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All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Lightweight Chambers for Thrust Assemblies

The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.

Elam, Sandra K.↗
NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for International Exploration

As the program moves out of the formulation phase and into implementation, work is well underway on NASA's new Space Launch System, the world's most powerful launch vehicle, which will enable a new era of human exploration of deep space. As assembly and testing of the rocket is taking place at numerous sites around the United States, mission planners within NASA and at the agency's international partners continue to evaluate utilization opportunities for this ground-breaking capability. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. NASA is developing this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history, via a path that will deliver an initial 70 metric ton (t) capability in December 2017 and then continuing through an incremental evolutionary strategy to reach a full capability greater than 130 t. SLS will be enabling for the first missions of human exploration beyond low Earth in almost half a century, and from its first crewed flight will be able to carry humans farther into space than they have ever voyaged before. In planning for the future of exploration, the International Space Exploration Coordination Group, representing 12 of the world's space agencies, has created the Global Exploration Roadmap, which outlines paths toward a human landing on Mars, beginning with capability-demonstrating missions to the Moon or an asteroid. The Roadmap and corresponding NASA research outline the requirements for reference missions for these destinations. SLS will offer a robust way to transport international crews and the air, water, food, and equipment they would need for such missions.

Creech, Stephen D.↗
NASA NTRS2014

NASA's Space Launch System: An Enabling Capability for International Exploration

As the program moves out of the formulation phase and into implementation, work is well underway on NASA's new Space Launch System, the world's most powerful launch vehicle, which will enable a new era of human exploration of deep space. As assembly and testing of the rocket is taking place at numerous sites around the United States, mission planners within NASA and at the agency's international partners continue to evaluate utilization opportunities for this ground-breaking capability. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. NASA is developing this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history, via a path that will deliver an initial 70 metric ton (t) capability in December 2017 and then continuing through an incremental evolutionary strategy to reach a full capability greater than 130 t. SLS will be enabling for the first missions of human exploration beyond low Earth in almost half a century, and from its first crewed flight will be able to carry humans farther into space than they have ever voyaged before. In planning for the future of exploration, the International Space Exploration Coordination Group, representing 12 of the world's space agencies, has created the Global Exploration Roadmap, which outlines paths toward a human landing on Mars, beginning with capability-demonstrating missions to the Moon or an asteroid. The Roadmap and corresponding NASA research outline the requirements for reference missions for these destinations. SLS will offer a robust way to transport international crews and the air, water, food, and equipment they would need for such missions.

Creech, Stephen D.↗
NASA NTRS1996

Low Frequency Vibration Characteristics of the Space Acceleration Measurement System 2 Tape Drive Assembly

This report summarizes results of force and moment measurements of the Space Acceleration Measurement System 2 (SAMS 2) Tape Drive Assembly (TDA) over the frequency range from 0.35 Hz to 256 Hz for steady state operations including write, read, rewind, and fast forward. Time domain force results are presented for transient TDA operations that include software eject, manual eject, and manual load. Three different mounting configurations were employed for attaching the inner box with the tape drive unit to the outer box. Two configurations employed grommet sets with spring rates of 42 and 62 pounds per inch respectively. The third configuration employed a set of metallic washers. For all four steady state operations the largest average forces were on the Y axis with the metallic washers and were less than 0.005 pounds. The largest average moments were on the X axes with the washers and were less than 0.030 pound inches. At the third octave centerband frequency of 31.5 Hz, the 42 pound per inch grommets showed the greatest forces and moments for read and write operations. At the third octave centerband frequency of 49.6 Hz, the 62 pound per inch grommets showed the greatest forces and moments for rewind operation. Transient operation forces ranged from 0.75 pounds for the software eject to greater than 1 pound for manual load and eject.

Javeed, Mehzad↗
NASA NTRS2017

Ground Demonstration on the Autonomous Docking of Two 3U CubeSats Using a Novel Permanent-Magnet Docking Mechanism

Small spacecraft autonomous rendezvous and docking is an essential technology for future space structure assembly missions. A novel magnetic capture and latching mechanism is analyzed that allows for docking of two CubeSats without precise sensors and actuators. The proposed magnetic docking hardware not only provides the means to latch the CubeSats but it also significantly increases the likelihood of successful docking in the presence of relative attitude and position errors. The simplicity of the design allows it to be implemented on many CubeSat rendezvous missions. A CubeSat 3-DOF ground demonstration effort is on-going at NASA Langley Research Center that enables hardware-in-the loop testing of the autonomous approach and docking of a follower CubeSat to an identical leader CubeSat. The test setup consists of a 3 meter by 4 meter granite table and two nearly frictionless air bearing systems that support the two CubeSats. Four cold-gas on-off thrusters are used to translate the follower towards the leader, while a single reaction wheel is used to control the attitude of each CubeSat. An innovative modified pseudo inverse control allocation scheme was developed to address interactions between control effectors. The docking procedure requires relatively high actuator precision, a novel minimal impulse bit mitigation algorithm was developed to minimize the undesirable deadzone effects of the thrusters. Simulation of the ground demonstration shows that the Guidance, Navigation, and Control system along with the docking subsystem leads to successful docking under 3-sigma dispersions for all key system parameters. Extensive simulation and ground testing will provide sufficient confidence that the proposed docking mechanism along with the choosen suite of sensors and actuators will perform successful docking in the space environment.

Pei, Jing↗
NASA NTRS2010

Verification Challenges of Dynamic Testing of Space Flight Hardware

The Six Degree-of-Freedom Dynamic Test System (SDTS) is a test facility at the National Aeronautics and Space Administration (NASA) Johnson Space Center in Houston, Texas for performing dynamic verification of space structures and hardware. Some examples of past and current tests include the verification of on-orbit robotic inspection systems, space vehicle assembly procedures and docking/berthing systems. The facility is able to integrate a dynamic simulation of on-orbit spacecraft mating or demating using flight-like mechanical interface hardware. A force moment sensor is utilized for input to the simulation during the contact phase, thus simulating the contact dynamics. While the verification of flight hardware presents many unique challenges, one particular area of interest is with respect to the use of external measurement systems to ensure accurate feedback of dynamic contact. There are many commercial off-the-shelf (COTS) measurement systems available on the market, and the test facility measurement systems have evolved over time to include two separate COTS systems. The first system incorporates infra-red sensing cameras, while the second system employs a laser interferometer to determine position and orientation data. The specific technical challenges with the measurement systems in a large dynamic environment include changing thermal and humidity levels, operational area and measurement volume, dynamic tracking, and data synchronization. The facility is located in an expansive high-bay area that is occasionally exposed to outside temperature when large retractable doors at each end of the building are opened. The laser interferometer system, in particular, is vulnerable to the environmental changes in the building. The operational area of the test facility itself is sizeable, ranging from seven meters wide and five meters deep to as much as seven meters high. Both facility measurement systems have desirable measurement volumes and the accuracies vary within the respective volumes. In addition, because this is a dynamic facility with a moving test bed, direct line-of-sight may not be available at all times between the measurement sensors and the tracking targets. Finally, the feedback data from the active test bed along with the two external measurement systems must be synchronized to allow for data correlation. To ensure the desired accuracy and resolution of these systems, calibration of the systems must be performed regularly. New innovations in sensor technology itself are periodically incorporated into the facility s overall measurement scheme. In addressing the challenges of the measurement systems, the facility is able to provide essential position and orientation data to verify the dynamic performance of space flight hardware.

Winnitoy, Susan↗
NASA NTRS1988

25-LBF GO2/GH2 space station thruster

Multiple 25-lbf oxygen/gaseous hydrogen thruster assemblies for the Space Station propulsion application were designed and fabricated by Rocketdyne and endurance tested at the NASA/Marshall Space Flight Center. The thrusters incorporate a regeneratively cooled thrust chamber with a nozzle area ratio of 30, a 12-element coaxial injector, an ignition system, and close-coupled propellant valves. The various thruster configurations comprised of mating different injectors and thrust chambers. Over 2 million lbf-sec of impulse was demonstrated at mixture ratios from 3 to 8.4 at vacuum conditions. A thruster was subjected to over 10,000 pulses during which minimum impulse bits of less than 0.5 lb/sec were repeatedly and reliably demonstrated. A total operating time of 25.6 hr was accumulated on the thruster assemblies with one 6.1-hr. continuous firing duration. The thrusters operated between a thrust range of 11.2 and 36.6 lbf. The test results indicate that all major technology issues for long-life gaseous oxygen/gaseous hydrogen thrusters for the Space Station application have been resolved.

Finden, L. E.↗
NASA NTRS1971

Modular space stations

Space station assembly in earth orbit, providing low transportation costs, modular elements return and incremental growth

Allen, L. B.↗
NASA NTRS1972

A shuttle and space station manipulator system for assembly, docking, maintenance, cargo handling and spacecraft retrieval (preliminary design). Volume 2: Concept development and selection

The overall program background, the various system concepts considered, and the rationale for the selected design are described. The concepts for each subsystem are also described and compared. Details are given for the requirements, boom configuration and dynamics, actuators, man/machine interface and control, visual system, control system, environmental control and life support, data processing, and materials.

Source record↗
NASA NTRS1972

A shuttle and space station manipulator system for assembly, docking, maintenance, cargo handling and spacecraft retrieval (preliminary design). Volume 4: Simulation studies

Laboratory simulations of three concepts, based on maximum use of available off-the-shelf hardware elements, are described. The concepts are a stereo-foveal-peripheral TV system with symmetric steroscopic split-image registration and 90 deg counter rotation; a computer assisted model control system termed the trajectory following control system; and active manipulator damping. It is concluded that the feasibility of these concepts is established.

Source record↗
NASA NTRS1971

Control of microbial contamination.

Two specific applications are discussed of microbial contamination control in planetary quarantine. Under the first concept, using the clean room to control environmental microorganisms, the objective is to reduce the microbial species and keep the numbers of microorganisms within an enclosure at a low level. The clean room concept is aimed at obtaining a product that has a controlled and reduced level of microbial contamination. Under the second concept, using the microbiological barrier to control microbial contamination of a specific product, the barrier techniques are designed to prevent the entry of any microorganisms into a sterile work area. Thus the assembly of space flight hardware within the confines of a microbiological barrier is aimed at obtaining a sterile product. In theory and practice, both approaches are shown to be applicable to the planetary quarantine program.

Mcdade, J. J.↗