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NASA NTRS2009

ATK Launch Vehicle (ALV-X1) Liftoff Acoustic Environments: Prediction vs. Measurement

The ATK Launch Vehicle (ALV-X1) provided an opportunity to measure liftoff acoustic noise data. NASA Marshall Space Flight Center (MSFC) engineers were interested in the ALV-X1 launch because the First Stage motor and launch pad conditions, including a relativity short deflector ducting, provide a potential analogue to future Ares I launches. This paper presents the measured liftoff acoustics on the vehicle and tower. Those measured results are compared to predictions based upon the method described in NASA SP-8072 "Acoustic Loads Generated by the Propulsion System" and the Vehicle Acoustic Environment Prediction Program (VAEPP) which was developed by MSFC acoustics engineers. One-third octave band sound pressure levels will be presented. This data is useful for the ALV-X1 in validating the pre-launch environments and loads predictions. Additionally, the ALV-X1 liftoff data can be scaled to define liftoff environments for the NASA Constellation program Ares vehicles. Vehicle liftoff noise is caused by the supersonic jet flow interaction with surrounding atmosphere or more simply, jet noise. As the vehicle's First Stage motor is ignited, an acoustic noise field is generated by the exhaust. This noise field persists due to the supersonic jet noise and reflections from the launch pad and tower, then changes as the vehicle begins to liftoff from the launch pad. Depending on launch pad and adjacent tower configurations, the liftoff noise is generally very high near the nozzle exit and decreases rapidly away from the nozzle. The liftoff acoustic time range of interest is typically 0 to 20 seconds after ignition. The exhaust plume thermo-fluid mechanics generates sound at approx.10 Hz to 20 kHz. Liftoff acoustic noise is usually the most severe dynamic environment for a launch vehicle or payload in the mid to high frequency range (approx.50 to 2000 Hz). This noise environment can induce high-level vibrations along the external surfaces of the vehicle and surrounding launch facility structures. The acoustic pressure fluctuations will induce severe vibrations in relatively large lightweight structures. Consequently, there is the potential for failure of the structure or attached electrical components. Due to these potential failures, the liftoff acoustic noise is one of the noise source inputs used to determine the vibro-acoustic qualification environment for a launch vehicle and its components.

Houston, Janice↗
NASA NTRS2008

Enabling and Enhancing Space Mission Success and Reduction of Risk through the Application of an Integrated Data Architecture

The engineering phases of design, development, test, and evaluation (DDT and E) and subsequent planning, preparation, and operation (Ops) of space vehicles in a complex and distributed environment requires massive and continuous flows of information across the enterprise and across temporal stages of the vehicle lifecycle. The resulting capabilities at each subsequent stage depend in part on the capture, preparation, storage, and subsequent provision of information from prior stages. The United States National Aeronautics and Space Administration (NASA) is currently designing a fleet of new vehicles that will replace the Space Shuttle and expand space operations and exploration capabilities. This includes the 2 stage human rated lift vehicle Ares 1 and its associated crew vehicle the Orion, and a service module; the heavy lift cargo vehicle, Ares 5, and an associated cargo stage known as the Earth Departure Stage; and a Lunar Lander vehicle that contains a descent stage, and ascent stage, and a habitation module. A variety of concurrent assorted ground operations infrastructure including software and facilities are also being developed, assorted technology and assembly designs and development for equipment such as EVA suits, life support systems, command and control technologies are also in the pipeline. The development is occurring in a distributed manner, with project deliverables being contributed by a large and diverse assortment of vendors and most space faring nations. Critical information about all of the components, software, and procedures must be shared during the DDT and E phases and then made readily available to the mission operations staff for access during the planning, preparation, and operations phases, and also need to be readily available for system to system interactions. The Constellation Data Systems Project (CxDS) is identifying the needs, and designing and deploying systems and processes to support these needs. This paper details the steps and processes that NASA is applying within the Constellation Program to manage this data and information, and to insure that the correct information is available, correctly annotated, and can be provisioned digitally to enhance response times, and support engineering analysis and anomaly resolution.

Brummett, Robert C.↗
NASA NTRS2009

Occupant Protection Project for the Orion Crew Vehicle

This powerpoint presentation describes the occupant protection project for the Orion Crew Vehicle. Background information on the Orion Crew Vehicle along with comparisons of the Space Shuttle, Ares I, Ares V, Saturn V and Soyuz-FG are also described. The contents include: 1) Background and Overview; 2) Crew health and safety overview; 3) Occupant Protection project overview; and 4) Suit Element injury risk.

Gernhardt, Michael L.↗
NASA NTRS2009

Explosion/Blast Dynamics for Constellation Launch Vehicles Assessment

An assessment methodology is developed to guide quantitative predictions of adverse physical environments and the subsequent effects on the Ares-1 crew launch vehicle associated with the loss of containment of cryogenic liquid propellants from the upper stage during ascent. Development of the methodology is led by a team at Sandia National Laboratories (SNL) with guidance and support from a number of National Aeronautics and Space Administration (NASA) personnel. The methodology is based on the current Ares-1 design and feasible accident scenarios. These scenarios address containment failure from debris impact or structural response to pressure or blast loading from an external source. Once containment is breached, the envisioned assessment methodology includes predictions for the sequence of physical processes stemming from cryogenic tank failure. The investigative techniques, analysis paths, and numerical simulations that comprise the proposed methodology are summarized and appropriate simulation software is identified in this report.

Baer, Mel↗
NASA NTRS2009

Engine Gimbal Requirements for Ground Testing of J-2X

Based on the Apollo-era J-2 that powered the second and third stages of the Saturn V, the current J-2X is the liquid hydrogen and oxygen high-altitude rocket engine in development for both the Ares I Upper Stage and Ares V Earth Departure Stage. During my summer 2009 internship, J-2X was at a stage in its design maturity where verification testing needed to be considered for the benefit of adequate test facility preparation. My task was to focus on gimbal requirements and gimbal related hot-fire test plans. Facility capabilities were also of interest, specifically for hot-fire testing slated to occur at test stands A-1, A-2, and A-3 at Stennis Space Center(SSC) in Bay St. Louis, Mississippi. Gimbal requirements and stage interface conditions were investigated by applying a top-to-bottom systems engineering approach, which involved system level requirements, engine level requirements from both government and engine contractor perspectives, component level requirements, and the J-2X to Upper Stage and Earth Departure Stage interface control documents. Previous hydrogen and oxygen liquid rocket engine gimbal verification methods were researched for a glimpse at lessons learned. Discussion among the J-2X community affected by gimballing was organized to obtain input relative to proper verification of their respective component. Implementing suggestions such as gimbal pattern, angulated dwell time, altitude testing options, power level, and feed line orientation, I was able to match tests to test stands in the A Complex at SSC. Potential test capability gaps and risks were identified and pursued. The culmination of all these efforts was to coordinate with SSC to define additional facility requirements for both the A-3 altitude test stand that is currently under construction and the A-1 sea level test stand which is being renovated

Kovalcik, Julia↗
NASA NTRS2009

Testing and Functions of the J2X Gas Generator

The Ares I, NASA s new solid rocket based crew launch vehicle, is a two stage in line rocket that has made its waytothe forefront of NASA s endeavors. The Ares I s Upper Stage (US) will be propelled by a J-2X engine which is fueled by liquid hydrogen and liquid oxygen. The J-2X is a variation based on two of its predecessor s, the J-2 and J-2S engines. ET50 is providing the design support for hardware required to run tests on the J-2X Gas Generator (GG) that increases the delivery pressure of the supplied combustion fuels that the engine burns. The test area will be running a series of tests using different lengths and curved segments of pipe and different sized nozzles to determine the configuration that best satisfies the thrust, heat, and stability requirements for the engine. I have had to research the configurations that are being tested and gain an understanding of the purpose of the tests. I then had to research the parts that would be used in the test configurations. I was taken to see parts similar to the ones used in the test configurations and was allowed to review drawings and dimensions used for those parts. My job over this summer has been to use the knowledge I have gained to design, model, and create drawings for the un-fabricated parts that are necessary for the J-2X Workhorse Gas Generator Phase IIcTest.

Miller, Nicholas↗
NASA NTRS2010

Evaluation of Anomaly Detection Capability for Ground-Based Pre-Launch Shuttle Operations

This chapter will provide a thorough end-to-end description of the process for evaluation of three different data-driven algorithms for anomaly detection to select the best candidate for deployment as part of a suite of IVHM (Integrated Vehicle Health Management) technologies. These algorithms were deemed to be sufficiently mature enough to be considered viable candidates for deployment in support of the maiden launch of Ares I-X, the successor to the Space Shuttle for NASA's Constellation program. Data-driven algorithms are just one of three different types being deployed. The other two types of algorithms being deployed include a "nile-based" expert system, and a "model-based" system. Within these two categories, the deployable candidates have already been selected based upon qualitative factors such as flight heritage. For the rule-based system, SHINE (Spacecraft High-speed Inference Engine) has been selected for deployment, which is a component of BEAM (Beacon-based Exception Analysis for Multimissions), a patented technology developed at NASA's JPL (Jet Propulsion Laboratory) and serves to aid in the management and identification of operational modes. For the "model-based" system, a commercially available package developed by QSI (Qualtech Systems, Inc.), TEAMS (Testability Engineering and Maintenance System) has been selected for deployment to aid in diagnosis. In the context of this particular deployment, distinctions among the use of the terms "data-driven," "rule-based," and "model-based," can be found in. Although there are three different categories of algorithms that have been selected for deployment, our main focus in this chapter will be on the evaluation of three candidates for data-driven anomaly detection. These algorithms will be evaluated upon their capability for robustly detecting incipient faults or failures in the ground-based phase of pre-launch space shuttle operations, rather than based oil heritage as performed in previous studies. Robust detection will allow for the achievement of pre-specified minimum false alarm and/or missed detection rates in the selection of alert thresholds. All algorithms will also be optimized with respect to an aggregation of these same criteria. Our study relies upon the use of Shuttle data to act as was a proxy for and in preparation for application to Ares I-X data, which uses a very similar hardware platform for the subsystems that are being targeted (TVC - Thrust Vector Control subsystem for the SRB (Solid Rocket Booster)).

Martin, Rodney Alexander↗
NASA NTRS2009

General Purpose Data-Driven Monitoring for Space Operations

As modern space propulsion and exploration systems improve in capability and efficiency, their designs are becoming increasingly sophisticated and complex. Determining the health state of these systems, using traditional parameter limit checking, model-based, or rule-based methods, is becoming more difficult as the number of sensors and component interactions grow. Data-driven monitoring techniques have been developed to address these issues by analyzing system operations data to automatically characterize normal system behavior. System health can be monitored by comparing real-time operating data with these nominal characterizations, providing detection of anomalous data signatures indicative of system faults or failures. The Inductive Monitoring System (IMS) is a data-driven system health monitoring software tool that has been successfully applied to several aerospace applications. IMS uses a data mining technique called clustering to analyze archived system data and characterize normal interactions between parameters. The scope of IMS based data-driven monitoring applications continues to expand with current development activities. Successful IMS deployment in the International Space Station (ISS) flight control room to monitor ISS attitude control systems has led to applications in other ISS flight control disciplines, such as thermal control. It has also generated interest in data-driven monitoring capability for Constellation, NASA's program to replace the Space Shuttle with new launch vehicles and spacecraft capable of returning astronauts to the moon, and then on to Mars. Several projects are currently underway to evaluate and mature the IMS technology and complementary tools for use in the Constellation program. These include an experiment on board the Air Force TacSat-3 satellite, and ground systems monitoring for NASA's Ares I-X and Ares I launch vehicles. The TacSat-3 Vehicle System Management (TVSM) project is a software experiment to integrate fault and anomaly detection algorithms and diagnosis tools with executive and adaptive planning functions contained in the flight software on-board the Air Force Research Laboratory TacSat-3 satellite. The TVSM software package will be uploaded after launch to monitor spacecraft subsystems such as power and guidance, navigation, and control (GN&C). It will analyze data in real-time to demonstrate detection of faults and unusual conditions, diagnose problems, and react to threats to spacecraft health and mission goals. The experiment will demonstrate the feasibility and effectiveness of integrated system health management (ISHM) technologies with both ground and on-board experiments.

Iverson, David L.↗
NASA NTRS2009

The Art and Science of Systems Engineering

The National Aeronautics and Space Administration (NASA) was established in 1958, and its Marshall Space Flight Center was founded in 1960, as space-related work was transferred from the Army Ballistic Missile Agency at Redstone Arsenal, where Marshall is located. With this heritage, Marshall contributes almost 50 years of systems engineering experience with human-rated launch vehicles and scientific spacecraft to fulfill NASA's mission exploration and discovery. These complex, highly specialized systems have provided vital platforms for expanding the knowledge base about Earth, the solar system, and cosmos; developing new technologies that also benefit life on Earth; and opening new frontiers for America's strategic space goals. From Mercury and Gemini, to Apollo and the Space Shuttle, Marshall's systems engineering expertise is an unsurpassed foundational competency for NASA and the nation. Current assignments comprise managing Space Shuttle Propulsion systems; developing environmental control and life support systems and coordinating science operations on the International Space Station; and a number of exploration-related responsibilities. These include managing and performing science missions, such as the Lunar Crater Observation and Sensing Satellite and the Lunar Reconnaissance Orbiter slated to launch for the Moon in April 2009, to developing the Ares I crew launch vehicle upper stage and integrating the vehicle stack in house, as well as designing the Ares V cargo launch vehicle and contributing to the development of the Altair Lunar Lander and an International Lunar Network with communications nodes and other infrastructure.

Singer, Christopher E.↗
NASA NTRS2009

Measurement and Characterization of Space Shuttle Solid Rocket Motor Plume Acoustics

NASA's current models to predict lift-off acoustics for launch vehicles are currently being updated using several numerical and empirical inputs. One empirical input comes from free-field acoustic data measured at three Space Shuttle Reusable Solid Rocket Motor (RSRM) static firings. The measurements were collected by a joint collaboration between NASA - Marshall Space Flight Center, Wyle Labs, and ATK Launch Systems. For the first time NASA measured large-thrust solid rocket motor plume acoustics for evaluation of both noise sources and acoustic radiation properties. Over sixty acoustic free-field measurements were taken over the three static firings to support evaluation of acoustic radiation near the rocket plume, far-field acoustic radiation patterns, plume acoustic power efficiencies, and apparent noise source locations within the plume. At approximately 67 m off nozzle centerline and 70 m downstream of the nozzle exit plan, the measured overall sound pressure level of the RSRM was 155 dB. Peak overall levels in the far field were over 140 dB at 300 m and 50-deg off of the RSRM thrust centerline. The successful collaboration has yielded valuable data that are being implemented into NASA's lift-off acoustic models, which will then be used to update predictions for Ares I and Ares V liftoff acoustic environments.

Kenny, Robert Jeremy↗
NASA NTRS2009

J-2X Upper Stage Engine: Hardware and Testing 2009

Mission: Common upper stage engine for Ares I and Ares V. Challenge: Use proven technology from Saturn X-33, RS-68 to develop the highest Isp GG cycle engine in history for 2 missions in record time . Key Features: LOX/LH2 GG cycle, series turbines (2), HIP-bonded MCC, pneumatic ball-sector valves, on-board engine controller, tube-wall regen nozzle/large passively-cooled nozzle extension, TEG boost/cooling . Development Philosophy: proven hardware, aggressive schedule, early risk reduction, requirements-driven.

Buzzell, James C.↗
NASA NTRS2010

Planning for Plume Diagnostics for Ground Testing of J-2X Engines at the SSC

John C. Stennis Space Center (SSC) is the premier test facility for liquid rocket engine development and certification for the National Aeronautics and Space Administration (NASA). Therefore, it is no surprise that the SSC will play the most prominent role in the engine development testing and certification for the J-2X engine. The Pratt & Whitney Rocketdyne J-2X engine has been selected by the Constellation Program to power the Ares I Upper Stage Element and the Ares V Earth Departure Stage in NASA s strategy of risk mitigation for hardware development by building on the Apollo program and other lessons learned to deliver a human-rated engine that is on an aggressive development schedule, with first demonstration flight in 2010 and human test flights in 2012. Accordingly, J-2X engine design, development, test, and evaluation is to build upon heritage hardware and apply valuable experience gained from past development and testing efforts. In order to leverage SSC s successful and innovative expertise in the plume diagnostics for the space shuttle main engine (SSME) health monitoring,1-10 this paper will present a blueprint for plume diagnostics for various proposed ground testing activities for J-2X at SSC. Complete description of the SSC s test facilities, supporting infrastructure, and test facilities is available in Ref. 11. The A-1 Test Stand is currently being prepared for testing the J-2X engine at sea level conditions. The A-2 Test Stand is currently being used for testing the SSME and may also be used for testing the J-2X engine at sea level conditions in the future. Very recently, ground-breaking ceremony for the new A-3 rocket engine test stand took place at SSC on August 23, 2007. A-3 is the first large - scale test stand to be built at the SSC since the A and B stands were constructed in the 1960s. The A-3 Test Stand will be used for testing J-2X engines under vacuum conditions simulating high altitude operation at approximately 30,480 m (100,000 ft). To achieve the simulated altitude environment, chemical steam generators using isopropyl alcohol, LOX, and RELEASED - Printed documents may be obsolete; validate prior to use. water would run for the duration of the test and would generate approximately 2096 Kg/s of steam to reduce pressure in the test cell and downstream of the engine. The testing at the A-3 Test Stand is projected to begin in late 2010, meanwhile the J-2X component testing on A-1 is scheduled to begin later this year.

SaintCyr, William W.↗
NASA NTRS2009

CxP Wireless DFI Summary Presentation for OTI Flight Test Working Group

This slide presentation reviews the wireless instrumentation architecture needed for the Alatir Lunar Lander, Ares I, Ares V, and the Block II Orion Crew Exploration Vehicle (CEV). It includes information about the Wireless DFI system, mission planning, and the technology roadmap.

Arteaga, Ricardo A.↗
NASA NTRS2007

Advanced Resistive Exercise Device

The advanced resistive exercise device (ARED), now at the prototype stage of development, is a versatile machine that can be used to perform different customized exercises for which, heretofore, it has been necessary to use different machines. Conceived as a means of helping astronauts and others to maintain muscle and bone strength and endurance in low-gravity environments, the ARED could also prove advantageous in terrestrial settings (e.g., health clubs and military training facilities) in which many users are exercising simultaneously and there is heavy demand for use of exercise machines.

Raboin, Jasen↗
NASA NTRS2010

Advanced Welding Applications

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Ding, Robert J.↗
NASA NTRS2010

Testing for the J-2X Upper Stage Engine

NASA selected the J-2X Upper Stage Engine in 2006 to power the upper stages of the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Based on the proven Saturn J-2 engine, this new engine will provide 294,000 pounds of thrust and a specific impulse of 448 seconds, making it the most efficient gas generator cycle engine in history. The engine's guiding philosophy emerged from the Exploration Systems Architecture Study (ESAS) in 2005. Goals established then called for vehicles and components based, where feasible, on proven hardware from the Space Shuttle, commercial, and other programs, to perform the mission and provide an order of magnitude greater safety. Since that time, the team has made unprecedented progress. Ahead of the other elements of the Constellation Program architecture, the team has progressed through System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of February 2010, more than 100,000 development engine parts have been ordered and more than 18,000 delivered. Approximately 1,300 of more than 1,600 engine drawings were released for manufacturing. A major factor in the J-2X development approach to this point is testing operations of heritage J-2 engine hardware and new J-2X components to understand heritage performance, validate computer modeling of development components, mitigate risk early in development, and inform design trades. This testing has been performed both by NASA and its J-2X prime contractor, Pratt & Whitney Rocketdyne (PWR). This body of work increases the likelihood of success as the team prepares for testing the J-2X powerpack and first development engine in calendar 2011. This paper will provide highlights of J-2X testing operations, engine test facilities, development hardware, and plans.

Buzzell, James C.↗
NASA NTRS2010

Finite Element Model Calibration Approach for Area I-X

Ares I-X is a pathfinder vehicle concept under development by NASA to demonstrate a new class of launch vehicles. Although this vehicle is essentially a shell of what the Ares I vehicle will be, efforts are underway to model and calibrate the analytical models before its maiden flight. Work reported in this document will summarize the model calibration approach used including uncertainty quantification of vehicle responses and the use of non-conventional boundary conditions during component testing. Since finite element modeling is the primary modeling tool, the calibration process uses these models, often developed by different groups, to assess model deficiencies and to update parameters to reconcile test with predictions. Data for two major component tests and the flight vehicle are presented along with the calibration results. For calibration, sensitivity analysis is conducted using Analysis of Variance (ANOVA). To reduce the computational burden associated with ANOVA calculations, response surface models are used in lieu of computationally intensive finite element solutions. From the sensitivity studies, parameter importance is assessed as a function of frequency. In addition, the work presents an approach to evaluate the probability that a parameter set exists to reconcile test with analysis. Comparisons of pretest predictions of frequency response uncertainty bounds with measured data, results from the variance-based sensitivity analysis, and results from component test models with calibrated boundary stiffness models are all presented.

Horta, Lucas G.↗
NASA NTRS2010

Altitude Testing of Large Liquid Propellant Engines

The National Aeronautics and Space Administration entered a new age on January 14, 2004 with President Bush s announcement of the creation the Vision for Space Exploration that will take mankind back to the Moon and on beyond to Mars. In January, 2006, after two years of hard, dedicated labor, engineers within NASA and its contractor workforce decided that the J2X rocket, based on the heritage of the Apollo J2 engine, would be the new engine for the NASA Constellation Ares upper stage vehicle. This engine and vehicle combination would provide assured access to the International Space Station to replace that role played by the Space Shuttle and additionally, would serve as the Earth Departure Stage, to push the Crew Excursion Vehicle out of Earth Orbit and head it on a path for rendezvous with the Moon. Test as you fly, fly as you test was chosen to be the guiding philosophy and a pre-requisite for the engine design, development, test and evaluation program. An exhaustive survey of national test facility assets proved the required capability to test the J2X engine at high altitude for long durations did not exist so therefore, a high altitude/near space environment testing capability would have to be developed. After several agency concepts the A3 High Altitude Testing Facility proposal was selected by the J2X engine program on March 2, 2007 and later confirmed by a broad panel of NASA senior leadership in May 2007. This facility is to be built at NASA s John C. Stennis Space Center located near Gulfport, Mississippi. 30 plus years of Space Shuttle Main Engine development and flight certification testing makes Stennis uniquely suited to support the Vision For Space Exploration Return to the Moon. Propellant handling infrastructure, engine assembly facilities, a trained and dedicated workforce and a broad and varied technical support base will all ensure that the A3 facility will be built on time to support the schedule needs of the J2X engine and the ultimate flight of the first Ares I vehicle. The A3 facility will be able to simulate pre-ignition altitude from sea-level to 100,000 feet and maintain it up to 650 seconds. Additionally the facility will be able to accommodate initial ignition, shutdown and then restart test profiles. A3 will produce up to 5000 lbm/sec of superheated steam utilizing a Chemical Steam generation system. Two separate inline steam ejectors will be used to produce a test cell vacuum to simulate the 100,000 ft required altitude. Operational capability will ensure that the facility can start up and shutdown without producing adverse pressure gradients across the J2X nozzle. The facility will have a modern thrust measurement system for accurate determination of engine performance. The latest advances in data acquisition and control will be incorporated to measure performance parameters during hotfire testing. Provisions are being made in the initial design of the new altitude facility to allow for testing of other, larger engines and potential upper stage launch vehicles that might require vacuum start testing of the engines. The new facility at Stennis Space Center will be complete and ready for hotfire operations in late 2010.

Maynard, Bryon T.↗