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NASA NTRS2008

Thermal Stir Welding Development at Marshall Space Flight Center

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Ding, Robert J.↗

NASA NTRS2009

Orion Guidance and Control Ascent Abort Algorithm Design and Performance Results

During the ascent flight phase of NASA s Constellation Program, the Ares launch vehicle propels the Orion crew vehicle to an agreed to insertion target. If a failure occurs at any point in time during ascent then a system must be in place to abort the mission and return the crew to a safe landing with a high probability of success. To achieve continuous abort coverage one of two sets of effectors is used. Either the Launch Abort System (LAS), consisting of the Attitude Control Motor (ACM) and the Abort Motor (AM), or the Service Module (SM), consisting of SM Orion Main Engine (OME), Auxiliary (Aux) Jets, and Reaction Control System (RCS) jets, is used. The LAS effectors are used for aborts from liftoff through the first 30 seconds of second stage flight. The SM effectors are used from that point through Main Engine Cutoff (MECO). There are two distinct sets of Guidance and Control (G&C) algorithms that are designed to maximize the performance of these abort effectors. This paper will outline the necessary inputs to the G&C subsystem, the preliminary design of the G&C algorithms, the ability of the algorithms to predict what abort modes are achievable, and the resulting success of the abort system. Abort success will be measured against the Preliminary Design Review (PDR) abort performance metrics and overall performance will be reported. Finally, potential improvements to the G&C design will be discussed.

Proud, Ryan W.↗

NASA NTRS2009

United States Human Access to Space, Exploration of the Moon and Preparation for Mars Exploration

In the past, men like Leonardo da Vinci and Jules Verne imagined the future and envisioned fantastic inventions such as winged flying machines, submarines, and parachutes, and posited human adventures like transoceanic flight and journeys to the Moon. Today, many of their ideas are reality and form the basis for our modern world. While individual visionaries like da Vinci and Verne are remembered for the accuracy of their predictions, today entire nations are involved in the process of envisioning and defining the future development of mankind, both on and beyond the Earth itself. Recently, Russian, European, and Chinese teams have all announced plans for developing their own next generation human space vehicles. The Chinese have announced their intention to conduct human lunar exploration, and have flown three crewed space missions since 2003, including a flight with three crew members to test their extravehicular (spacewalking) capabilities in September 2008. Very soon, the prestige, economic development, scientific discovery, and strategic security advantage historically associated with leadership in space exploration and exploitation may no longer be the undisputed province of the United States. Much like the sponsors of the seafaring explorers of da Vinci's age, we are motivated by the opportunity to obtain new knowledge and new resources for the growth and development of our own civilization. NASA's new Constellation Program, established in 2005, is tasked with maintaining the United States leadership in space, exploring the Moon, creating a sustained human lunar presence, and eventually extending human operations to Mars and beyond. Through 2008, the Constellation Program developed a full set of detailed program requirements and is now completing the preliminary design phase for the new Orion Crew Exploration Vehicle (CEV), the Ares I Crew Launch Vehicle, and the associated infrastructure necessary for humans to explore the Moon. Component testing is well underway, and integrated flight testing will begin in 2009. This white paper summarizes 3 years of Constellation Program progress and accomplishments, and it describes the foundation set for human lunar return in 2020.

Rhatigan, Jennifer L.↗

NASA NTRS2009

An Evidence-Based Approach To Exercise Prescriptions on ISS

This presentation describes current exercise countermeasures and exercise equipment for astronauts onboard the ISS. Additionally, a strategy for evaluating evidence supporting spaceflight exercise is described and a new exercise prescription is proposed. The current exercise regimen is not fully effective as the ISS exercise hardware does not allow for sufficient exercise intensity, the exercise prescription is adequate and crew members are noncompliant with the prescription. New ISS hardware is proposed, Advanced Resistance Exercise Device (ARED), which allows additional exercises, is instrumented for data acquisition and offers improved loading. The new T2 hardware offers a better harness and subject loading system, is instrumented to allow ground reaction force data, and offers improved speed. A strategy for developing a spaceflight exercise prescription is described and involves identifying exercise training programs that have been shown to maximize adaptive benefits of people exercising in both 0 and 1 g environments. Exercise intensity emerged as an important factor in maintaining physiologic adaptations in the spaceflight environment and interval training is suggested. New ISS exercise hardware should allow for exercise at intensities high enough to elicit adaptive responses. Additionally, new exercise prescriptions should incorporate higher intensity exercises and seek to optimize intensity, duration and frequency for greater efficiency.

Ploutz-Snyder, Lori↗

NASA NTRS2009

Ultrasonic Phased Array Inspection Simulations of Welded Components at NASA

Comprehensive and accurate inspections of welded components have become of increasing importance as NASA develops new hardware such as Ares rocket segments for future exploration missions. Simulation and modeling will play an increased role in the future for nondestructive evaluation in order to better understand the physics of the inspection process and help explain the experimental results. It will also help to prove or disprove the feasibility for an inspection method or inspection scenario, help optimize inspections, and allow to a first approximation limits of detectability. This study presents simulation and experimental results for an ultrasonic phased array inspection of a critical welded structure important for NASA future exploration vehicles.

Roth, D. J.↗

NASA NTRS2008

An 8 Meter Monolithic UV/Optical Space Telescope

The planned Ares V launch vehicle with its 10 meter fairing and at least 55,600 kg capacity to Earth Sun L2 enables entirely new classes of space telescopes. A consortium from NASA, Space Telescope Science Institute, and aerospace industry are studying an 8-meter monolithic primary mirror UV/optical/NIR space telescope to enable new astrophysical research that is not feasible with existing or near-term missions, either space or ground. This paper briefly reviews the science case for such a mission and presents the results of an on-going technical feasibility study, including: optical design; structural design/analysis including primary mirror support structure, sun shade and secondary mirror support structure; thermal analysis; launch vehicle performance and trajectory; spacecraft including structure, propulsion, GN&C, avionics, power systems and reaction wheels; operations & servicing; mass budget and cost.

Stahl, H. Philip↗

NASA NTRS2008

Large Space Optics: From Hubble to JWST and Beyond

If necessity truly is the mother of invention, then advances in lightweight space mirror technology have been driven by launch vehicle mass and volume constraints. In the late 1970 s, at the start of Hubble development, the state of the art in ground based telescopes was 3 to 4 meter monolithic primary mirrors with masses of 6000 to 10,000 kg - clearly too massive for the planned space shuttle 25,000 kg capability to LEO. Necessity led Hubble to a different solution. Launch vehicle mass constraints (and cost) resulted in the development of a 2.4 meter lightweight eggcrate mirror. At 810 kg (180 kg/m2), this mirror was approximately 7.4% of HST s total 11,110 kg mass. And, the total observatory structure at 4.3 m x 13.2 m fit snuggly inside the space shuttle 4.6 m x 18.3 m payload bay. In the early 1990 s, at the start of JWST development, the state of the art in ground based telescopes was 8 meter class monolithic primary mirrors (16,000 to 23,000 kg) and 10 meter segmented mirrors (14,400 kg). Unfortunately, launch vehicles were still constrained to 4.5 meter payloads and 25,000 kg to LEO or 6,600 kg to L2. Furthermore, science now demanded a space telescope with 6 to 8 meter aperture operating at L2. Mirror technology was identified as a critical capability necessary to enable the next generation of large aperture space telescopes. Specific telescope architectures were explored via three independent design concept studies conducted during the summer of 1996 (1). These studies identified two significant architectural constraints: segmentation and areal density. Because the launch vehicle fairing payload dynamic envelop diameter is approximately 4.5 meters, the only way to launch an 8 meter class mirror is to segment it, fold it and deploy it on orbit - resulting in actuation and control requirements. And, because of launch vehicle mass limits, the primary mirror allocation was only 1000 kg - resulting in a maximum areal density of 20 kg/m2. At the inception of JWST in 1996, such a capability did not exist. A highly successful technology development program was initiated resulting in matured and demonstrated mirror technology for JWST (2, 3). Today, the JWST 6.5 meter primary mirror has an areal density of 25 kg/m2 for a total mass of 625 kg or 9.6% of the total JWST observatory mass of 6,500 kg. Looking into the future, science requires increasing larger collecting apertures. Ground based telescopes are already moving towards 30+ meter mirrors. The only way to meet this challenge for space telescopes is via even lower areal density mirrors or on-orbit assembly or larger launch vehicles (4). The planned NASA Ares V with its 10 meter fairing and 55,000 kg payload to L2 eliminates this constraint (5).

Stahl, H. Philip↗

NASA NTRS2008

Subscale Injector Testing to Support J-2X Engine Development

The J-2X engine being pursued for the Ares I will be a derivative of the J-2 engine developed by Pratt & Whitney Rocketdyne (PWR). As part of the engine development, a subscale injector was fabricated by PWR and hot-fire tested at NASA s Marshall Space Flight Center (MSFC) to evaluate performance data. This subscale injector had a reduced injector diameter and fewer elements than the full scale design, but the element density (#elements / injector area), and element geometries nearly identical to the full scale design. Three different materials were used for the LOX posts in order to test for durability. The subscale injector included 46 standard elements and 6 baffle elements, corresponding to the ratio of baffled elements to core elements in the full scale design. The baffle elements were included to demonstrate thermal compatibility of the baffles and to more closely represent the full scale performance. Fifteen hot-fire tests were conducted totaling over 200 seconds of mainstage time on the injector. Chamber pressures with oxygen/hydrogen propellants ranged from 870-1380 psig with mixture ratios ranging from 4.8-6.1. Fuel manifold inlet temperatures were varied from 190 to 300 R. Modular, water cooled, calorimeter chamber assemblies were used to provide heating rate data and evaluate the effects of characteristic length (L*). Performance was evaluated relative to the resulting characteristic velocity (C*) efficiency. Performance met the value required in order to proceed with this design for the full scale hardware. Hardware inspections show no evidence of cracking at the tip of the LOX post for any of the materials tested. Minor erosion of the baffle element tips was observed in the early testing. A design change was quickly implemented and tested, and this change resolved the issue. Development of the J-2X is continuing with this element density and design.

Protz, Christopher↗

NASA NTRS2008

8-Meter UV/Optical Space Telescope

This slide presentation proposes using the unprecedented capability of the planned Ares V launch vehicle, to place a 8 meter monolithic space telescope at the Earth-Sun L2 point. This new capability enables a new design pardigm -- simplicity. The six to eight meter class telescope with a massive high Technical Readiness Level ground observatory class monolithic primary mirror has been determined feasible. The proposed design, structural analysis, spacecraft design and shroud integration, thermal analysis, propulsion system, guidance navigation and pointing control assumptions about the avionics, and power systems, operational lifetime, and the idea of in-space servicing are reviewed.

Stahl, H. Philip↗

NASA NTRS2009

Lunar Regolith Characterization for Simulant Design and Evaluation using Figure of Merit Algorithms

NASA's Marshall Space Flight Center (MSFC), in conjunction with the United States Geological Survey (USGS) and aided by personnel from the Astromaterials Research and Exploration Science group at Johnson Space Center (ARES-JSC), is implementing a new data acquisition strategy to support the development and evaluation of lunar regolith simulants. The first analyses of lunar regolith samples by the simulant group were carried out in early 2008 on samples from Apollo 16 core 64001/64002. The results of these analyses are combined with data compiled from the literature to generate a reference composition and particle size distribution (PSD)) for lunar highlands regolith. In this paper we present the specifics of particle type composition and PSD for this reference composition. Furthermore. we use Figure-of-Merit (FoM) routines to measure the characteristics of a number of lunar regolith simulants against this reference composition. The lunar highlands regolith reference composition and the FoM results are presented to guide simulant producers and simulant users in their research and development processes.

Schrader, Christian M.↗

NASA NTRS2009

Marshall Space Flight Center Engineering Directorate Overview: Launching the Future of Science and Exploration

The Marshall Small Business Association (MSBA) serves as a central point of contact to inform and educate small businesses interested in pursuing contracting and subcontracting opportunities at the Marshall Space Flight Center. The MSBA meets quarterly to provide industry with information about how to do business with Marshall and to share specific information about Marshall s mission, which allows private businesses to envision how they might contribute. For the February 19 meeting, the Engineering Directorate will give an overview of its unique capabilities and how it is organized to provide maximum support for the programs and projects resident at Marshall, for example, the Space Shuttle Propulsion Office, Ares Projects Office, and Science and Mission Systems Office. This briefing provides a top-level summary of the work conducted by Marshall s largest organization, while explaining how resources are deployed to perform the volume of work under Marshall s purview.

Miley, Steven C.↗

NASA NTRS2009

Open-Loop Pitch Table Optimization for the Maximum Dynamic Pressure Orion Abort Flight Test

NASA has scheduled the retirement of the space shuttle orbiter fleet at the end of 2010. The Constellation program was created to develop the next generation of human spaceflight vehicles and launch vehicles, known as Orion and Ares respectively. The Orion vehicle is a return to the capsule configuration that was used in the Mercury, Gemini, and Apollo programs. This configuration allows for the inclusion of an abort system that safely removes the capsule from the booster in the event of a failure on launch. The Flight Test Office at NASA's Dryden Flight Research Center has been tasked with the flight testing of the abort system to ensure proper functionality and safety. The abort system will be tested in various scenarios to approximate the conditions encountered during an actual Orion launch. Every abort will have a closed-loop controller with an open-loop backup that will direct the vehicle during the abort. In order to provide the best fit for the desired total angle of attack profile with the open-loop pitch table, the table is tuned using simulated abort trajectories. A pitch table optimization program was created to tune the trajectories in an automated fashion. The program development was divided into three phases. Phase 1 used only the simulated nominal run to tune the open-loop pitch table. Phase 2 used the simulated nominal and three simulated off nominal runs to tune the open-loop pitch table. Phase 3 used the simulated nominal and sixteen simulated off nominal runs to tune the open-loop pitch table. The optimization program allowed for a quicker and more accurate fit to the desired profile as well as allowing for expanded resolution of the pitch table.

Stillwater, Ryan A.↗

NASA NTRS2009

Residual Stresses and Critical Initial Flaw Size Analyses of Welds

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). A series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on the fatigue life. The purpose of the weld analyses was to model the weld process using a variety of sequences to determine the 'best' sequence in terms of weld residual stresses and distortions. The many factors examined in this study include weld design (single-V, double-V groove), weld sequence, boundary conditions, and material properties, among others. The results of this weld analysis are included with service loads to perform a fatigue and critical initial flaw size evaluation.

Brust, Frederick W.↗

NASA NTRS2009

Single-Point Attachment Wind Damper for Launch Vehicle On-Pad Motion

A single-point-attachment wind-damper device is proposed to reduce on-pad motion of a cylindrical launch vehicle. The device is uniquely designed to attach at only one location along the vehicle and capable of damping out wind gusts from any lateral direction. The only source of damping is from two viscous dampers in the device. The effectiveness of the damper design in reducing vehicle displacements is determined from transient analysis results using an Ares I-X launch vehicle. Combinations of different spring stiffnesses and damping are used to show how the vehicle's displacement response is significantly reduced during a wind gust.

Hrinda, Glenn A.↗

NASA NTRS2009

NASA Constellation Program (CxP) Key Driving Requirements and Element Descriptions for International Architecture Working Group (IAWG) Functional Teams Human Transportation Cargo Transportation

The NASA Constellation uncrewed cargo mission delivers cargo to any designated location on the lunar surface (or other staging point) in a single mission. This capability is used to deliver surface infrastructure needed for lunar outpost construction, to provide periodic logistics resupply to support a continuous human lunar presence, and potentially deliver other assets to various locations.In the nominal mission mode, the Altair lunar lander is launched on Ares V into Low Earth Orbit (LEO), following a short Low Earth Orbit (LEO) loiter period, the Earth Departure Stage (EDS) performs the Trans Lunar Injection (TLI) burn and is then jettisoned. The Altair performs translunar trajectory correction maneuvers as necessary and performs the Lunar Orbit Insertion (LOI) burn. Altair then descends to the surface to land near a designated target, presumably in proximity to an Outpost location or another site of interest for exploration.Alternatively, the EDS and Altair Descent Stage could deliver assets to various staging points within their propulsive capabilities.

Martinez, Roland M.↗

NASA NTRS2008

John F. Kennedy Space Center's Technology Development and Application 2006-2007 Report

Topics covered include: Reversible Chemochromic Hydrogen Detectors; Determining Trajectory of Triboelectrically Charged Particles, Using Discrete Element Modeling; Using Indium Tin Oxide To Mitigate Dust on Viewing Ports; High-Performance Polyimide Powder Coatings; Controlled-Release Microcapsules for Smart Coatings for Corrosion Applications; Aerocoat 7 Replacement Coatings; Photocatalytic Coatings for Exploration and Spaceport Design; New Materials for the Repair of Polyimide Electrical Wire Insulation; Commodity-Free Calibration; Novel Ice Mitigation Methods; Crack Offset Measurement With the Projected Laser Target Device; New Materials for Structural Composites and Protective Coatings; Fire Chemistry Testing of Spray-On Foam Insulation (SOFI); Using Aerogel-Based Insulation Material To Prevent Foam Loss on the Liquid-Hydrogen Intertank; Particle Ejection and Levitation Technology (PELT); Electrostatic Characterization of Lunar Dust; Numerical Analysis of Rocket Exhaust Cratering; RESOLVE Projects: Lunar Water Resource Demonstration and Regolith Volatile Characterization; Tribocharging Lunar Soil for Electrostatic Beneficiation; Numerically Modeling the Erosion of Lunar Soil by Rocket Exhaust Plumes; Trajectory Model of Lunar Dust Particles; Using Lunar Module Shadows To Scale the Effects of Rocket Exhaust Plumes; Predicting the Acoustic Environment Induced by the Launch of the Ares I Vehicle; Measuring Ultrasonic Acoustic Velocity in a Thin Sheet of Graphite Epoxy Composite; Hail Size Distribution Mapping; Launch Pad 39 Hail Monitor Array System; Autonomous Flight Safety System - Phase III; The Photogrammetry Cube; Bird Vision System; Automating Range Surveillance Through Radio Interferometry and Field Strength Mapping Techniques; Next-Generation Telemetry Workstation; GPS Metric Tracking Unit; and Space-Based Range.

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NASA NTRS2008

Multi-Terrain Earth Landing Systems Applicable for Manned Space Capsules

A key element of the President's Vision for Space Exploration is the development of a new space transportation system to replace Shuttle that will enable manned exploration of the moon, Mars, and beyond. NASA has tasked the Constellation Program with the development of this architecture, which includes the Ares launch vehicle and Orion manned spacecraft. The Orion spacecraft must carry six astronauts and its primary structure should be reusable, if practical. These requirements led the Constellation Program to consider a baseline land landing on return to earth. To assess the landing system options for Orion, a review of current operational parachute landing systems such as those used for the F-111 escape module and the Soyuz is performed. In particular, landing systems with airbags and retrorockets that would enable reusability of the Orion capsule are investigated. In addition, Apollo tests and analyses conducted in the 1960's for both water and land landings are reviewed. Finally, tests and dynamic finite element simulations to understand land landings for the Orion spacecraft are also presented.

Fasanella, Edwin L.↗

NASA NTRS2009

Applications of Meteorological Tower Data at Kennedy Space Center

Members of the National Aeronautics and Space Administration (NASA) design and operation communities rely on meteorological information collected at Kennedy Space Center (KSC), located near Cape Canaveral, Florida, to correctly apply the ambient environment to various tasks. The Natural Environments Branch/EV44, located at Marshall Space Flight Center (MSFC) in Huntsville, Alabama, is responsible for providing its NASA customers with meteorological data using various climatological data sources including balloons, surface stations, aircraft, hindcast models, and meteorological towers. Of the many resources available within the KSC region, meteorological towers are preferred for near-surface applications because they record data at regular, frequent intervals over an extensive period of record at a single location. This paper discusses the uses of data measured at several different meteorological towers for a common period of record and how the data can be applied to various engineering decisions for the new Constellation Program Ares and Orion space vehicles.

Altino, Karen M.↗