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NASA NTRS2009

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.↗
NASA NTRS2007

Design for Reliability and Safety Approach for the NASA New Launch Vehicle

The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program intended for sending crew and cargo to the international Space Station (ISS), to the moon, and beyond. This program is called Constellation. As part of the Constellation program, NASA is developing new launch vehicles aimed at significantly increase safety and reliability, reduce the cost of accessing space, and provide a growth path for manned space exploration. Achieving these goals requires a rigorous process that addresses reliability, safety, and cost upfront and throughout all the phases of the life cycle of the program. This paper discusses the "Design for Reliability and Safety" approach for the NASA new crew launch vehicle called ARES I. The ARES I is being developed by NASA Marshall Space Flight Center (MSFC) in support of the Constellation program. The ARES I consists of three major Elements: A solid First Stage (FS), an Upper Stage (US), and liquid Upper Stage Engine (USE). Stacked on top of the ARES I is the Crew exploration vehicle (CEV). The CEV consists of a Launch Abort System (LAS), Crew Module (CM), Service Module (SM), and a Spacecraft Adapter (SA). The CEV development is being led by NASA Johnson Space Center (JSC). Designing for high reliability and safety require a good integrated working environment and a sound technical design approach. The "Design for Reliability and Safety" approach addressed in this paper discusses both the environment and the technical process put in place to support the ARES I design. To address the integrated working environment, the ARES I project office has established a risk based design group called "Operability Design and Analysis" (OD&A) group. This group is an integrated group intended to bring together the engineering, design, and safety organizations together to optimize the system design for safety, reliability, and cost. On the technical side, the ARES I project has, through the OD&A environment, implemented a probabilistic approach to analyze and evaluate design uncertainties and understand their impact on safety, reliability, and cost. This paper focuses on the use of the various probabilistic approaches that have been pursued by the ARES I project. Specifically, the paper discusses an integrated functional probabilistic analysis approach that addresses upffont some key areas to support the ARES I Design Analysis Cycle (DAC) pre Preliminary Design (PD) Phase. This functional approach is a probabilistic physics based approach that combines failure probabilities with system dynamics and engineering failure impact models to identify key system risk drivers and potential system design requirements. The paper also discusses other probabilistic risk assessment approaches planned by the ARES I project to support the PD phase and beyond.

Safie, Fayssal, M.↗
NASA NTRS2010

Building and Leading the Next Generation of Exploration Launch Vehicles

NASA s Constellation Program is depending on the Ares Projects to deliver the crew and cargo launch capabilities needed to send human explorers to the Moon and beyond. Ares I and V will provide the core space launch capabilities needed to continue providing crew and cargo access to the International Space Station (ISS), and to build upon the U.S. history of human spaceflight to the Moon and beyond. Since 2005, Ares has made substantial progress on designing, developing, and testing the Ares I crew launch vehicle and has continued its in-depth studies of the Ares V cargo launch vehicle. In 2009, the Ares Projects plan to: conduct the first flight test of Ares I, test-fire the Ares I first stage solid rocket motor; build the first integrated Ares I upper stage; continue testing hardware for the J-2X upper stage engine, and continue refining the design of the Ares V cargo launch vehicle. These efforts come with serious challenges for the project leadership team as it continues to foster a culture of ownership and accountability, operate with limited funding, and works to maintain effective internal and external communications under intense external scrutiny.

Cook, Stephen A.↗
NASA NTRS2006

Mechanism Development, Testing, and Lessons Learned for the Advanced Resistive Exercise Device

The Advanced Resistive Exercise Device (ARED) has been developed at NASA Johnson Space Center, for the International Space Station (ISS) program. ARED is a multi-exercise, high-load resistive exercise device, designed for long duration, human space missions. ARED will enable astronauts to effectively maintain their muscle strength and bone mass in the micro-gravity environment more effectively than any other existing devices. ARED's resistance is provided via two, 20.3 cm (8 in) diameter vacuum cylinders, which provide a nearly constant resistance source. ARED also has a means to simulate the inertia that is felt during a 1-G exercise routine via the flywheel subassembly, which is directly tied to the motion of the ARED cylinders. ARED is scheduled to fly on flight ULF 2 to the ISS and will be located in Node 1. Presently, ARED is in the middle of its qualification and acceptance test program. An extensive testing program and engineering evaluation has increased the reliability of ARED by bringing potential design issues to light before flight production. Some of those design issues, resolutions, and design details will be discussed in this paper.

Lamoreaux, Christopher D.↗
NASA NTRS2008

Integrated Vehicle Ground Vibration Testing in Support of NASA Launch Vehicle Loads and Controls Analysis

The National Aeronautics and Space Administration (NASA) Ares Projects Office (APO) is continuing to make progress toward the final design of the Ares I crew launch vehicle and Ares V cargo launch vehicle. Ares I and V will form the space launch capabilities necessary to fulfill NASA's exploration strategy of sending human beings to the Moon, Mars, and beyond. As with all new space vehicles there will be a number of tests to ensure the design can be Human Rated. One of these is the Integrated Vehicle Ground Vibration Test (IVGVT) that will be measuring responses of the Ares I as a system. All structural systems possess a basic set of physical characteristics unique to that system. These unique characteristics include items such as mass distribution, frequency and damping. When specified, they allow engineers to understand and predict how a structural system like the Ares I launch vehicle behaves under given loading conditions. These physical properties of launch vehicles may be predicted by analysis or measured through certain types of tests. Generally, these properties are predicted by analysis during the design phase of a launch vehicle and then verified through testing before the vehicle is Human Rated. The IVGVT is intended to measure by test the fundamental dynamic characteristics of Ares I during various phases of operational/flight. This testing includes excitations of the vehicle in lateral, longitudinal, and torsional directions at vehicle configurations representing different trajectory points. During the series of tests, properties such as natural frequencies, mode shapes, and transfer functions are measured directly. These data will then be used to calibrate loads and Guidance, Navigation, and Controls (GN&C) analysis models for verifying analyses of Ares I. NASA launch vehicles from Saturn to Shuttle have undergone Ground Vibration Tests (GVTs) leading to successful launch vehicles. A GVT was not performed on the unmanned Delta III. This vehicle was lost during launch. Subsequent analyses indicated that had a GVT been conducted on the vehicle, problems with vehicle modes and control may have been discovered and corrected, avoiding loss of the vehicle/mission. This paper will address GVT planning, set-up, conduction and analyses, for the Saturn and Shuttle programs, and also focus on the current and on-going planning for the Ares I and V IVGVT.

Tuma, Margaret L.↗
NASA NTRS2008

Development Status of the J-2X

In June 2006, the NASA Marshall Space Flight Center (MSFC) and Pratt & Whitney Rocketdyne began development of an engine for use on the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The development program will be completed in December 2012 at the end of a Design Certification Review and after certification testing of two flight configuration engines. A team of over 600 people within NASA and Pratt & Whitney Rocketdyne are currently working to prepare for the fall 2008 Critical Design Review (CDR), along with supporting an extensive risk mitigation test program. The J-2X will power the Ares I upper stage and the Ares V earth departure stage (EDS). The initial use will be in the Ares I, used to launch the Orion crew exploration vehicle. In this application, it will power the upper stage after being sent aloft on a Space Shuttle-derived. 5-segment solid rocket booster first stage. In this mission. the engine will ignite at altitude and provide the necessary acceleration force to allow the Orion to achieve orbital velocity. The Ares I upper stage, along with the J-2X. will then be expended. On the Ares V. first stage propulsion is provided by five RS-68B engines and two 5-segment boosters similar to the Ares I configuration. In the Ares V mission. the J-2X is first started to power the EDS and its payload. the Altair lunar lander. into earth orbit, then shut-down and get prepared for its next start. The EDS/Altair will remain in a parking orbit, awaiting rendezvous and docking with Orion. Once the two spacecraft are mated, the J-2X will be restarted to achieve earth departure velocity. After powering the Orion and Altair, the EDS will be expended. By using the J-2X Engine in both applications, a significant infrastructure cost savings is realized. Only one engine development is required, and the sustaining engineering and flight support infrastructures can be combined. There is also flexibility for changing, the production and flight manifest because a single production line can support both missions with minimal differences between each engine configuration kit.

Kynard, Mike↗
NASA NTRS2009

Propelling Exploration to the Moon and Beyond

As the Constellation Program enters its fourth year, the Ares Projects have made substantial progress toward sending human explorers beyond Earth orbit. The Ares I crew launch vehicle, which will take six astronauts or cargo to the International Space Station or four astronauts to rendezvous with Ares V for missions to the Moon, is the first human-rated vehicle NASA has developed in over 30 years. Since the Exploration Systems Architecture Study in 2005, the Ares Projects have completed a successful system requirements review, system definition review, and preliminary design review for the Ares I crew launch vehicle. The Ares I elements are well into development, beginning with the Shuttle-derived, five-segment solid rocket motor that will provide first-stage propulsion. The first stage team has poured its first production simulation article motor and will be pouring and firing the first five-segment development motor in 2009. Large-scale tooling has been installed and tested to produce propellant tanks for the liquid-fuel upper stage at Marshall Space Flight Center (MSFC) in Alabama. The initial upper stage units and main propulsion test article will be manufactured and tested at MSFC before transferring to Michoud Assembly Facility in Louisiana. The upper stage engine team has completed powerpack testing using Apollo J-2 heritage hardware and begun construction of a new altitude test stand at Stennis Space Center in Mississippi. The flight and integrated testing group has designed and built hardware for the Ares I-X test flight scheduled for 2009, as well as begun refurbishing existing infrastructure to support ground testing. Additionally, a base configuration has been selected for the Ares V cargo launch vehicle, which will send the Altair lunar lander and Orion to the Moon. Today, the Ares Projects are well on the way to building America s next generation of exploration-capable launch vehicles.

Cook, Stephen A.↗
NASA NTRS2010

From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration

The NASA/industry team responsible for developing the J-2X Upper Stage Engine for the Constellation Program's Ares I and Ares V launch vehicles has made significant progress toward moving the design from paper to production during the past year. The J-2X exemplifies the Constellation goal of using proven technology and experience from more than 50 years of United States spaceflight experience and seeking where possible to employ common hardware in the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The J-2X will power the Ares I upper stage to place the Orion crew vehicle in orbit. For the Ares V, the J-2X will place the Earth departure stage (EDS) and lunar lander in orbit and later re-start to send the Orion and lander to the Moon. Pratt & Whitney Rocketdyne (PWR) is under contract to develop and produce the engine, leveraging its flight-proven LH2/LOX, gas generator cycle J-2 and RS-68 engine capabilities, recent experience with the X-33 aerospike XRS-2200 engine, and development knowledge of the J-2S tap-off cycle engine. The J-2X employs a gas generator operating cycle designed to produce 294,000 pounds of thrust in primary operating mode for the Ares I and Ares V ascent phases. It also has a secondary mode, during which it operates at 80 percent thrust by altering its mixture ratio to perform the TLI burn for the Ares V lunar sortie and lunar cargo missions. The J-2X development philosophy is based on proven hardware, an aggressive development schedule, and early risk reduction. NASA Marshall Space Flight Center (MSFC) and PWR began development of the J-2X in June 2006. The government/industry team of more than 600 people within NASA and PWR successfully completed the Critical Design Review (CDR) in November 2008, following extensive risk mitigation testing. The team is working toward a first flight of the J-2X on the Orion 1 mission in 2014. This paper will discuss the J-2X development background and provide top-level information on design and testing to date. Details will be provided on overcoming challenges such as gas generator instability, turbine blade life, and nozzle extension selection and materials.

Kynard, Mike↗
NASA NTRS2014

Bisphosphonate ISS Flight Experiment

The bisphosphonate study is a collaborative effort between the NASA and JAXA space agencies to investigate the potential for antiresorptive drugs to mitigate bone changes associated with long-duration spaceflight. Elevated bone resorption is a hallmark of human spaceflight and bed rest (common zero-G analog). We tested whether an antiresorptive drug in combination with in-flight exercise would ameliorate bone loss and hypercalcuria during longduration spaceflight. Measurements include DXA, QCT, pQCT, and urine and blood biomarkers. We have completed analysis of 7 crewmembers treated with alendronate during flight and the immediate postflight (R+<2 week) data collection in 5 of 10 controls without treatment. Both groups used the advanced resistive exercise device (ARED) during their missions. We previously reported the pre/postflight results of crew taking alendronate during flight (Osteoporosis Int. 24:2105-2114, 2013). The purpose of this report is to present the 12-month follow-up data in the treated astronauts and to compare these results with preliminary data from untreated crewmembers exercising with ARED (ARED control) or without ARED (Pre-ARED control). Results: the table presents DXA and QCT BMD expressed as percentage change from preflight in the control astronauts (18 Pre-ARED and the current 5 ARED-1-year data not yet available) and the 7 treated subjects. As shown previously the combination of exercise plus antiresorptive is effective in preventing bone loss during flight. Bone measures for treated subjects, 1 year after return from space remain at or near baseline values. Except in one region, the treated group maintained or gained bone 1 year after flight. Biomarker data are not currently available for either control group and therefore not presented. However, data from other studies with or without ARED show elevated bone resorption and urinary Ca excretion while bisphosphonate treated subjects show decreases during flight. Comparing the two control groups suggests significant but incomplete improvement in maintaining BMD using the newer exercise protocols compared to earlier resistive exercise protocols. Quantitative characterization of this improvement requires additional measurements in the ARED control group that we are currently collecting. In conclusion, these results indicate that an antiresorptive may be an effective adjunct to exercise during long-duration spaceflight.

LeBlanc, Adrian↗
NASA NTRS2008

Building on 50 Years of Systems Engineering Experience for a New Era of Space Exploration

Over the past 50 years, the National Aeronautics and Space Administration (NASA) has delivered space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides the United States (US) capability for both crew and heavy cargo to low-Earth orbit to construct the International Space Station, before the Shuttle is retired in 2010. In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The goals for this new system include increased safety and reliability coupled with lower operations costs that promote sustainable space exploration for decades to come. The Ares I will loft the Orion crew exploration vehicle, while the heavy-lift Ares V will carry the Altair lunar lander, as well as the equipment and supplies needed to construct a lunar outpost for a new generation of human and robotic space pioneers. NASA's Marshall Space Flight Center manages the Shuttle's propulsion elements and is managing the design and development of the Ares rockets, along with a host of other engineering assignments in the field of scientific space exploration. Specifically, the Marshall Center's Engineering Directorate houses the skilled workforce and unique facilities needed to build capable systems upon the foundation laid by the Mercury, Gemini, Apollo, and Shuttle programs. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level testing activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity and to validate computer modeling and simulation, as well as the main propulsion test article analysis to be conducted in the Static Test Stand. Ultimately, fielding a robust space transportation solution that will carry international explorers and essential payloads will pave the way for a new era of scientific discovery now dawning beyond planet Earth.

Dumbacher, Daniel L.↗
NASA NTRS2014

TBS (Trabecular Bone Score) Expands Understanding of Spaceflight Effects on the Lumbar Spine of Long-Duration Astronauts

Bone loss due to long‐duration spaceflight has been characterized by both DXA and QCT serial scans. It is unclear if these spaceflight‐induced changes in bone mineral density (BMD) and structure result in increased fracture incidence. NASA astronauts currently fly 5 to 6‐month missions on the International Space Station (ISS) and at least one 12‐month mission is planned. While NASA has measured areal BMD (by DXA) and volumetric BMD (by QCT) and has estimated hip strength (by finite element models of QCT data, no method has yet been used to examine bone micro‐architecture from lumbar spine (LS). DXA scans are routinely performed pre‐ and postflight on all ISS astronauts to follow BMD changes associated with spaceflight. Trabecular Bone Score (TBS) is a relatively new method that measures grey‐scale‐level texture information extracted from LS DXA images and correlates with 3D parameters of bone micro‐architecture. We evaluated the ability of LS TBS to discriminate changes in astronauts who have flown on ISS missions and to determine if TBS can provide additional information compared to DXA. Methods: Lumbar Spine (L1‐4) DXA scans from 51 astronauts (mean age, 47 +/- 4 yrs) were divided into 3 groups based on the exercise regimens performed onboard the ISS. "Pre‐ARED" (exercise using a load‐limited resistive exercise device, <300 lb), "ARED" (exercise with a high‐load resistive exercise device, up to 600 lb) and "Bisphos+ARED" group (ARED exercise and a 70‐mg alendronate tablet once a week before and during flight, starting 17 days before launch). DXA scans were performed and analyzed on a Hologic Discovery W using the same technician for the pre‐ and post‐flight scans. LSC for the LS in our laboratory is 0.025 g/sq. cm. TBS was performed at the Mercy Hospital, Cincinnati, Ohio on a similar Hologic computer. Data were analyzed using a paired, 2‐tailed Student's t‐test for the difference between pre‐ and postflight means. Percent change and % change per month are noted. Interpretation: Our data suggest that: TBS and DXA both detected significant decrements in the LS in these pre‐ ARED astronauts, not unexpected given the insufficient loads provided by this early exercise device. TBS did not detect significant changes in the ARED or Bisphos+ARED groups while DXA did detect significant changes in the ARED astronauts. These findings suggest that DXA and TBS are detecting independent effects of bone loss interventions tested in ISS astronauts in space, which may be due to distinct effects of interventions on mineral content of separate cortical vs. trabecular bone. Conclusion: TBS, in conjunction with DXA BMD, may provide additional insight into the nature of changes (or lack thereof) in the microstructure of trabecular bone and the areal BMD of vertebral bodies.

Smith, Scott A.↗
NASA NTRS2014

ISS Squat and Deadlift Kinematics on the Advanced Resistive Exercise Device

Visual assessment of exercise form on the Advanced Resistive Exercise Device (ARED) on orbit is difficult due to the motion of the entire device on its Vibration Isolation System (VIS). The VIS allows for two degrees of device translational motion, and one degree of rotational motion. In order to minimize the forces that the VIS must damp in these planes of motion, the floor of the ARED moves as well during exercise to reduce changes in the center of mass of the system. To help trainers and other exercise personnel better assess squat and deadlift form a tool was developed that removes the VIS motion and creates a stick figure video of the exerciser. Another goal of the study was to determine whether any useful kinematic information could be obtained from just a single camera. Finally, the use of these data may aid in the interpretation of QCT hip structure data in response to ARED exercises performed in-flight. After obtaining informed consent, four International Space Station (ISS) crewmembers participated in this investigation. Exercise was videotaped using a single camera positioned to view the side of the crewmember during exercise on the ARED. One crewmember wore reflective tape on the toe, heel, ankle, knee, hip, and shoulder joints. This technique was not available for the other three crewmembers, so joint locations were assessed and digitized frame-by-frame by lab personnel. A custom Matlab program was used to assign two-dimensional coordinates to the joint locations throughout exercise. A second custom Matlab program was used to scale the data, calculate joint angles, estimate the foot center of pressure (COP), approximate normal and shear loads, and to create the VIS motion-corrected stick figure videos. Kinematics for the squat and deadlift vary considerably for the four crewmembers in this investigation. Some have very shallow knee and hip angles, and others have quite large ranges of motion at these joints. Joint angle analysis showed that crewmembers do not return to a normal upright stance during squat, but remain somewhat bent at the hips. COP excursions were quite large during these exercises covering the entire length of the base of support in most cases. Anterior-posterior shear was very pronounced at the bottom of the squat and deadlift correlating with a COP shift to the toes at this part of the exercise. The stick figure videos showing a feet fixed reference frame have made it visually much easier for exercise personnel and trainers to assess exercise kinematics. Not returning to fully upright, hips extended position during squat exercises could have implications for the amount of load that is transmitted axially along the skeleton. The estimated shear loads observed in these crewmembers, along with a concomitant reduction in normal force, may also affect bone loading. The increased shear is likely due to the surprisingly large deviations in COP. Since the footplate on ARED moves along an arced path, much of the squat and deadlift movement is occurring on a tilted foot surface. This leads to COP movements away from the heel. The combination of observed kinematics and estimated kinetics make squat and deadlift exercises on the ARED distinctly different from their ground-based counterparts. CONCLUSION This investigation showed that some useful exercise information can be obtained at low cost, using a single video camera that is readily available on ISS. Squat and deadlift kinematics on the ISS ARED differ from ground-based ARED exercise. The amount of COP shift during these exercises sometimes approaches the limit of stability leading to modifications in the kinematics. The COP movement and altered kinematics likely reduce the bone loading experienced during these exercises. Further, the stick figure videos may prove to be a useful tool in assisting trainers to identify exercise form and make suggestions for improvements

Newby, N.↗
NASA NTRS2008

Engineering America's Current and Future Space Transportation Systems: 50 Years of Systems Engineering Innovation for Sustainable Exploration

Over the past 50 years, the National Aeronautics and Space Administration (NASA) has delivered space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides the United States' (U.S.) capability for both crew and heavy cargo to low-Earth orbit to' construct the International Space Station, before the Shuttle is retired in 2010. In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle (Figure 1). The goals for this new system include increased safety and reliability coupled with lower operations costs that promote sustainable space exploration for decades to come. The Ares I will loft the Orion Crew Exploration Vehicle, while the heavy-lift Ares V will carry the Altair Lunar Lander and the equipment and supplies needed to construct a lunar outpost for a new generation of human and robotic space pioneers. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level test activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity and to validate computer modeling and simulation (Figure 2), as well as the main propulsion test article analysis to be conducted in the Static Test Stand. These activities also will help prove and refine mission concepts of operation, while supporting the spectrum of design and development work being performed by Marshall's Engineering Directorate, ranging from launch vehicles and lunar rovers to scientific spacecraft and associated experiments. Ultimately, fielding a robust space transportation solution that will carry international explorers and essential payloads will pave the way for a new century of scientific discovery beyond planet Earth.

Dmbacher, Daniel L.↗
NASA NTRS2008

Engineering America's Future in Space: Systems Engineering Innovations for Sustainable Exploration

The National Aeronautics and Space Administration (NASA) delivers space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides U.S. capability for both crew and cargo to low-Earth orbit to construct the International Space Station, before the Shuttle is retired in 2010, as outlined in the 2006 NASA Strategic Plan. I In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I Crew Launch Vehicle/Orion Crew Exploration Vehicle and the Ares V Cargo Launch Vehicle/Altair Lunar Lander. The goals for this new system include increased safety and reliability, coupled with lower operations costs that promote sustainable space exploration over a multi-decade schedule. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level test activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity against predictions made by modern modeling and simulation analysis. It also will give information about the work in progress for the Ares I-X developmental test flight planned in 2009 to provide key data before the Ares I Critical Design Review. Activities such as these will help prove and refine mission concepts of operation, while supporting the spectrum of design and development tasks being performed by Marshall's Engineering Directorate, ranging from launch vehicles and lunar rovers to scientific spacecraft and associated experiments. Ultimately, the work performed will lead to the fielding of a robust space transportation solution that will carry international explorers and essential payloads for sustainable scientific discovery beyond planet Earth.

Dumbacher, Daniel L.↗
NASA NTRS2010

The J-2X Upper Stage Engine: From Design to Hardware

NASA is well on its way toward developing a new generation of launch vehicles to support of national space policy to retire the Space Shuttle fleet, complete the International Space Station, and return to the Moon as the first step in resuming this nation s exploration of deep space. The Constellation Program is developing the launch vehicles, spacecraft, surface systems, and ground systems to support those plans. Two launch vehicles will support those ambitious plans the Ares I and Ares V. (Figure 1) The J-2X Upper Stage Engine is a critical element of both of these new launchers. This paper will provide an overview of the J-2X design background, progress to date in design, testing, and manufacturing. The Ares I crew launch vehicle will lift the Orion crew exploration vehicle and up to four astronauts into low Earth orbit (LEO) to rendezvous with the space station or the first leg of mission to the Moon. The Ares V cargo launch vehicle is designed to lift a lunar lander into Earth orbit where it will be docked with the Orion spacecraft, and provide the thrust for the trans-lunar journey. While these vehicles bear some visual resemblance to the 1960s-era Saturn vehicles that carried astronauts to the Moon, the Ares vehicles are designed to carry more crew and more cargo to more places to carry out more ambitious tasks than the vehicles they succeed. The government/industry team designing the Ares rockets is mining a rich history of technology and expertise from the Shuttle, Saturn and other programs and seeking commonality where feasible between the Ares crew and cargo rockets as a way to minimize risk, shorten development times, and live within the budget constraints of its original guidance.

Byrd, Thomas↗
NASA NTRS2015

Update of Bisphosphonate Flight Experiment

Elevated bone resorption is a hallmark of human spaceflight and bed rest indicating that elevated remodeling is a major factor in the etiology of space flight bone loss. In a collaborative effort between the NASA and JAXA space agencies, we are testing whether an antiresorptive drug would provide additional benefit to in-flight exercise to ameliorate bone loss and hypercalciuria during long-duration spaceflight. Measurements of bone loss include DXA, QCT, pQCT, urinary and blood biomarkers. We have completed analysis of R+1year data from 7 crewmembers treated with alendronate during flight, as well as immediate post flight (R+<2wks) data from 6 of 10 concurrent controls without treatment. The treated astronauts used the Advanced Resistive Exercise Device (ARED) during their missions. The purpose of this report is twofold: 1) to report the results of inflight, post flight and one year post flight bone measures compared with available controls with and without the use of ARED; and 2) to discuss preliminary data on concurrent controls. The figure below compares the BMD changes in ISS crewmembers exercising with and without the current ARED protocol and the alendronate treated crewmembers also using the ARED. This shows that the use of ARED prevents about half the bone loss seen in early ISS crewmembers and that the addition of an antiresorptive provides additional benefit. Resorption markers and urinary Ca excretion are not impacted by exercise alone but are significantly reduced with antiresorptive treatment. Bone measures for treated subjects, 1 year after return from space remain at or near baseline. DXA data for the 6 concurrent controls using the ARED device are similar to DXA data shown in the figure below. QCT data for these six indicate that the integral data are consistent with the DXA data, i.e., comparing the two control groups suggests significant but incomplete improvement in maintaining BMD using the ARED protocol. Biochemical data of the concurrent control group await sample return and analysis. The preliminary conclusion is that an antiresorptive may be an effective adjunct to exercise during long-duration spaceflight.

LeBlanc, A.↗
NASA NTRS2006

NASA Crew Launch Vehicle Flight Test Options

Options for development flight testing (DFT) of the Ares I Crew Launch Vehicle (CLV) are discussed. The Ares-I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to launch the Crew Exploration Vehicle (CEV) into low Earth Orbit (LEO). The Ares-I implements one of the components of the Vision for Space Exploration (VSE), providing crew and cargo access to the International Space Station (ISS) after retirement of the Space Shuttle and, eventually, forming part of the launch capability needed for lunar exploration. The role of development flight testing is to demonstrate key sub-systems, address key technical risks, and provide flight data to validate engineering models in representative flight environments. This is distinguished from certification flight testing, which is designed to formally validate system functionality and achieve flight readiness. Lessons learned from Saturn V, Space Shuttle, and other flight programs are examined along with key Ares-I technical risks in order to provide insight into possible development flight test strategies. A strategy for the first test flight of the Ares I, known as Ares I-1, is presented.

Cockrell, Charles E., Jr.↗
NASA NTRS2008

The J-2X Upper Stage Engine: From Heritage to Hardware

NASA's Global Exploration Strategy requires safe, reliable, robust, efficient transportation to support sustainable operations from Earth to orbit and into the far reaches of the solar system. NASA selected the Ares I crew launch vehicle and the Ares V cargo launch vehicle to provide that transportation. Guiding principles in creating the architecture represented by the Ares vehicles were the maximum use of heritage hardware and legacy knowledge, particularly Space Shuttle assets, and commonality between the Ares vehicles where possible to streamline the hardware development approach and reduce programmatic, technical, and budget risks. The J-2X exemplifies those goals. It was selected by the Exploration Systems Architecture Study (ESAS) as the upper stage propulsion for the Ares I Upper Stage and the Ares V Earth Departure Stage (EDS). The J-2X is an evolved version ofthe historic J-2 engine that successfully powered the second stage of the Saturn I launch vehicle and the second and third stages of the Saturn V launch vehicle. The Constellation architecture, however, requires performance greater than its predecessor. The new architecture calls for larger payloads delivered to the Moon and demands greater loss of mission reliability and numerous other requirements associated with human rating that were not applied to the original J-2. As a result, the J-2X must operate at much higher temperatures, pressures, and flow rates than the heritage J-2, making it one of the highest performing gas generator cycle engines ever built, approaching the efficiency of more complex stage combustion engines. Development is focused on early risk mitigation, component and subassembly test, and engine system test. The development plans include testing engine components, including the subscale injector, main igniter, powerpack assembly (turbopumps, gas generator and associated ducting and structural mounts), full-scale gas generator, valves, and control software with hardware-in-the-loop. Testing expanded in 2007, accompanied by the refinement of the design through several key milestones. This paper discusses those 2007 tests and milestones, as well as updates key developments in 2008.

Byrd, THomas↗