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This slide presentation reviews the elements that make up the Ares I launch vehicle, with particular attention devoted to the upper stage of the vehicle. The upper stage elememnts, a lunar mission profile, and the upper stage objectives are reviewed. The work that Marshall Space Flight Center is doing is highlighted: work on the full scale welding process, the vertical milling machining, and the thermal protection system.
Propellant Mass Fraction (pmf) calculation methods vary throughout the aerospace industry. While typically used as a means of comparison between candidate launch vehicle designs, the actual pmf calculation method varies slightly from one entity to another. It is the purpose of this paper to present various methods used to calculate the pmf of launch vehicles. This includes fundamental methods of pmf calculation that consider only the total propellant mass and the dry mass of the vehicle; more involved methods that consider the residuals, reserves and any other unusable propellant remaining in the vehicle; and calculations excluding large mass quantities such as the installed engine mass. Finally, a historical comparison is made between launch vehicles on the basis of the differing calculation methodologies, while the unique mission and design requirements of the Ares V Earth Departure Stage (EDS) are examined in terms of impact to pmf.
This paper focuses on the vibration challenges inherent in the design of NASA s Ares launch vehicles. A brief overview of the launch system architecture is provided to establish the context for the discussion. Following this is a general discussion of the design considerations and analytical disciplines that are affected by vibration. The first challenge discussed is that of coupling between the vehicle flight control system and fundamental vibrational modes of the vehicle. The potential destabilizing influence of the vibrational dynamics is described along with discussion of the typical methods employed to overcome this issue. Next is a general discussion of the process for developing the design loads for the primary structure. This includes quasi-steady loads and dynamic loads induced by the structural dynamic response. The two principal parts of this response are the gust induced responses of the lower frequency modes and the buffet induced responses of the higher frequency modes. Structural dynamic model validation will also be addressed. Following this, discussions of three somewhat unique topics of Pogo Instability, Solid Booster Thrust Oscillation, and Liquid Rocket Engine Turbopump Rotordynamic Stability and Response are presented.
The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.
NASA has begun preliminary concept work on the vehicle. Over 1,700 alternatives have been investigated since ESAS. Focused on design of EDS, payload shroud, core stage, and RS-68 core stage engines. Recent point of departure update was made following the Lunar Capability Concept Review. Adds additional performance margin using an additional RS-68. Adds half segment on the first stage boosters . Shroud size is dictated by eventual size of Altair lunar lander. Also investigating alternate uses for Ares V not related to human space exploration . Astronomy applications (e.g., large aperture telescopes), . Deep space missions, DoD applications, Other applications.
This slide presentation represents the 30 day report on the Ares I-X test flight. Included in the review is information on the following areas: (1) Ground Systems, (2) Guidance, Navigation and Control, (3) Roll Response, (4) Vehicle Response, (5) Control System Performance, (6) Structural Damping, (7) Thrust Oscillation, (8) Stage Separation, (9) Connector Assessment, (10) USS Splashdown, (11) Data Recorder and (12) FS Hardware Assessment.
This slide presentation reviews attempts to counteract the effects of being in space. It includes information on the Resistive Exercise Device (RED), the Advanced Resistive Exercise Device (ARED), Cycle Ergometer with Vibration Isolation and Stabilization (CEVIS), Treadmill with Vibration Isolation and Stabilization (TVIS) and periodic fitness evaluation with specific information on BP/ECG, heart rate monitor 2 and data distribution.
Project Managers often face challenging technical, schedule and budget issues. This presentation will explore how the Ares I-X Roll Control System Integrated Product Team (IPT) mitigated challenges such as concurrent engineering requirements and environments and evolving program processes, while successfully managing an aggressive project schedule and tight budget. IPT challenges also included communications and negotiations among inter- and intra-government agencies, including the US Air Force, NASA/MSFC Propulsion Engineering, LaRC, GRC, KSC, WSTF, and the Constellation Program. In order to successfully meet these challenges it was essential that the IPT define those items that most affected the schedule critical path, define early mitigation strategies to reduce technical, schedule, and budget risks, and maintain the end-product focus of an "unmanned test flight" context for the flight hardware. The makeup of the IPT and how it would function were also important considerations. The IPT consisted of NASA/MSFC (project management, engineering, and safety/quality) and contractors (Teledyne Brown Engineering and Pratt and Whitney Rocketdyne, who supplied heritage hardware experience). The early decision to have a small focused IPT working "badgelessly" across functional lines to eliminate functional stove-piping allowed for many more tasks to be done by fewer people. It also enhanced a sense of ownership of the products, while still being able to revert back to traditional roles in order to provide the required technical independence in design reviews and verification closures. This presentation will highlight several prominent issues and discuss how they were mitigated and the resulting Lessons Learned that might benefit other projects.
The video contains information about the Ares-1 Launch vehicle history.
The Mission Control Center Console is shown in quicktime along with the launching of the Ares I Upper Stage Vehicle.
This presentation provides footage of the Ares 1-X launch and subsequent roll control system testing.
A large scale bonding demonstration test article was fabricated to prove out manufacturing techniques for the current design of the NASA Ares I Upper Stage common bulkhead. The common bulkhead serves as the single interface between the liquid hydrogen and liquid oxygen portions of the Upper Stage propellant tank. The bulkhead consists of spin-formed aluminum domes friction stir welded to Y-rings and bonded to a perforated phenolic honeycomb core. Nondestructive evaluation methods are being developed for assessing core integrity and the core-to-dome bond line of the common bulkhead. Detection of manufacturing defects such as delaminations between the core and face sheets as well as service life defects such as crushed or sheared core resulting from impact loading are all of interest. The focus of this work will be on the application of thermographic, shearographic, and phased array ultrasonic methods to the bonding demonstration article as well as various smaller test panels featuring design specific defect types and geometric features.
Techniques for studying the performance of Naflex pressure-assisted seals in the Ares-I Upper Stage liquid hydrogen tank manhole cover seal joint are explored. To assess the feasibility of using the identical seal design for the Upper Stage as was used for the Space Shuttle External Tank manhole covers, a preliminary seal deflection analysis using the ABAQUS commercial finite element software is employed. The ABAQUS analyses are performed using three-dimensional symmetric wedge finite element models. This analysis technique is validated by first modeling a heritage External Tank liquid hydrogen tank manhole cover joint and correlating the results to heritage test data. Once the technique is validated, the Upper Stage configuration is modeled. The Upper Stage analyses are performed at 1.4 times the expected pressure to comply with the Constellation Program factor of safety requirement on joint separation. Results from the analyses performed with the External Tank and Upper Stage models demonstrate the effects of several modeling assumptions on the seal deflection. The analyses for Upper Stage show that the integrity of the seal is successfully maintained.
Naflex seals have long history of use in launch vehicle components, including Saturn stages and Space Shuttle External Tank. Ares-I Upper Stage tank pressures are higher than ET pressures, requiring performance verification of heritage seal design in new manhole cover configurations. Heritage external tank analyses are reviewed for potential application to Upper Stage.
The Attitude Control Motor (ACM) is being developed for use in the Launch Abort System (LAS) of NASA's Ares I launch vehicle. The ACM consists of a small solid rocket motor and eight actuated pintle valves that directionally allocate.thrust_- 1t.has-been- predicted-that significant unsteady. pressure.fluctuations.will.exist. inside the-valves during operation. The dominant frequencies of these oscillations correspond to the lowest several acoustic natural frequencies of the individual valves. An acoustic finite element model of the fluid volume inside the valve has been critical to the prediction of these frequencies and their associated mode shapes. This work describes an effort to experimentally validate the acoustic finite model of the valve with an acoustic modal test. The modal test involved instrumenting a flight-like valve with six microphones and then exciting the enclosed air with a loudspeaker. The loudspeaker was configured to deliver broadband noise at relatively high sound pressure levels. The aquired microphone signals were post-processed and compared to results generated from the acoustic finite element model. Initial comparisons between the test data and the model results revealed that additional model refinement was necessary. Specifically, the model was updated to implement a complex impedance boundary condition at the entrance to the valve supply tube. This boundary condition models the frequency-dependent impedance that an acoustic wave will encounter as it reaches the end of the supply tube. Upon invoking this boundary condition, significantly improved agreement between the test data and the model was realized.
A Reynolds averaged Navier-Stokes analysis, with and without dynamic aeroelastic effects, is presented for the Ares I-X launch vehicle at transonic Mach numbers and flight Reynolds numbers for two grid resolutions and two angles of attack. The purpose of the study is to quantify the force and moment increment imparted by the sudden transition from fully separated flow around the crew module - service module junction to that of the bi-modal flow state in which only part of the flow reattaches. The bi-modal flow phenomenon is of interest to the guidance, navigation and control community because it causes a discontinuous jump in forces and moments. Computations with a rigid structure at zero zero angle of attack indicate significant increases in normal force and pitching moment. Dynamic aeroelastic computations indicate the bi-modal flow state is insensitive to vehicle flexibility due to the resulting deflections imparting only very small changes in local angle of attack. At an angle of attack of 2.5deg, the magnitude of the pitching moment increment resulting from the bi-modal state nearly triples, while occurring at a slightly lower Mach number. Significant grid induced variations between the solutions indicate that further grid refinement is warranted.
This paper presents grid refinement and adaptation studies performed in conjunction with computational aeroelastic analyses of the Ares crew launch vehicle (CLV). The unstructured grids used in this analysis were created with GridTool and VGRID while the adaptation was performed using the Computational Fluid Dynamic (CFD) code FUN3D with a feature based adaptation software tool. GridTool was developed by ViGYAN, Inc. while the last three software suites were developed by NASA Langley Research Center. The feature based adaptation software used here operates by aligning control volumes with shock and Mach line structures and by refining/de-refining where necessary. It does not redistribute node points on the surface. This paper assesses the sensitivity of the complex flow field about a launch vehicle to grid refinement. It also assesses the potential of feature based grid adaptation to improve the accuracy of CFD analysis for a complex launch vehicle configuration. The feature based adaptation shows the potential to improve the resolution of shocks and shear layers. Further development of the capability to adapt the boundary layer and surface grids of a tetrahedral grid is required for significant improvements in modeling the flow field.
The objective of the work presented here is to quantify the effects of purge gas temperature, pressure, and mass flow rate on Hydrazine (Hz) decontamination rates of the Ares I Roll Control System and Reaction Control System. A survey of experts in this field revealed the absence of any decontamination rate prediction models. Three basic decontamination methods were identified for analysis and modeling. These include low pressure eduction, high flow rate purge, and pulse purge. For each method, an approach to predict the Hz mass transfer rate, as a function of system pressure, temperature, and purge gas mass flow rate, is developed based on the applicable physics. The models show that low pressure eduction is two orders of magnitude more effective than the high velocity purge, which in turn is two orders of magnitude more effective than the pure diffusion component of pulse purging of deadheads. Eduction subjects the system to low pressure conditions that promote the extraction of Hz vapors. At 120 F, Hz is saturated at approximately 1 psia. At lower pressures and 120 F, Hz will boil, which is an extremely efficient means to remove liquid Hz. The Hz boiling rate is predicted by equating the rate at which energy is added to the saturated liquid Hz through heaters at the tube outer wall with the energy removed from the liquid through evaporation. Boil-off fluxes were predicted by iterating through the range of local pressures with limits set by the minimum allowed pressure of 0.2 psia and maximum allowed wall temperature of 120 F established by the heaters, which gives a saturation pressure of approximately 1.0 psia. Figure 1 shows the resulting boil-off fluxes as a function of local eduction pressure. As depicted in figure 1, the flux is a strong inverse function of eduction pressure, and that minimizing the eduction pressure maximizes the boil-off flux. Also, higher outer wall temperatures lead to higher boil-off fluxes and allow for boil-off over a greater range of eduction pressures.