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Executive Summary of Propulsion on the Orion Abort Flight-Test Vehicles

The National Aeronautics and Space Administration Orion Flight Test Office was tasked with conducting a series of flight tests in several launch abort scenarios to certify that the Orion Launch Abort System is capable of delivering astronauts aboard the Orion Crew Module to a safe environment, away from a failed booster. The first of this series was the Orion Pad Abort 1 Flight-Test Vehicle, which was successfully flown on May 6, 2010 at the White Sands Missile Range in New Mexico. This report provides a brief overview of the three propulsive subsystems used on the Pad Abort 1 Flight-Test Vehicle. An overview of the propulsive systems originally planned for future flight-test vehicles is also provided, which also includes the cold gas Reaction Control System within the Crew Module, and the Peacekeeper first stage rocket motor encased within the Abort Test Booster aeroshell. Although the Constellation program has been cancelled and the operational role of the Orion spacecraft has significantly evolved, lessons learned from Pad Abort 1 and the other flight-test vehicles could certainly contribute to the vehicle architecture of many future human-rated space launch vehicles

Jones, Daniel S.

The DOE ETV-1 Electric Test Vehicle. Phase 3: Performance Testing and system evaluation

Engineering tests were conducted in order to characterize overall system performance and component efficiencies within the system environment. A dynamometer was used in order to minimize the ambient effects and large uncertainties present in track testing. Extensive test requirements were defined and procedures were carefully controlled in order to maintain a high degree of credibility. Limited track testing was performed in order to corroborate the dynamometer results. Test results include an energy flow analysis through the major subsystems and incorporate the aerodynamic and rolling losses under cyclic and various steady speed conditions. The major output from all relevant dynamometer and track tests is also included.

Kurtz, D.

Flight and Integrated Vehicle Testing: Laying the Groundwork for the Next Generation of Space Exploration Launch Vehicles

Integrated vehicle testing will be critical to ensuring proper vehicle integration of the Ares I crew launch vehicle and Ares V cargo launch vehicle. The Ares Projects, based at Marshall Space Flight Center in Alabama, created the Flight and Integrated Test Office (FITO) as a separate team to ensure that testing is an integral part of the vehicle development process. As its name indicates, FITO is responsible for managing flight testing for the Ares vehicles. FITO personnel are well on the way toward assembling and flying the first flight test vehicle of Ares I, th Ares I-X. This suborbital development flight will evaluate the performance of Ares I from liftoff to first stage separation, testing flight control algorithms, vehicle roll control, separation and recovery systems, and ground operations. Ares I-X is now scheduled to fly in summer 2009. The follow-on flight, Ares I-Y, will test a full five-segment first stage booster and will include cryogenic propellants in the upper stage, an upper stage engine simulator, and an active launch abort system. The following flight, Orion 1, will be the first flight of an active upper stage and upper stage engine, as well as the first uncrewed flight of an Orion spacecraft into orbit. The Ares Projects are using an incremental buildup of flight capabilities prior to the first operational crewed flight of Ares I and the Orion crew exploration vehicle in 2015. In addition to flight testing, the FITO team will be responsible for conducting hardware, software, and ground vibration tests of the integrated launch vehicle. These efforts will include verifying hardware, software, and grou handling interfaces. Through flight and integrated testing, the Ares Projects will identify and mitigate risks early the United States prepares to take its next giant leaps to the Moon and beyond.

Taylor, Jim

Flight and Integrated Vehicle Testing: Laying the Groundwork for the Next Generation of Space Exploration Launch Vehicles

Integrated vehicle testing will be critical to ensuring proper vehicle integration of the Ares I crew launch vehicle and Ares V cargo launch vehicle. The Ares Projects, based at Marshall Space Flight Center in Alabama, created the Flight and Integrated Test Office (FITO) as a separate team to ensure that testing is an integral part of the vehicle development process. As its name indicates, FITO is responsible for managing flight testing for the Ares vehicles. FITO personnel are well on the way toward assembling and flying the first flight test vehicle of Ares I, the Ares I-X. This suborbital development flight will evaluate the performance of Ares I from liftoff to first stage separation, testing flight control algorithms, vehicle roll control, separation and recovery systems, and ground operations. Ares I-X is now scheduled to fly in summer 2009. The follow-on flight, Ares I-Y, will test a full five-segment first stage booster and will include cryogenic propellants in the upper stage, an upper stage engine simulator, and an active launch abort system. The following flight, Orion 1, will be the first flight of an active upper stage and upper stage engine, as well as the first uncrewed flight of an Orion spacecraft into orbit. The Ares Projects are using an incremental buildup of flight capabilities prior to the first operational crewed flight of Ares I and the Orion crew exploration vehicle in 2015. In addition to flight testing, the FITO team will be responsible for conducting hardware, software, and ground vibration tests of the integrated launch vehicle. These efforts will include verifying hardware, software, and ground handling interfaces. Through flight and integrated testing, the Ares Projects will identify and mitigate risks early as the United States prepares to take its next giant leaps to the Moon and beyond.

Taylor, J. L.

Environmentally Responsible Aviation (ERA) Project - N+2 Advanced Vehicle Concepts Study and Conceptual Design of Subscale Test Vehicle (STV) Final Report

NASA has set demanding goals for technology developments to meet national needs to improve fuel efficiency concurrent with improving the environment to enable air transportation growth. A figure shows NASA's subsonic transport system metrics. The results of Boeing ERA N+2 Advanced Vehicle Concept Study show that the Blended Wing Body (BWB) vehicle, with ultra high bypass propulsion systems have the potential to meet the combined NASA ERA N+2 goals. This study had 3 main activities. 1) The development of an advanced vehicle concepts that can meet the NASA system level metrics. 2) Identification of key enabling technologies and the development of technology roadmaps and maturation plans. 3) The development of a subscale test vehicle that can demonstrate and mature the key enabling technologies needed to meet the NASA system level metrics. Technology maturation plans are presented and include key performance parameters and technical performance measures. The plans describe the risks that will be reduced with technology development and the expected progression of technical maturity.

Aircraft Engines

Test Vehicle Forebody Wake Effects on CPAS Parachutes

Parachute drag performance has been reconstructed for a large number of Capsule Parachute Assembly System (CPAS) flight tests. This allows for determining forebody wake effects indirectly through statistical means. When data are available in a "clean" wake, such as behind a slender test vehicle, the relative degradation in performance for other test vehicles can be computed as a Pressure Recovery Fraction (PRF). All four CPAS parachute types were evaluated: Forward Bay Cover Parachutes (FBCPs), Drogues, Pilots, and Mains. Many tests used the missile-shaped Parachute Compartment Drop Test Vehicle (PCDTV) to obtain data at high airspeeds. Other tests used the Orion "boilerplate" Parachute Test Vehicle (PTV) to evaluate parachute performance in a representative heatshield wake. Drag data from both vehicles are normalized to a "capsule" forebody equivalent for Orion simulations. A separate database of PCDTV-specific performance is maintained to accurately predict flight tests. Data are shared among analogous parachutes whenever possible to maximize statistical significance.

Ray, Eric S.

B-52B-008/DTV (Drop Test Vehicle) configuration 1 (with and without fins) flight test results - captive flight and drop test missions

The B-52B-008 drop test consisted of one takeoff roll to 60 KCAS, two captive flights to accomplish limited safety of flight flutter and structural demonstration testing, and seven drop test flights. Of the seven drop test missions, one flight was aborted due to the failure of the hook mechanism to release the drop test vehicle (DTV); but the other six flights successfully dropped the DTV.

Quade, D. A.

Ground Contact Modeling for the Morpheus Test Vehicle Simulation

The Morpheus vertical test vehicle is an autonomous robotic lander being developed at Johnson Space Center (JSC) to test hazard detection technology. Because the initial ground contact simulation model was not very realistic, it was decided to improve the model without making it too computationally expensive. The first development cycle added capability to define vehicle attachment points (AP) and to keep track of their states in the lander reference frame (LFRAME). These states are used with a spring damper model to compute an AP contact force. The lateral force is then overwritten, if necessary, by the Coulomb static or kinetic friction force. The second development cycle added capability to use the PolySurface class as the contact surface. The class can load CAD data in STL (Stereo Lithography) format, and use the data to compute line of sight (LOS) intercepts. A polygon frame (PFRAME) is computed from the facet intercept normal and used to convert the AP state to PFRAME. Three flat plane tests validate the transitions from kinetic to static, static to kinetic, and vertical impact. The hazardous terrain test will be used to test for visual reasonableness. The improved model is numerically inexpensive, robust, and produces results that are reasonable.

Cordova, Luis

Ground Contact Modeling for the Morpheus Test Vehicle Simulation

The Morpheus vertical test vehicle is an autonomous robotic lander being developed at Johnson Space Center (JSC) to test hazard detection technology. Because the initial ground contact simulation model was not very realistic, it was decided to improve the model without making it too computationally expensive. The first development cycle added capability to define vehicle attachment points (AP) and to keep track of their states in the lander reference frame (LFRAME). These states are used with a spring damper model to compute an AP contact force. The lateral force is then overwritten, if necessary, by the Coulomb static or kinetic friction force. The second development cycle added capability to use the PolySurface class as the contact surface. The class can load CAD data in STL (Stereo Lithography) format, and use the data to compute line of sight (LOS) intercepts. A polygon frame (PFRAME) is computed from the facet intercept normal and used to convert the AP state to PFRAME. Three flat plane tests validate the transitions from kinetic to static, static to kinetic, and vertical impact. The hazardous terrain test will be used to test for visual reasonableness. The improved model is numerically inexpensive, robust, and produces results that are reasonable.

Cordova, Luis

Comparison of Wind-Tunnel and Flight Unsteady Pressure Environments for the Ares I-X Flight Test Vehicle

Wind-tunnel testing of highly-instrumented rigid models is the current standard for the estimation of unsteady environments acting on a launch vehicle during ascent. However, uncertainties are present in how well these constant condition wind-tunnel data model the unsteady environments for a full-scale launch vehicle during accelerating flight. The Ares I-X wind-tunnel and flight tests provided rich data sets for comparative analysis that have been used to develop answers to the question of tunnel-to-flight validity and uncertainty. In this paper, additional comparisons are presented for the unsteady pressure data acquired during wind-tunnel and flight testing to describe current methods that are used to evaluate preflight predictions. Utilizing these methods to generate ensembles of flight-comparable realizations from wind-tunnel data is shown to yield fluctuating magnitudes and spectra that compare well with flight data for the Ares I-X flight test vehicle throughout the transonic flight regime.

buffet

Comparison of Wind-Tunnel and Flight Unsteady Pressure Environments for the Ares I-X Flight Test Vehicle

Wind-tunnel testing of highly-instrumented rigid models is the current standard for the estimation of unsteady environments acting on a launch vehicle during ascent. However, uncertainties are present in how well these constant condition wind-tunnel data model the unsteady environments for a full-scale launch vehicle during accelerating flight. The Ares I-X wind-tunnel and flight tests provided rich data sets for comparative analysis that have been used to develop answers to the question of tunnel-to-flight validity and uncertainty. In this paper, additional comparisons are presented for the unsteady pressure data acquired during wind-tunnel and flight testing to describe current methods that are used to evaluate preflight predictions. Utilizing these methods to generate ensembles of flight-comparable realizations from wind-tunnel data is shown to yield fluctuating magnitudes and spectra that compare well with flight data for the Ares I-X flight test vehicle throughout the transonic flight regime.

buffet

Extraction and Separation Modeling of Orion Test Vehicles with ADAMS Simulation

The Capsule Parachute Assembly System (CPAS) project has increased efforts to demonstrate the performance of fully integrated parachute systems at both higher dynamic pressures and in the presence of wake fields using a Parachute Compartment Drop Test Vehicle (PCDTV) and a Parachute Test Vehicle (PTV), respectively. Modeling the extraction and separation events has proven challenging and an understanding of the physics is required to reduce the risk of separation malfunctions. The need for extraction and separation modeling is critical to a successful CPAS test campaign. Current PTV-alone simulations, such as Decelerator System Simulation (DSS), require accurate initial conditions (ICs) drawn from a separation model. Automatic Dynamic Analysis of Mechanical Systems (ADAMS), a Commercial off the Shelf (COTS) tool, was employed to provide insight into the multi-body six degree of freedom (DOF) interaction between parachute test hardware and external and internal forces. Components of the model include a composite extraction parachute, primary vehicle (PTV or PCDTV), platform cradle, a release mechanism, aircraft ramp, and a programmer parachute with attach points. Independent aerodynamic forces were applied to the mated test vehicle/platform cradle and the separated test vehicle and platform cradle. The aero coefficients were determined from real time lookup tables which were functions of both angle of attack ( ) and sideslip ( ). The atmospheric properties were also determined from a real time lookup table characteristic of the Yuma Proving Grounds (YPG) atmosphere relative to the planned test month. Representative geometries were constructed in ADAMS with measured mass properties generated for each independent vehicle. Derived smart separation parameters were included in ADAMS as sensors with defined pitch and pitch rate criteria used to refine inputs to analogous avionics systems for optimal separation conditions. Key design variables were dispersed in a Monte Carlo analysis to provide the maximum expected range of the state variables at programmer deployment to be used as ICs in DSS. Extensive comparisons were made with Decelerator System Simulation Application (DSSA) to validate the mated portion of the ADAMS extraction trajectory. Results of the comparisons improved the fidelity of ADAMS with a ramp pitch profile update from DSSA. Post-test reconstructions resulted in improvements to extraction parachute drag area knock-down factors, extraction line modeling, and the inclusion of ball-to-socket attachments used as a release mechanism on the PTV. Modeling of two Extraction parachutes was based on United States Air Force (USAF) tow test data and integrated into ADAMS for nominal and Monte Carlo trajectory assessments. Video overlay of ADAMS animations and actual C-12 chase plane test videos supported analysis and observation efforts of extraction and separation events. The COTS ADAMS simulation has been integrated with NASA based simulations to provide complete end to end trajectories with a focus on the extraction, separation, and programmer deployment sequence. The flexibility of modifying ADAMS inputs has proven useful for sensitivity studies and extraction/separation modeling efforts. 1

Fraire, Usbaldo, Jr.

Vehicles testing of near-term batteries

Vehicles test results are reported for nickel-iron, nickel-zinc, and improved lead-acid batteries developed under the Near-Term Battery Program sponsored by the Department of Energy. The batteries have demonstrated a range improvement of up to 90% over current lead-acid batteries due to improved energy density and ampere-hour capacity, combined with relatively small weight and volume. However, the nickel-iron battery requires a substantial development effort in packaging the circulating electrolyte system and handling the generated hydrogen volume, while the nickel-zinc batteries tested suffer from short cycle life.

Conover, R. C.

Load and dynamic assessment of B-52B-008 carrier aircraft for finned configuration 1 space shuttle solid rocket booster deceleration subsystem drop test vehicle. Volume 4: Pylon load data

The pylon loading at the drop test vehicle and wing interface attack points is presented. The loads shown are determined using a stiffness method, which assumes the side stiffness of the forward hook guide and the fore and aft stiffness of each drag pin to be equal. The net effect of this assumption is that the forward hook guide reacts approximately 96% of the drop test vehicle yawing moment. For a comparison of these loads to previous X-15 analysis design loadings, see Volume 1 of this document.

Quade, D. A.

Aerodynamic Reconstruction Applied to Parachute Test Vehicle Flight Data Analysis

The aerodynamics, both static and dynamic, of a test vehicle are critical to determining the performance of the parachute cluster in a drop test and for conducting a successful test. The Capsule Parachute Assembly System (CPAS) project is conducting tests of NASA's Orion Multi-Purpose Crew Vehicle (MPCV) parachutes at the Army Yuma Proving Ground utilizing the Parachute Test Vehicle (PTV). The PTV shape is based on the MPCV, but the height has been reduced in order to fit within the C-17 aircraft for extraction. Therefore, the aerodynamics of the PTV are similar, but not the same as, the MPCV. A small series of wind tunnel tests and computational fluid dynamics cases were run to modify the MPCV aerodynamic database for the PTV, but aerodynamic reconstruction of the flights has proven an effective source for further improvements to the database. The acceleration and rotational rates measured during free flight, before parachute inflation but during deployment, were used to con rm vehicle static aerodynamics. A multibody simulation is utilized to reconstruct the parachute portions of the flight. Aerodynamic or parachute parameters are adjusted in the simulation until the prediction reasonably matches the flight trajectory. Knowledge of the static aerodynamics is critical in the CPAS project because the parachute riser load measurements are scaled based on forebody drag. PTV dynamic damping is critical because the vehicle has no reaction control system to maintain attitude - the vehicle dynamics must be understood and modeled correctly before flight. It will be shown here that aerodynamic reconstruction has successfully contributed to the CPAS project.

Cassady, Leonard D.