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NASA NTRS2007

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗

NASA NTRS2005

The Application of Infrared Thermographic Inspection Techniques to the Space Shuttle Thermal Protection System

The Nondestructive Evaluation Sciences Branch at NASA s Langley Research Center has been actively involved in the development of thermographic inspection techniques for more than 15 years. Since the Space Shuttle Columbia accident, NASA has focused on the improvement of advanced NDE techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter s wing leading edge. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can be used to inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Principal Component Analysis (PCA) has been shown effective for reducing thermographic NDE data. A typical implementation of PCA is when the eigenvectors are generated from the data set being analyzed. Although it is a powerful tool for enhancing the visibility of defects in thermal data, PCA can be computationally intense and time consuming when applied to the large data sets typical in thermography. Additionally, PCA can experience problems when very large defects are present (defects that dominate the field-of-view), since the calculation of the eigenvectors is now governed by the presence of the defect, not the "good" material. To increase the processing speed and to minimize the negative effects of large defects, an alternative method of PCA is being pursued where a fixed set of eigenvectors, generated from an analytic model of the thermal response of the material under examination, is used to process the thermal data from the RCC materials. Details of a one-dimensional analytic model and a two-dimensional finite-element model will be presented. An overview of the PCA process as well as a quantitative signal-to-noise comparison of the results of performing both embodiments of PCA on thermographic data from various RCC specimens will be shown. Finally, a number of different applications of this technology to various RCC components will be presented.

Cramer, K. E.↗

NASA NTRS2013

Polymers Advance Heat Management Materials for Vehicles

For 6 years prior to the retirement of the Space Shuttle Program, the shuttles carried an onboard repair kit with a tool for emergency use: two tubes of NOAX, or "good goo," as some people called it. NOAX flew on all 22 flights following the Columbia accident, and was designed to repair damage that occurred on the exterior of the shuttle. Bill McMahon, a structural materials engineer at Marshall Space Flight Center says NASA needed a solution for the widest range of possible damage to the shuttle s exterior thermal protection system. "NASA looked at several options in early 2004 and decided on a sealant. Ultimately, NOAX performed the best and was selected," he says. To prove NOAX would work effectively required hundreds of samples manufactured at Marshall and Johnson, and a concerted effort from various NASA field centers. Johnson Space Center provided programmatic leadership, testing, tools, and crew training; Glenn Research Center provided materials analysis; Langley Research Center provided test support and led an effort to perform large patch repairs; Ames Research Center provided additional testing; and Marshall provided further testing and the site of NOAX manufacturing. Although the sealant never had to be used in an emergency situation, it was tested by astronauts on samples of reinforced carbon-carbon (RCC) during two shuttle missions. (RCC is the thermal material on areas of the shuttle that experience the most heat, such as the nose cone and wing leading edges.) The material handled well on orbit, and tests showed the NOAX patch held up well on RCC.

Source record↗

NASA NTRS2008

Dimensions of Credibility in Models and Simulations

Based on the National Aeronautics and Space Administration's (NASA's) work in developing a standard for models and simulations (M&S), the subject of credibility in M&S became a distinct focus. This is an indirect result from the Space Shuttle Columbia Accident Investigation Board (CAIB), which eventually resulted in an action, among others, to improve the rigor in NASA's M&S practices. The focus of this action came to mean a standardized method for assessing and reporting results from any type of M&S. As is typical in the standards development process, this necessarily developed into defming a common terminology base, common documentation requirements (especially for M&S used in critical decision making), and a method for assessing the credibility of M&S results. What surfaced in the development of the NASA Standard was the various dimensions credibility to consider when accepting the results from any model or simulation analysis. The eight generally relevant factors of credibility chosen in the NASA Standard proved only one aspect in the dimensionality of M&S credibility. At the next level of detail, the full comprehension of some of the factors requires an understanding along a couple of dimensions as well. Included in this discussion are the prerequisites for the appropriate use of a given M&S, the choice of factors in credibility assessment with their inherent dimensionality, and minimum requirements for fully reporting M&S results.

Steele, Martin J.↗

NASA NTRS2006

Status of Thermal NDT of Space Shuttle Materials at NASA

Since the Space Shuttle Columbia accident, NASA has focused on improving advanced nondestructive evaluation (NDE) techniques for the Reinforced Carbon-Carbon (RCC) panels that comprise the orbiter's wing leading edge and nose cap. Various nondestructive inspection techniques have been used in the examination of the RCC, but thermography has emerged as an effective inspection alternative to more traditional methods. Thermography is a non-contact inspection method as compared to ultrasonic techniques which typically require the use of a coupling medium between the transducer and material. Like radiographic techniques, thermography can inspect large areas, but has the advantage of minimal safety concerns and the ability for single-sided measurements. Details of the analysis technique that has been developed to allow insitu inspection of a majority of shuttle RCC components is discussed. Additionally, validation testing, performed to quantify the performance of the system, will be discussed. Finally, the results of applying this technology to the Space Shuttle Discovery after its return from the STS-114 mission in July 2005 are discussed.

Cramer, K. Elliott↗

NASA NTRS2002

NASA Aviation Safety Program Weather Accident Prevention/weather Information Communications (WINCOMM)

Weather is a contributing factor in approximately 25-30 percent of general aviation accidents. The lack of timely, accurate and usable weather information to the general aviation pilot in the cockpit to enhance pilot situational awareness and improve pilot judgment remains a major impediment to improving aviation safety. NASA Glenn Research Center commissioned this 120 day weather datalink market survey to assess the technologies, infrastructure, products, and services of commercial avionics systems being marketed to the general aviation community to address these longstanding safety concerns. A market survey of companies providing or proposing to provide graphical weather information to the general aviation cockpit was conducted. Fifteen commercial companies were surveyed. These systems are characterized and evaluated in this report by availability, end-user pricing/cost, system constraints/limits and technical specifications. An analysis of market survey results and an evaluation of product offerings were made. In addition, recommendations to NASA for additional research and technology development investment have been made as a result of this survey to accelerate deployment of cockpit weather information systems for enhancing aviation safety.

Feinberg, Arthur↗

NASA NTRS1982

Transport aircraft accident dynamics

A study was carried out of 112 impact survivable jet transport aircraft accidents (world wide) of 27,700 kg (60,000 lb.) aircraft and up extending over the last 20 years. This study centered on the effect of impact and the follow-on events on aircraft structures and was confined to the approach, landing and takeoff segments of the flight. The significant characteristics, frequency of occurrence and the effect on the occupants of the above data base were studied and categorized with a view to establishing typical impact scenarios for use as a basis of verifying the effectiveness of potential safety concepts. Studies were also carried out of related subjects such as: (1) assessment of advanced materials; (2) human tolerance to impact; (3) merit functions for safety concepts; and (4) impact analysis and test methods.

Cominsky, A.↗

NASA NTRS2006

What Happened, and Why: Toward an Understanding of Human Error Based on Automated Analyses of Incident Reports

The objective of the Aviation System Monitoring and Modeling project of NASA's Aviation Safety and Security Program was to develop technologies to enable proactive management of safety risk, which entails identifying the precursor events and conditions that foreshadow most accidents. Information about what happened can be extracted from quantitative data sources, but the experiential account of the incident reporter is the best available source of information about why an incident happened. In Volume I, the concept of the Scenario was introduced as a pragmatic guide for identifying similarities of what happened based on the objective parameters that define the Context and the Outcome of a Scenario. In this Volume II, that study continues into the analyses of the free narratives to gain understanding as to why the incident occurred from the reporter s perspective. While this is just the first experiment, the results of our approach are encouraging and indicate that it will be possible to design an automated analysis process guided by the structure of the Scenario that can achieve the level of consistency and reliability of human analysis of narrative reports.

Ferryman, Thomas A.↗

NASA NTRS2011

Comparison of In-Situ, Model and Ground Based In-Flight Icing Severity

As an aircraft flies through supercooled liquid water, the liquid freezes instantaneously to the airframe thus altering its lift, drag, and weight characteristics. In-flight icing is a contributing factor to many aviation accidents, and the reliable detection of this hazard is a fundamental concern to aviation safety. The scientific community has recently developed products to provide in-flight icing warnings. NASA's Icing Remote Sensing System (NIRSS) deploys a vertically--pointing Ka--band radar, a laser ceilometer, and a profiling multi-channel microwave radiometer for the diagnosis of terminal area in-flight icing hazards with high spatial and temporal resolution. NCAR s Current Icing Product (CIP) combines several meteorological inputs to produce a gridded, three-dimensional depiction of icing severity on an hourly basis. Pilot reports are the best and only source of information on in-situ icing conditions encountered by an aircraft. The goal of this analysis was to ascertain how the testbed NIRSS icing severity product and the operational CIP severity product compare to pilot reports of icing severity, and how NIRSS and CIP compare to each other. This study revealed that the icing severity product from the ground-based NASA testbed system compared very favorably with the operational model-based product and pilot reported in-situ icing.

Johnston, Christopher J.↗

NASA NTRS2004

Development of a Flexible Framework for Hypersonic Navier-Stoke Space Shuttle Orbiter Meshes

A flexible framework constructing block structured volume grids for hypersonic Navier-Strokes flow simulations was developed for the analysis of the Shuttle Orbiter Columbia. The development of the framework, which was partially basedon the requirements of the primary flow solvers used resulted in an ability to directly correlate solutions contributed by participating groups on a common surface mesh. A foundation was built through the assessment of differences between differnt solvers, which provided confidence for independent assessment of other damage scenarios by team members. The framework draws on the experience of NASA Langley and NASA Ames Research Centers in structured grid generation, and consists of a grid generation, and consist of a grid generation process implemented through a division of responsibilities. The nominal division of labor consisted of NASA Johnson Space Center coordinating the damage scenarios to be analyzed by the Aerothermodynamics Columbia Accident Investigation (ACAI) team, Ames developing the surface grids that described the computational volume about the Orbiter, and Langley improving grid quality of Ames generated data and constructing the final computational volume grids. Distributing the work among the participant in th ACAI team resulted in significantl less time required to construct complete meshes than possible by any individual participant. The approach demonstrated that the One-NASA grid generation team could sustain the demand of for five new meshes to explore new damage scenarios within an aggressive time-line.

Alter, Stephen J.↗

NASA NTRS2014

NASA-STD-7009 Guidance Document for Human Health and Performance Models and Simulations

Rigorous verification, validation, and credibility (VVC) processes are imperative to ensure that models and simulations (MS) are sufficiently reliable to address issues within their intended scope. The NASA standard for MS, NASA-STD-7009 (7009) [1] was a resultant outcome of the Columbia Accident Investigation Board (CAIB) to ensure MS are developed, applied, and interpreted appropriately for making decisions that may impact crew or mission safety. Because the 7009 focus is engineering systems, a NASA-STD-7009 Guidance Document is being developed to augment the 7009 and provide information, tools, and techniques applicable to the probabilistic and deterministic biological MS more prevalent in human health and performance (HHP) and space biomedical research and operations.

numerical analysis↗

NASA NTRS1994

Implementing Software Safety in the NASA Environment

Until recently, NASA did not consider allowing computers total control of flight systems. Human operators, via hardware, have constituted the ultimate safety control. In an attempt to reduce costs, NASA has come to rely more and more heavily on computers and software to control space missions. (For example. software is now planned to control most of the operational functions of the International Space Station.) Thus the need for systematic software safety programs has become crucial for mission success. Concurrent engineering principles dictate that safety should be designed into software up front, not tested into the software after the fact. 'Cost of Quality' studies have statistics and metrics to prove the value of building quality and safety into the development cycle. Unfortunately, most software engineers are not familiar with designing for safety, and most safety engineers are not software experts. Software written to specifications which have not been safety analyzed is a major source of computer related accidents. Safer software is achieved step by step throughout the system and software life cycle. It is a process that includes requirements definition, hazard analyses, formal software inspections, safety analyses, testing, and maintenance. The greatest emphasis is placed on clearly and completely defining system and software requirements, including safety and reliability requirements. Unfortunately, development and review of requirements are the weakest link in the process. While some of the more academic methods, e.g. mathematical models, may help bring about safer software, this paper proposes the use of currently approved software methodologies, and sound software and assurance practices to show how, to a large degree, safety can be designed into software from the start. NASA's approach today is to first conduct a preliminary system hazard analysis (PHA) during the concept and planning phase of a project. This determines the overall hazard potential of the system to be built. Shortly thereafter, as the system requirements are being defined, the second iteration of hazard analyses takes place, the systems hazard analysis (SHA). During the systems requirements phase, decisions are made as to what functions of the system will be the responsibility of software. This is the most critical time to affect the safety of the software. From this point, software safety analyses as well as software engineering practices are the main focus for assuring safe software. While many of the steps proposed in this paper seem like just sound engineering practices, they are the best technical and most cost effective means to assure safe software within a safe system.

Wetherholt, Martha S.↗

NASA NTRS1987

An investigation of transitional management problems for the NSTS

Analysis and recommendations were provided to the National Space Transportation System (NSTS) on managing the transition from a research and development (R/D) structure to an operational structure. Summaries of published literature on the theory and applications of transition, or change management, and the results of interviews with additional industry personnel whose organizations either have gone through or are now going through change are contained. The issues of flight rates and the flight decision are addressed. The use of a computer simulation model to analyze the effect of varying different parameters on the flight rate was also discussed. The issue of NASA's changing demographics was examined and why this may be a cause for concern. The impact of the whole shuttle system structure on the Challenger accident was presented along with the highlights of the Rogers Commission Report. The proposed reorganization of the NSTS management structure is discussed and how this transition from R/D to operations can be performed.

Hunsucker, John L.↗

NASA NTRS2011

Cavity Heating Experiments Supporting Shuttle Columbia Accident Investigation

The two-color thermographic phosphor method has been used to map the local heating augmentation of scaled idealized cavities at conditions simulating the windward surface of the Shuttle Orbiter Columbia during flight STS-107. Two experiments initiated in support of the Columbia Accident Investigation were conducted in the Langley 20-Inch Mach 6 Tunnel. Generally, the first test series evaluated open (length-to-depth less than 10) rectangular cavity geometries proposed as possible damage scenarios resulting from foam and ice impact during launch at several discrete locations on the vehicle windward surface, though some closed (length-to-depth greater than 13) geometries were briefly examined. The second test series was designed to parametrically evaluate heating augmentation in closed rectangular cavities. The tests were conducted under laminar cavity entry conditions over a range of local boundary layer edge-flow parameters typical of re-entry. Cavity design parameters were developed using laminar computational predictions, while the experimental boundary layer state conditions were inferred from the heating measurements. An analysis of the aeroheating caused by cavities allowed exclusion of non-breeching damage from the possible loss scenarios being considered during the investigation.

Everhart, Joel L.↗

NASA NTRS2009

Ares V Overview and Status

As part of NASA s Constellation Program to resume exploration beyond low Earth orbit (LEO), the Ares V heavy-lift cargo launch vehicle as currently conceived will be able to send more crew and cargo to more places on the Moon than the Apollo Program Saturn V. (Figure 1) It also has unprecedented cargo mass and volume capabilities that will be a national asset for science, commerce, and national defense applications. Compared to current systems, it will offer approximately five times the mass and volume to most orbits and locations. The Columbia space shuttle accident, the resulting investigation, the Vision for Space Exploration, and the Exploration Systems Architecture Study (ESAS) broadly shaped the Constellation architecture. Out of those events and initiatives emerged an architecture intended to replace the space shuttle, complete the International Space Station (ISS), resume a much more ambitious plan to explore the moon as a stepping stone to other destinations in the solar system. The Ares I was NASA s main priority because of the goal to retire the Shuttle. Ares V remains in a concept development phase, evolving through hundreds of configurations. The current reference design was approved during the Lunar Capabilities Concept Review/Ares V Mission Concept Review (LCCR/MCR) in June 2008. This reference concept serves as a starting point for a renewed set of design trades and detailed analysis into its interaction with the other components of the Constellation architecture and existing launch infrastructure. In 2009, the Ares V team was heavily involved in supporting the Review of U.S. Human Space Flight Plans Committee. Several alternative designs for Ares V have been supplied to the committee. This paper will discuss the origins of the Ares V design, the evolution to the current reference configuration, and the options provided to the review committee.

Creech, Steve↗

NASA NTRS2010

Composite Overwrapped Pressure Vessels (COPV): Developing Flight Rationale for the Space Shuttle Program

Introducing composite vessels into the Space Shuttle Program represented a significant technical achievement. Each Orbiter vehicle contains 24 (nominally) Kevlar tanks for storage of pressurized helium (for propulsion) and nitrogen (for life support). The use of composite cylinders saved 752 pounds per Orbiter vehicle compared with all-metal tanks. The weight savings is significant considering each Shuttle flight can deliver 54,000 pounds of payload to the International Space Station. In the wake of the Columbia accident and the ensuing Return to Flight activities, the Space Shuttle Program, in 2005, re-examined COPV hardware certification. Incorporating COPV data that had been generated over the last 30 years and recognizing differences between initial Shuttle Program requirements and current operation, a new failure mode was identified, as composite stress rupture was deemed credible. The Orbiter Project undertook a comprehensive investigation to quantify and mitigate this risk. First, the engineering team considered and later deemed as unfeasible the option to replace existing all flight tanks. Second, operational improvements to flight procedures were instituted to reduce the flight risk and the danger to personnel. Third, an Orbiter reliability model was developed to quantify flight risk. Laser profilometry inspection of several flight COPVs identified deep (up to 20 mil) depressions on the tank interior. A comprehensive analysis was performed and it confirmed that these observed depressions were far less than the criterion which was established as necessary to lead to liner buckling. Existing fleet vessels were exonerated from this failure mechanism. Because full validation of the Orbiter Reliability Model was not possible given limited hardware resources, an Accelerated Stress Rupture Test of a flown flight vessel was performed to provide increased confidence. A Bayesian statistical approach was developed to evaluate possible test results with respect to the model credibility and thus flight rationale for continued operation of the Space Shuttle with existing flight hardware. A non-destructive evaluation (NDE) technique utilizing Raman Spectroscopy was developed to directly measure the overwrap residual stress state. Preliminary results provide optimistic results that patterns of fluctuation in fiber elastic strains over the outside vessel surface could be directly correlated with increased fiber stress ratios and thus reduced reliability.

Kezirian, Michael T.↗

NASA NTRS2000

NASA/FAA Tailplane Icing Program: Flight Test Report

This report presents results from research flights that explored the characteristics of an ice-contaminated tailplane using various simulated ice shapes attached to the leading edge of the horizontal tailplane. A clean leading edge provided the baseline case, then three ice shapes were flown in order of increasing severity. Flight tests included both steady state and dynamic maneuvers. The steady state points were 1G wings level and steady heading sideslips. The primary dynamic maneuvers were pushovers to various G-levels; elevator doublets; and thrust transitions. These maneuvers were conducted for a full range of flap positions and aircraft angle of attack where possible. The analysis of this data set has clearly demonstrated the detrimental effects of ice contamination on aircraft stability and controllability. Paths to tailplane stall were revealed through parameter isolation and transition studies. These paths are (1) increasing ice shape severity, (2) increasing flap deflection, (3) high or low speeds, depending on whether the aircraft is in a steady state (high speed) or pushover maneuver (low speed), and (4) increasing thrust. The flight research effort was very comprehensive, but did not examine effects of tailplane design and location, or other aircraft geometry configuration effects. However, this effort provided the role of some of the parameters in promoting tailplane stall. The lessons learned will provide guidance to regulatory agencies, aircraft manufacturers, and operators on ice-contaminated tailplane stall in the effort to increase aviation safety and reduce the fatal accident rate.

Ratvasky, Thomas P.↗

NASA NTRS1994

Residual strength of thin panels with cracks

The previous design philosophies involving safe life, fail-safe and damage tolerance concepts become inadequate for assuring the safety of aging aircraft structures. For example, the failure mechanism for the Aloha Airline accident involved the coalescence of undetected small cracks at the rivet holes causing a section of the fuselage to peel open during flight. Therefore, the fuselage structure should be designed to have sufficient residual strength under worst case crack configurations and in-flight load conditions. Residual strength is interpreted as the maximum load carrying capacity prior to unstable crack growth. Internal pressure and bending moment constitute the two major components of the external loads on the fuselage section during flight. Although the stiffeners in the form of stringers, frames and tear straps sustain part of the external loads, the significant portion of the load is taken up by the skin. In the presence of a large crack in the skin, the crack lips bulge out with considerable yielding; thus, the geometric and material nonlinearities must be included in the analysis for predicting residual strength. Also, these nonlinearities do not permit the decoupling of in-plane and out-of-plane bending deformations. The failure criterion combining the concepts of absorbed specific energy and strain energy density addresses the aforementioned concerns. The critical absorbed specific energy (local toughness) for the material is determined from the global specimen response and deformation geometry based on the uniaxial tensile test data and detailed finite element modeling of the specimen response. The use of the local toughness and stress-strain response at the continuum level eliminates the size effect. With this critical parameter and stress-strain response, the finite element analysis of the component by using STAGS along with the application of this failure criterion provides the stable crack growth calculations for residual strength predictions.

Madenci, Erdogan↗