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This viewgraph presentation contains information on development and testing of the Approach and Landing Test Vehicle (ALTV), and the Orbital Vehicle (OV) for the X-37 Project.
A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.
NASA s Next Generation Launch Technology (NGLT) Program, in conjunction with the office of the Director of Defense Research and Engineering (DDR&E), developed an integrated hypersonic technology demonstration roadmap. This roadmap is an integral part of the National Aerospace Initiative (NAI), a multi-year, multi-agency cooperative effort to invest in and develop, among other things, hypersonic technologies. This roadmap contains key ground and flight demonstrations required along the path to developing a reusable hypersonic space access system. One of the key flight demonstrations required for systems that will operate in the high Mach number regime is the X-43D. As currently conceived, the X-43D is a Mach 15 flight test vehicle that incorporates a hydrogen-fueled scramjet engine. The purpose of the X-43D is to gather high Mach number flight environment and engine operability information which is difficult, if not impossible, to gather on the ground. During 2003, the NGLT Future Hypersonic Flight Demonstration Office initiated a feasibility study on the X-43D. The objective of the study was to develop a baseline conceptual design, assess its performance, and identify the key technical issues. The study also produced a baseline program plan, schedule, and cost, along with a list of key programmatic risks.
This paper reports the results of an experiment that utilized the JPL's area array consortium test vehicle design, containing a myriad of mixed technology components with an OSP finish. The details of the reliability study are presented in this paper.
Spacecraft electronics including those used at the Jet Propulsion Laboratory (JPL), demand production of highly reliable assemblies. More than 400 test vehicles were assembled using ceramic and plastic ball grid arrays (BGAs), LCCs, J-leads, and gull wing components.
The discovery of tin whiskers (TW) on space shuttle hardware led to a program to investigate and removal and mitigation of the source of the tin whiskers. A Flight Control System (FCS) avionics box failed during vehicle testing, and was routed to the NASA Shuttle Logistics Depot for testing and disassembly. The internal inspection of the box revealed TW growth visible without magnification. The results of the Tiger Team that was assembled to investigate and develop recommendations are reviewed in this viewgraph presentation.
A general overview of NASA Dryden Flight Research Center's C-17 Aircraft is presented. The topics include: 1) 2006 Activities PHM Instrumentation Refurbishment; 2) Acoustic and Vibration Sensors; 3) Gas Path Sensors; 4) NASA Instrumentation System Racks; 5) NASA C-17 Simulator; 6) Current Activities; 7) Future Work; 8) Lawn Dart ; 9) Weight Tub; and 10) Parachute Test Vehicle.
Through research contracts with NASA, Materials and Electrochemical Research Corporation (MER), of Tucson, Arizona, contributed a number of technologies to record-breaking hypersonic flights. Through this research, MER developed a coating that successfully passed testing to simulate Mach 10 conditions, as well as provide several additional carbon-carbon (C-C) composite components for the flights. MER created all of the leading edges for the X-43A test vehicles at Dryden-considered the most critical parts of this experimental craft. In addition to being very heat resistant, the coating had to be very lightweight and thin, as the aircraft was designed to very precise specifications and could not afford to have a bulky coating. MER patented its carbon-carbon (C-C) composite process and then formed a spinoff company, Frontier Materials Corporation (FMC), also based in Tucson. FMC is using the patent in conjunction with low-cost PAN (polyacrylonitrile)-based fibers to introduce these materials to the commercial markets. The C-C composites are very lightweight and exceptionally strong and stiff, even at very high temperatures. The composites have been used in industrial heating applications, the automotive and aerospace industries, as well as in glass manufacturing and on semiconductors. Applications also include transfer components for glass manufacturing and structural members for carrier support in semiconductor processing.
Recent studies have been undertaken to investigate and develop aerodynamic models that predict aircraft response in nonlinear unsteady flight regimes for transport configurations. The models retain conventional static and rotary dynamic terms but replace conventional acceleration terms with more general indicial functions. In the Integrated Resilient Aircraft Controls project of the NASA Aviation Safety Program one aspect of the research is to apply these current developments to transport configurations to facilitate development of advanced controls technology. This paper describes initial application of a more general modeling methodology to the NASA Langley Generic Transport Model, a sub-scale flight test vehicle.
Sulcata software simulates the operation of the Mars Science Laboratory (MSL) radar terminal descent sensor (TDS). The program models TDS radar antennas, RF hardware, and digital processing, as well as the physics of scattering from a coherent ground surface. This application is specific to this sensor and is flexible enough to handle end-to-end design validation. Sulcata is a high-fidelity simulation and is used for performance evaluation, anomaly resolution, and design validation. Within the trajectory frame, almost all internal vectors are represented in whatever coordinate system is used to represent platform position. The trajectory frame must be planet-fixed. The platform body frame is specified relative to arbitrary reference points relative to the platform (spacecraft or test vehicle). Its rotation is a function of time from the trajectory coordinate system specified via dynamics input (file for open loop, callback for closed loop). Orientation of the frame relative to the body is arbitrary, but constant over time. The TDS frame must have a constant rotation and translation from the platform body frame specified at run time. The DEM frame has an arbitrary, but time-constant, rotation and translation with respect to the simulation frame specified at run time. It has the same orientation as sigma0 frame, but is possibly translated. Surface sigma0 has the same arbitrary rotation and translation as DEM frame.
During the launch countdown of the Ares I-X test vehicle, engineers from Langley Research Center will use profiles of atmospheric density and winds in evaluating vehicle ascent loads and controllability. A schedule for the release of balloons to measure atmospheric density and winds has been developed by the Natural Environments Branch at Marshall Space Flight Center to help ensure timely evaluation of the vehicle ascent loads and controllability parameters and support a successful launch of the Ares I-X vehicle.
This paper presents a novel technique to validate and predict the rover slips on Martian surface for NASA's Mars Exploration Rovers. Different from the traditional approach, the proposed method uses the actual velocity profile of the wheels and the digital elevation map (DEM) from the stereo images of the terrain to formulate simplified equations of motion of the rovers. A weighted factor to the wheel-ground speed from the empirical data comprises the velocity equations of the simplified differential-algebraic system of the rover motion. Applying the discretization operator to these equations, the full kinematics state of the rover is then resolved by the configuration kinematics solution in the Robot Sequencing and Visualization Program (RSVP). This method produced accurate simulation of the rover movements compared with these of the earth testing vehicle. Using the telemetry from the onboard Visual Odometry, the simulated rover path also compares well with the actual track of the vehicle. Preliminary results indicated that the proposed computational method is very effective in planning the path of the rovers on the high-slope areas.
This position paper is written as a result of a number of emails and a presentation that have recently been circulated concerning the potential reduction of Development Flight Instrumentation (DFI) to be included on the Ares I-X flight test vehicle. A reduction in instrumentation has been proposed presumably to reduce project costs and relieve project schedule pressures. This proposal has generated a significant amount of discussion on both sides of the issue, primarily from those within the project. The intention here is to provide a perspective on this issue from outside the mainline project.
This slide presentation reviews several forms of nonvolatile memory for use in space applications. The intent is to: (1) Determine inherent radiation tolerance and sensitivities, (2) Identify challenges for future radiation hardening efforts, (3) Investigate new failure modes and effects, and technology modeling programs. Testing includes total dose, single event (proton, laser, heavy ion), and proton damage (where appropriate). Test vehicles are expected to be a variety of non-volatile memory devices as available including Flash (NAND and NOR), Charge Trap, Nanocrystal Flash, Magnetic Memory (MRAM), Phase Change--Chalcogenide, (CRAM), Ferroelectric (FRAM), CNT, and Resistive RAM.
NASA Marshall Space Flight Center (MSFC) and The Johns Hopkins University Applied Physics Laboratory (APL) have been conducting mission studies and performing risk reduction activities for NASA s robotic lunar lander flight projects. This paper describes some of the lunar lander concepts derived from these studies conducted by the MSFC/APL Robotic Lunar Lander Development Project team. In addition, the results to date of the lunar lander development risk reduction efforts including high pressure propulsion system testing, structure and mechanism development and testing, long cycle time battery testing and combined GN&C and avionics testing will be addressed. The most visible elements of the risk reduction program are two autonomous lander flight test vehicles: a compressed air system with limited flight durations and a second version using hydrogen peroxide propellant to achieve significantly longer flight times and the ability to more fully exercise flight sensors and algorithms.
The National Aeronautics and Space Administration (NASA) Engineering and Safety Center (NESC) designed, developed and flew the alternative Max Launch Abort System (MLAS) as risk mitigation for the baseline Orion spacecraft launch abort system (LAS) already in development. The NESC was tasked with both formulating a conceptual objective system (OS) design of this alternative MLAS as well as demonstrating this concept with a simulated pad abort flight test. The goal was to obtain sufficient flight test data to assess performance, validate models/tools, and to reduce the design and development risks for a MLAS OS. Less than 2 years after Project start the MLAS simulated pad abort flight test was successfully conducted from Wallops Island on July 8, 2009. The entire flight test duration was 88 seconds during which time multiple staging events were performed and nine separate critically timed parachute deployments occurred as scheduled. Overall, the as-flown flight performance was as predicted prior to launch. This paper provides an overview of the guidance navigation and control (GN&C) technical approaches employed on this rapid prototyping activity. This paper describes the methodology used to design the MLAS flight test vehicle (FTV). Lessons that were learned during this rapid prototyping project are also summarized.
Continued studies have been undertaken to investigate and develop aerodynamic models that predict aircraft response in nonlinear unsteady flight regimes for transport configurations. The models retain conventional static and dynamic terms but replace conventional acceleration terms with indicial functions. In the Subsonic Fixed Wing Project of the NASA Fundamental Aeronautics Program and the Integrated Resilient Aircraft Controls project of the NASA Aviation Safety Program one aspect of the research is to apply these current developments to transport configurations to facilitate development of advanced simulation and control design technology. This paper continues development and application of a more general modeling methodology to the NASA Langley Generic Transport Model, a sub-scale flight test vehicle. In the present study models for the lateral-directional aerodynamics are developed.
This slide presentation reviews the use of modular infrastructure to assist in the development of flight software. A feature of this program is the use of model based approach for application unique software. A review of two programs that this approach was use on are: the development of software for Hover Test Vehicle (HTV), and Lunar Atmosphere and Dust Environment Experiment (LADEE).