, integration procedure and added numerical stability mechanisms. A range of numerical results are discussed focusing on key topics guiding future research directions.

Baker, A. J.

The environmental control and life-support system for a lunar base: What drives its design

The purpose of this paper is to identify and briefly discuss some of the ground rules and mission scenario details that become drivers of the environmental control and life support (ECLS) system design and of the logistics related to the design. This paper is written for mission planners and non-ECLS system engineers to inform them of the details that will be important to the ECLS engineer when the design phase is reached. In addition, examples illustrate the impact of some selected mission characteristics on the logistics associated with ECLS systems. The last section of this paper focuses on the ECLS system technology development sequence and highlights specific portions that need emphasis.

Hypes, Warren D.

Low Cost Uplink Concepts

In order to minimize the cost of developing sequences of commands for small, low cost missions, a cost effective set of uplink tools used in conjunction with an appropriate ground system architecture (including a multi-mission operations facility) must be utilized.

ground system architecture generic uplink process

Asteroid 5535 Annefrank size, shape, and orientation: Stardust first results

The NASA Discovery Stardust spacecraft flew by the main belt asteroid 5535 Annefrank at a distance of 3100 km and a speed of 7.4 km/s in November 2002 to test the encounter sequence developed for its primary science target, the comet 81P/Wild2. During this testing, over 70 images of Annefrank were obtained, taken over a phase angle range from 40 to 140 degrees.

Asteroids NASA Stardust Mission

Rover Sequencing and Visualization Program

The Rover Sequencing and Visualization Program (RSVP) is the software tool for use in the Mars Exploration Rover (MER) mission for planning rover operations and generating command sequences for accomplishing those operations. RSVP combines three-dimensional (3D) visualization for immersive exploration of the operations area, stereoscopic image display for high-resolution examination of the downlinked imagery, and a sophisticated command-sequence editing tool for analysis and completion of the sequences. RSVP is linked with actual flight-code modules for operations rehearsal to provide feedback on the expected behavior of the rover prior to committing to a particular sequence. Playback tools allow for review of both rehearsed rover behavior and downlinked results of actual rover operations. These can be displayed simultaneously for comparison of rehearsed and actual activities for verification. The primary inputs to RSVP are downlink data products from the Operations Storage Server (OSS) and activity plans generated by the science team. The activity plans are high-level goals for the next day s activities. The downlink data products include imagery, terrain models, and telemetered engineering data on rover activities and state. The Rover Sequence Editor (RoSE) component of RSVP performs activity expansion to command sequences, command creation and editing with setting of command parameters, and viewing and management of rover resources. The HyperDrive component of RSVP performs 2D and 3D visualization of the rover s environment, graphical and animated review of rover-predicted and telemetered state, and creation and editing of command sequences related to mobility and Instrument Deployment Device (IDD) operations. Additionally, RoSE and HyperDrive together evaluate command sequences for potential violations of flight and safety rules. The products of RSVP include command sequences for uplink that are stored in the Distributed Object Manager (DOM) and predicted rover state histories stored in the OSS for comparison and validation of downlinked telemetry. The majority of components comprising RSVP utilize the MER command and activity dictionaries to automatically customize the system for MER activities. Thus, RSVP, being highly data driven, may be tailored to other missions with minimal effort. In addition, RSVP uses a distributed, message-passing architecture to allow multitasking, and collaborative visualization and sequence development by scattered team members.

Cooper, Brian

Independent Verification and Validation (IV and V) - Adding Mission Assurance to NASA Flight Software

The NASA Independent Verification and Validation (IV&V) Facility objective is to identify potential defects in flight software using independent analysis techniques. This paper describes the tailored IV&V techniques that have been developed in support of critical interactions on the Mars Science Laboratory (MSL) project, scheduled to launch in November, 2011. The IV&V techniques for interface analysis use independently developed sequence diagrams of critical scenarios. The results from these analyses have had a positive impact on the requirements flow down, consistency amongst MSL requirements and identification of missing requirements. The results of these analyses and the positive impact to the MSL project are provided.

performance evaluation