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Orion Abort Flight Test

The purpose of NASA's Constellation project is to create the new generation of spacecraft for human flight to the International Space Station in low-earth orbit, the lunar surface, as well as for use in future deep-space exploration. One portion of the Constellation program was the development of the Orion crew exploration vehicle (CEV) to be used in spaceflight. The Orion spacecraft consists of a crew module, service module, space adapter and launch abort system. The crew module was designed to hold as many as six crew members. The Orion crew exploration vehicle is similar in design to the Apollo space capsules, although larger and more massive. The Flight Test Office is the responsible flight test organization for the launch abort system on the Orion crew exploration vehicle. The Flight Test Office originally proposed six tests that would demonstrate the use of the launch abort system. These flight tests were to be performed at the White Sands Missile Range in New Mexico and were similar in nature to the Apollo Little Joe II tests performed in the 1960s. The first flight test of the launch abort system was a pad abort (PA-1), that took place on 6 May 2010 at the White Sands Missile Range in New Mexico. Primary flight test objectives were to demonstrate the capability of the launch abort system to propel the crew module a safe distance away from a launch vehicle during a pad abort, to demonstrate the stability and control characteristics of the vehicle, and to determine the performance of the motors contained within the launch abort system. The focus of the PA-1 flight test was engineering development and data acquisition, not certification. In this presentation, a high level overview of the PA-1 vehicle is given, along with an overview of the Mobile Operations Facility and information on the White Sands tracking sites for radar & optics. Several lessons learned are presented, including detailed information on the lessons learned in the development of wind placards for flight. PA-1 flight data is shown, as well as a comparison of PA-1 flight data to nonlinear simulation Monte Carlo data.

Hayes, Peggy Sue

Trajectory Design for the Transiting Exoplanet Survey Satellite

The Transiting Exoplanet Survey Satellite (TESS) is a National Aeronautics and Space Administration (NASA) mission, scheduled to be launched in 2017. TESS will travel in a highly eccentric orbit around Earth, with initial perigee radius near 17 Earth radii (Re) and apogee radius near 59 Re. The orbit period is near 2:1 resonance with the Moon, with apogee nearly 90 degrees out-of-phase with the Moon, in a configuration that has been shown to be operationally stable. TESS will execute phasing loops followed by a lunar flyby, with a final maneuver to achieve 2:1 resonance with the Moon. The goals of a resonant orbit with long-term stability, short eclipses and limited oscillations of perigee present significant challenges to the trajectory design. To rapidly assess launch opportunities, we adapted the Schematics Window Methodology (SWM76) launch window analysis tool to assess the TESS mission constraints. To understand the long-term dynamics of such a resonant orbit in the Earth-Moon system we employed Dynamical Systems Theory in the Circular Restricted 3-Body Problem (CR3BP). For precise trajectory analysis we use a high-fidelity model and multiple shooting in the General Mission Analysis Tool (GMAT) to optimize the maneuver delta-V and meet mission constraints. Finally we describe how the techniques we have developed can be applied to missions with similar requirements. Keywords: resonant orbit, stability, lunar flyby, phasing loops, trajectory optimization

Stationkeepting

Application of Stuffed Whipple Shield to Robotic Spacecraft

Protection of human life onboard the International Space Station (ISS) requires reinforced shielding of crewed modules to prevent penetration of micro-meteoroid and orbital debris (MMOD), while optimizing the necessary mass for that application. An efficient way to achieve that protection consists in combining metal plates with ceramic and Kevlar fabrics in critical areas, a configuration known as the “Stuffed Whipple Shield”. In robotic spacecraft, fuel tanks are particularly vulnerable to MMOD impacts due to their pressurized contents and thin walls. Risk assessment of the Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) spacecraft using the Bumper3-Sat hypervelocity impact simulation tool demonstrated that the risk of propulsion tank damage due to MMOD particles coming from the ram direction (Launch Vehicle Adapter side) violated NASA requirements to limit the generation of orbital debris and threatened mission success. To mitigate the risk and achieve compliance, the basic configuration of the ISS Stuffed Whipple shield was scaled down and adapted to become a tank shield in the spacecraft ram direction. This paper will describe the adaptation of the ISS Stuffed Shield to a robotic spacecraft, while also comparing the effectiveness of the proposed shield design with more traditional single-wall and double-wall alternatives used in robotic spacecraft under similar conditions.

Ivonne M. Rodriguez

NASA Space Launch System Completes Key Hot Fire Test and Begins Vehicle Integration

NASA and its commercial and international partners are on the way back to the Moon. Significant progress towards that goal was made in 2021, including on the agency’s Space Launch System (SLS) rocket – a key part of the Artemis initiative. The SLS core stage for the Artemis I mission – the first launch of SLS and an uncrewed Orion capsule – completed its Green Run test series in early 2021 and was successfully mated with the SLS twin solid rocket boosters on the mobile launcher at Kennedy Space Center (KSC). The launch vehicle stage adapter, interim cryogenic propulsion stage, and the Orion stage adapter structural test article and Orion spacecraft mass simulator were also stacked. The flight Orion spacecraft and Orion stage adapter are being prepared for stacking and launch, targeted for late 2021 following a wet dress rehearsal at Launch Complex 39B. SLS hardware for Artemis II, which will be the first flight of crew on Orion and SLS, is also in work. Work progressed on core stage components, booster segments, and other hardware for Artemis III and future missions. This paper will detail the progress made.

John Honeycutt

Sandwich Structure Risk Reduction in Support of the Payload Adapter Fitting

Reducing risk for utilizing honeycomb sandwich structure for the Space Launch System payload adapter fitting includes determining what parameters need to be tested for damage tolerance to ensure a safe structure. Specimen size and boundary conditions are the most practical parameters to use in damage tolerance inspection. The effect of impact over core splices and foreign object debris between the facesheet and core is assessed. Effects of enhanced damage tolerance by applying an outer layer of carbon fiber woven cloth is examined. A simple repair technique for barely visible impact damage that restores all compression strength is presented.

Nettles, A. T.

Probabilistic Sensitivity Analysis for Launch Vehicles with Varying Payloads and Adapters for Structural Dynamics and Loads

This paper examines Probabilistic Sensitivity Analysis (PSA) methods and tools in an effort to understand their utility in vehicle loads and dynamic analysis. Specifically, this study addresses how these methods may be used to establish limits on payload mass and cg location and requirements on adaptor stiffnesses while maintaining vehicle loads and frequencies within established bounds. To this end, PSA methods and tools are applied to a realistic, but manageable, integrated launch vehicle analysis where payload and payload adaptor parameters are modeled as random variables. This analysis is used to study both Regional Response PSA (RRPSA) and Global Response PSA (GRPSA) methods, with a primary focus on sampling based techniques. For contrast, some MPP based approaches are also examined.

McGhee, David S.

Low Cost Access to Mars Surface using a Small Impact Lander

In order to reduce the cost of landing small payloads on Mars, a new technology is being developed: the Small High Impact Energy Landing Device concept (SHIELD). The purpose of SHIELD is to provide a low-cost option to deliver up to 6 kg of science payload to the surface of Mars. SHIELD could be launched as a hosted payload, rideshare on an EELV secondary payload adapter (ESPA), or launching from a dedicated small launch vehicle using a kick stage. The SHIELD concept can achieve low-cost access to Mars by taking advantage of a low ballistic coefficient design to decelerate safely instead of using the typically required parachutes and/or propulsion to decelerate and stabilize itself during entry, decent, and landing (EDL). Current finite element simulations suggest that SHIELD would experience an impact acceleration pulse ranging from 1000 to 2000 g’s with a duration of 8 milliseconds. The SHIELD concept payload subsystem includes a “ruggedized” small warm electronics box (WEB). The WEB houses the telecommunications, command and data handling, thermal control, electrical power, and payload subsystems while maintaining an internal operating temperature ranging between -20° to 20° C. The system is designed to survive the Martian night by utilizing electric heaters powered with solar cells during the day and secondary batteries. The WEB is designed to be impact resistant capable of surviving an impact acceleration pulse equal to or less than 2000 g’s.

Woolley, Ryan

Clean Air Shower Curtain for Protection of Contamination Sensitive Telescopes on the Ariane 5 Launcher

The launch of the James Webb Space Telescope (JWST) was successfully performed by Ariane 5 from French Guiana on December 25th 2021. The unique nature of the JWST mission led to various adaptations of the Ariane 5 launch system to fulfill stringent cleanliness and hygrometry requirements all along the launch preparation. JWST integration and test activities in the Final Assembly Building (BAF) had to be performed in ISO Class 7 equivalent conditions under Volatile Organic Compounds (VOC) protection and monitoring. For this purpose, a dedicated air supply system equipped with Airborne Molecular Contamination (AMC) filters was installed in the umbilical mast. The fairing itself was specially sealed to protect the inner environment, and to, guarantee ISO Class 7, the BAF Composite Hall (BAF-HC) facilities were upgraded with a removable “Air Shower Curtain” (AShC) containment enclosure between the mobile platforms around JWST. The preparation of these Ariane 5 launch system adaptations started several years before the launch campaign with close cooperation and coordination between Arianespace, ArianeGroup, the European Space Agency (ESA) and the National Aeronautics and Space Administration (NASA). This paper describes their specificities and addresses the challenges experienced to achieve the successful mission preparation.

Contamination Control, James Webb Space Telescope,

Clean Air Shower Curtain for Protection of Contamination Sensitive Telescopes on the Ariane 5 Launcher

The launch of the James Webb Space Telescope (JWST) was successfully performed by Ariane 5 from French Guiana on December 25th 2021. The unique nature of the JWST mission led to various adaptations of the Ariane 5 launch system to fulfill stringent cleanliness and hygrometry requirements all along the launch preparation. JWST integration and test activities in the Final Assembly Building (BAF) had to be performed in ISO Class 7 equivalent conditions under Volatile Organic Compounds (VOC) protection and monitoring. For this purpose, a dedicated air supply system equipped with Airborne Molecular Contamination (AMC) filters was installed in the umbilical mast. The fairing itself was specially sealed to protect the inner environment, and to, guarantee ISO Class 7, the BAF Composite Hall (BAF-HC) facilities were upgraded with a removable “Air Shower Curtain” (AShC) containment enclosure between the mobile platforms around JWST. The preparation of these Ariane 5 launch system adaptations started several years before the launch campaign with close cooperation and coordination between Arianespace, ArianeGroup, the European Space Agency (ESA) and the National Aeronautics and Space Administration (NASA). This paper describes their specificities and addresses the challenges experienced to achieve the successful mission preparation.

Contamination Control, James Webb Space Telescope,

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John

NASA’s Space Launch System: First Mission Hardware Nears Completion

The Space Launch System (SLS) Program (Fig. 1) completed several significant production milestones in 2018 for its first mission and is poised for greater accomplishments in 2019. With manufacturing and hardware installation complete, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success and scientific discovery. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John

NASA Collaborative Design Processes

This is Block 1, the first evolution of the world's most powerful and versatile rocket, the Space Launch System, built to return humans to the area around the moon. Eventually, larger and even more powerful and capable configurations will take astronauts and cargo to Mars. On the sides of the rocket are the twin solid rocket boosters that provide more than 75 percent during liftoff and burn for about two minutes, after which they are jettisoned, lightening the load for the rest of the space flight. Four RS-25 main engines provide thrust for the first stage of the rocket. These are the world's most reliable rocket engines. The core stage is the main body of the rocket and houses the fuel for the RS-25 engines, liquid hydrogen and liquid oxygen, and the avionics, or "brain" of the rocket. The core stage is all new and being manufactured at NASA's "rocket factory," Michoud Assembly Facility near New Orleans. The Launch Vehicle Stage Adapter, or LVSA, connects the core stage to the Interim Cryogenic Propulsion Stage. The Interim Cryogenic Propulsion Stage, or ICPS, uses one RL-10 rocket engine and will propel the Orion spacecraft on its deep-space journey after first-stage separation. Finally, the Orion human-rated spacecraft sits atop the massive Saturn V-sized launch vehicle. Managed out of Johnson Space Center in Houston, Orion is the first spacecraft in history capable of taking humans to multiple destinations within deep space. 2) Each element of the SLS utilizes collaborative design processes to achieve the incredible goal of sending human into deep space. Early phases are focused on feasibility and requirements development. Later phases are focused on detailed design, testing, and operations. There are 4 basic phases typically found in each phase of development.

Jones, Davey

NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch

The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.

Steve Creech

Maiden Voyage of the Rodent Habitat on ISS: Opportunities for Investigating Molecular Mechanisms and Biomedical Consequences of Long Duration Spaceflight

Research using rodents is an essential tool for advancing biomedical research on Earth and in space. The National Research Counsel’s Decadal survey (1) emphasized the importance of expanding NASAs life sciences research to perform long duration, rodent experiments on the International Space Station (ISS). To accomplish this objective, flight hardware, operations, and science capabilities were developed at NASA ARC to support both commercial and government-sponsored research. In preparation for the maiden voyage of the Rodent Habitat hardware and operations system (Rodent Research-1), and in close consultation with a Science Working Group comprised of veterinarians and experienced spaceflight investigators, we modified existing Animal Enclosure Module hardware, developed new hardware, operations, and science activities, and performed a series of ground-based verification tests. Preflight, ground based hardware tests included a simulation of SpaceX Dragon launch conditions (vibration and hypergravity) using the Transporter, and also two long-term biocompatibility tests (32 and 92 days) using the Habitat developed for long term housing on the ISS. The launch simulation test showed that adult mice housed in Transporter hardware adapted well, even if launch simulation was followed by a period of simulated weightlessness (via hind limb unloading). The biocompatibility tests demonstrated that the Habitat successfully supported animal health and also provided a useful video imaging system that enables frequent monitoring of animal health and behavior by veterinary and scientific experts on the ground, independent of ISS crew intervention. At the conclusion of all tests, mice were deemed healthy and suitable for conducting biological research. Additional preflight analyses of tissues preserved by freezing or fixation for gene expression analyses revealed that spleen and liver tissues recovered under conditions that simulated on-orbit activities yielded high quality RNA (RIN values 8-10) and liver enzyme activities and protein content (e.g. catalase). In addition, new methods were developed to optimize future science return by dissecting tissues post-euthanasia and storage. Various tissues were harvested from either intact or partially dissected, frozen carcasses after storage for ~2-6 months; most of the tissues (brain, heart, kidney, eye, adrenal glands and skeletal muscle) were of high RNA quality for science return, whereas some tissues (small intestine, bone marrow and bones) were not. These data demonstrated the protocols developed for future flight experiments supported science return despite delayed preservation post-euthanasia or prolonged storage, and furthermore, that high-quality RNA samples from many different tissues can be recovered by dissection following prolonged storage of the tissue in situ at -80˚C. The first flight experiments carrying 20 mice were launched on Sept 21, 2014 in an unmanned Dragon Capsule, SpaceX4; Rodent Research-1 is dedicated to achieving both NASA validation and CASIS science objectives. Ground based control groups (housed in flight hardware or standard cages) were maintained in environmental chambers at Kennedy Space Center. Crewmembers previously trained in animal handling transferred mice from the Transporter into Habitats under simultaneous veterinary supervision by video streaming and were deemed healthy. Health and behavior of all mice on the ISS was monitored by video feed on a daily basis. The 10 mice for validation (16wk old, female C57Bl6/J) ambulated freely and actively throughout the Habitat, relying heavily on their forelimbs for locomotion. The first on-orbit dissections of mice were performed successfully on Oct 12 and 13, 2014, and the validation mice will reside on ISS for up to 30 days. In conclusion, new capability for long duration rodent research is under development, including in-flight sample collection (which avoids the complication of reentry); results obtained to date will be described. This new Rodent Research system enables achievement of both basic science and translational research objectives to advance human exploration of space.

maiden voyage