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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

The Disposal of Spacecraft and Launch Vehicle Stages in Low Earth Orbit

As a result of the increasing number of debris in low Earth orbit (LEO), numerous national and international orbital debris mitigation guidelines recommend the removal of spacecraft and launch vehicle stages from LEO within 25 years after mission termination. The primary purpose of this action is to enhance space safety by significantly limiting the potential of future accidental collisions resulting in the creation of large numbers of new orbital debris. Likewise, the passivation of these objects, i.e., the removal of residual stored energies, while they remain in orbit is important to prevent the generation of debris via self-induced explosions. Characteristics and trends in the growth of the derelict spacecraft and launch vehicle stage populations in LEO are examined. Depending upon the final operational altitude of the vehicle, achieving the goal of orbital lifetime reduction can influence the design and deployment philosophy of a new space system. Some spacecraft and launch vehicle stages have combined their end-of-mission passivation operations with maneuvers to vacate long-lived orbital regimes. Perhaps the most dramatic demonstration of this type occurred in 2006 when a U.S. Delta IV second stage executed an unprecedented controlled-reentry maneuver from a circular orbit at an altitude near 850 km. For space systems in orbital regimes near the upper regions of LEO (i.e., between 1400 km and 2000 km altitude), maneuvers to place the vehicle above LEO might be more attractive than attempting to ensure an atmospheric reentry within 25 years, and at least one space system operator has selected this option. In some cases, careful consideration of natural orbital perturbations can also lead to reduced orbital lifetimes, although new launch constraints might need to be imposed.

Johnson, Nicholas L.↗
NASA NTRS2006

Orion Aerodynamics for Hypersonic Free Molecular to Continuum Conditions

Numerical simulations are performed for the Orion Crew Module, previously known as the Crew Exploration Vehicle (CEV) Command Module, to characterize its aerodynamics during the high altitude portion of its reentry into the Earth's atmosphere, that is, from free molecular to continuum hypersonic conditions. The focus is on flow conditions similar to those that the Orion Crew Module would experience during a return from the International Space Station. The bulk of the calculations are performed with two direct simulation Monte Carlo (DSMC) codes, and these data are anchored with results from both free molecular and Navier-Stokes calculations. Results for aerodynamic forces and moments are presented that demonstrate their sensitivity to rarefaction, that is, for free molecular to continuum conditions (Knudsen numbers of 111 to 0.0003). Also included are aerodynamic data as a function of angle of attack for different levels of rarefaction and results that demonstrate the aerodynamic sensitivity of the Orion CM to a range of reentry velocities (7.6 to 15 km/s).

Moss, James N.↗
NASA NTRS2006

Lightweight Ablative and Ceramic Thermal Protection System Materials for NASA Exploration Systems Vehicles

As a collaborative effort among NASA Centers, the "Lightweight Nonmetallic Thermal Protection Materials Technology" Project was set up to assist mission/vehicle design trade studies, to support risk reduction in thermal protection system (TPS) material selections, to facilitate vehicle mass optimization, and to aid development of human-rated TPS qualification and certification plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on advanced heatshields that allow reductions in spacecraft mass by minimizing propellant requirements. Information will be presented on candidate materials for such reentry approaches and on screening tests conducted (material property and space environmental effects tests) to evaluate viable candidates. Seventeen materials, in three classes (ablatives, tiles, and ceramic matrix composites), were studied. In additional to physical, mechanical, and thermal property tests, high heat flux laser tests and simulated-reentry oxidation tests were performed. Space environmental effects testing, which included exposures to electrons, atomic oxygen, and hypervelocity impacts, was also conducted.

Valentine, Peter G.↗
NASA NTRS2007

Testing of the Crew Exploration Vehicle in NASA Langley's Unitary Plan Wind Tunnel

As part of a strategic, multi-facility test program, subscale testing of NASA s Crew Exploration Vehicle was conducted in both legs of NASA Langley s Unitary Plan Wind Tunnel. The objectives of these tests were to generate aerodynamic and surface pressure data over a range of supersonic Mach numbers and reentry angles of attack for experimental and computational validation and aerodynamic database development. To provide initial information on boundary layer transition at supersonic test conditions, transition studies were conducted using temperature sensitive paint and infrared thermography optical techniques. To support implementation of these optical diagnostics in the Unitary Wind Tunnel, the experiment was first modeled using the Virtual Diagnostics Interface software. For reentry orientations of 140 to 170 degrees (heat shield forward), windward surface flow was entirely laminar for freestream unit Reynolds numbers equal to or less than 3 million per foot. Optical techniques showed qualitative evidence of forced transition on the windward heat shield with application of both distributed grit and discreet trip dots. Longitudinal static force and moment data showed the largest differences with Mach number and angle of attack variations. Differences associated with Reynolds number variation and/or laminar versus turbulent flow on the heat shield were very small. Static surface pressure data supported the aforementioned trends with Mach number, Reynolds number, and angle of attack.

Murphy, Kelly J.↗
NASA NTRS2007

Space Shuttle Debris Impact Tool Assessment Using the Modern Design of Experiments

Complex computer codes are used to estimate thermal and structural reentry loads on the Shuttle Orbiter induced by ice and foam debris impact during ascent. Such debris can create cavities in the Shuttle Thermal Protection System. The sizes and shapes of these cavities are approximated to accommodate a code limitation that requires simple "shoebox" geometries to describe the cavities -- rectangular areas and planar walls that are at constant angles with respect to vertical. These approximations induce uncertainty in the code results. The Modern Design of Experiments (MDOE) has recently been applied to develop a series of resource-minimal computational experiments designed to generate low-order polynomial graduating functions to approximate the more complex underlying codes. These polynomial functions were then used to propagate cavity geometry errors to estimate the uncertainty they induce in the reentry load calculations performed by the underlying code. This paper describes a methodological study focused on evaluating the application of MDOE to future operational codes in a rapid and low-cost way to assess the effects of cavity geometry uncertainty.

DeLoach, Richard↗
NASA NTRS2007

Orbiter Gap Filler Bending Model for Re-entry

Pressure loads on a protruding gap filler during an Orbiter reentry are investigated to evaluate the likelihood of extraction due to pressure loads, and to ascertain how much bending will be induced by re-entry pressure loads. Oblique shock wave theory is utilized to develop a representation of the pressure loads induced on a gap filler for the ISSHVFW trajectory, representative of a heavy weight ISS return. A free body diagram is utilized to react the forces induced by the pressure forces. Preliminary results developed using these methods demonstrate that pressure loads, alone, are not likely causes of gap filler extraction during reentry. Assessment of the amount a gap filler will bend over is presented. Implications of gap filler bending during re-entry include possible mitigation of early boundary layer transition concerns, uncertainty in ground based measurement of protruding gap fillers from historical Orbiter flight history, and uncertainty in the use of Orbiter gap fillers for boundary layer prediction calibration. Authors will be added to the author list as appropriate.

Campbell, Charles H.↗
NASA NTRS2007

Fluorescence Visualization of Hypersonic Flow over Rapid Prototype Wind-Tunnel Models

Reentry models for use in hypersonic wind tunnel tests were fabricated using a stereolithography apparatus. These models were produced in one day or less, which is a significant time savings compared to the manufacture of ceramic or metal models. The models were tested in the NASA Langley Research Center 31-Inch Mach 10 Air Tunnel. Most of the models did not survive repeated tests in the tunnel, and several failure modes of the models were identified. Planar laser-induced fluorescence (PLIF) of nitric oxide (NO) was used to visualize the flowfields in the wakes of these models. Pure NO was either seeded through tubes plumbed into the model or via a tube attached to the strut holding the model, which provided localized addition of NO into the model s wake through a porous metal cylinder attached to the end of the tube. Models included several 2-inch diameter Inflatable Reentry Vehicle Experiment (IRVE) models and 5-inch diameter Crew Exploration Vehicle (CEV) models. Various configurations were studied including different sting placements relative to the models, different model orientations and attachment angles, and different NO seeding methods. The angle of attack of the models was also varied and the location of the laser sheet was scanned to provide three-dimensional flowfield information. Virtual Diagnostics Interface technology, developed at NASA Langley, was used to visualize the data sets in post processing. The use of calibration "dotcards" was investigated to correct for camera perspective and lens distortions in the PLIF images. Lessons learned and recommendations for future experiments are discussed.

Alderfer, D. W.↗
NASA NTRS2007

The Columbia Accident Investigation and The NASA Glenn Ballistic Impact Laboratory Contributions Supporting NASA's Return to Flight

On February 1, 2003, the Space Shuttle Columbia broke apart during reentry, resulting in loss of the vehicle and its seven crewmembers. For the next several months, an extensive investigation of the accident ensued involving a nationwide team of experts from NASA, industry, and academia, spanning dozens of technical disciplines. The Columbia Accident Investigation Board (CAIB), a group of experts assembled to conduct an investigation independent of NASA, concluded in August, 2003 that the most likely cause of the loss of Columbia and its crew was a breach in the left wing leading edge Reinforced Carbon-Carbon (RCC) thermal protection system initiated by the impact of thermal insulating foam that had separated from the orbiters external fuel tank 81 seconds into the mission's launch. During reentry, this breach allowed superheated air to penetrate behind the leading edge and erode the aluminum structure of left wing, which ultimately led to the breakup of the orbiter. The findings of the CAIB were supported by ballistic impact tests, which simulated the physics of External Tank Foam impact on the RCC wing leading edge material. These tests ranged from fundamental material characterization tests to full-scale Orbiter Wing Leading Edge tests. Following the accident investigation, NASA spent the next 18 months focused on returning the shuttle safely to flight. In order to fully evaluate all potential impact threats from the many debris sources on the Space Shuttle during ascent, NASA instituted a significant impact testing program. The results from these tests led to the validation of high-fidelity computer models, capable of predicting actual or potential Shuttle impact events, were used in the certification of STS-114, NASA s Return to Flight Mission, as safe to fly. This presentation will provide a look into the inner workings of the Space Shuttle and a behind the scenes perspective on the impact analysis and testing done for the Columbia Accident Investigation and NASA's Return to Flight programs. In addition, highlights from recent Shuttle missions are presented.

Melis, Matthew E.↗
NASA NTRS2009

Medical Operational Challenges in the Expedition 16 Landing and Recovery

On April 19, 2008 the crew of Expedition 16 left the International Space Station and returned to earth via their Soyuz TMA-11 capsule after 192 days on orbit. Their capsule experienced the second consecutive and third ballistic reentry in the last 10 TMA recoveries and landed approximately 260 miles (420 km) from the prime landing site. Issues: The purpose of this presentation will be to describe, not only the typical medical operational challenges faced by Flight Surgeons recovering a long duration crew from space, but also address the unique challenges that existed with the Expedition 16 landing and crew recovery. Nominal Soyuz recovery challenges include remote recovery sites with crew exposures to sleep shifting and fatigue, dehydration, hypothermia and hyperthermia, and rotational, sustained, and impact g-forces. These environmental factors coupled with the patho-physiologic neuro-vestibular and orthostatic intolerance changes that occur secondary to the crews reintroduction into the earth s gravity field will be detailed. Additional challenges that were unique to this expedition included a ballistic reentry with higher g-loads, the presence of fire outside of the capsule on landing, a contingency medical event of a ground support personnel, and loss of communications with the crew just prior to landing and during recovery operations. Conclusions: In spite of these unique challenges the Russian Search and Rescue Forces and Medical Support personnel along with U.S. Medical Support performed well together. Possible improvements in training and coordination will be discussed.

Moynihan, S.↗
NASA NTRS2008

Fluorescence Imaging and Streamline Visualization of Hypersonic Flow over Rapid Prototype Wind-Tunnel Models

Reentry models for use in hypersonic wind tunnel tests were fabricated using a stereolithography apparatus. These models were produced in one day or less, which is a significant time savings compared to the manufacture of ceramic or metal models. The models were tested in the NASA Langley Research Center 31-Inch Mach 10 Air Tunnel. Only a few of the models survived repeated tests in the tunnel, and several failure modes of the models were identified. Planar laser-induced fluorescence (PLIF) of nitric oxide (NO) was used to visualize the flowfields in the wakes of these models. Pure NO was either seeded through tubes plumbed into the model or via a tube attached to the strut holding the model, which provided localized addition of NO into the model s wake through a porous metal cylinder attached to the end of the tube. Models included several 2- inch diameter Inflatable Reentry Vehicle Experiment (IRVE) models and 5-inch diameter Crew Exploration Vehicle (CEV) models. Various model configurations and NO seeding methods were used, including a new streamwise visualization method based on PLIF. Virtual Diagnostics Interface (ViDI) technology, developed at NASA Langley Research Center, was used to visualize the data sets in post processing. The use of calibration "dotcards" was investigated to correct for camera perspective and lens distortions in the PLIF images.

Danehy, Paul M.↗
NASA NTRS2009

Handbook for Designing MMOD Protection

Spacecraft are subject to micro-meteoroid and orbital debris (MMOD) impact damage which have the potential to degrade performance, shorten the mission, or result in catastrophic loss of the vehicle. Specific MMOD protection requirements are established by NASA for each spacecraft early in the program/project life, to ensure the spacecraft meets desired safety and mission success goals. Both the design and operations influences spacecraft survivability in the MMOD environment, and NASA considers both in meeting MMOD protection requirements. The purpose of this handbook is to provide spacecraft designers and operations personnel with knowledge gained by NASA in implementing effective MMOD protection for the International Space Station, Space Shuttle, and various science spacecraft. It has been drawn from a number of previous publications [10-14], as well as new work. This handbook documents design and operational methods to reduce MMOD risk. In addition, this handbook describes tools and equations needed to design proper MMOD protection. It is a living report, in that it will be updated and re-released periodically in future with additional information. Providing effective and efficient MMOD protection is essential for ensuring safe and successful operations of spacecraft and satellites. A variety of shields protect crew modules, external pressurized vessels and critical equipment from MMOD on the International Space Station (ISS). Certain Space Shuttle Orbiter vehicle systems are hardened from MMOD impact, and operational rules are established to reduce the risk from MMOD (i.e., flight attitudes are selected and late inspection of sensitive thermal protection surfaces are conducted to reduce MMOD impacts). Science spacecraft include specific provisions to meet MMOD protection requirements in their design (for example, Stardust & GLAST). Commercial satellites such as Iridium and Bigelow Aerospace Genesis spacecraft incorporate MMOD protection. The development of low-weight, effective MMOD protection has enabled these spacecraft missions to be performed successfully. This handbook describes these shielding techniques. For future exploration activities to the Moon and Mars, implementing high-performance MMOD shielding will be necessary to meet protection requirements with minimum mass penalty. A current area of technology development in MMOD shielding is the incorporation of sensors to detect and locate MMOD impact damage. Depending on the type of sensor the signals from the sensor can be processed to infer the location of the impact and the extent of damage. The objective of the sensors is to locate critical damage that would endanger the spacecraft or crew immediately or during reentry (such as an air leak from crew module or critical damage to thermal protection system of reentry vehicles). The information from the sensors can then be used with repair kits, patch kits, hatch closure or other appropriate remedial techniques to reduce MMOD risk.

Arnold, Jim↗
NASA NTRS2009

Ballistic Performance of Porous-Ceramic, Thermal-Protection-Systems

Porous-ceramic, thermal protection systems are used heavily in current reentry vehicles like the Space Shuttle and are currently being proposed for the next generation of manned spacecraft, Orion. These materials insulate the structural components of a spacecraft against the intense thermal environments of atmospheric reentry. Furthermore, these materials are also highly exposed to space environmental hazards like meteoroid and orbital debris impacts. This paper discusses recent impact testing up to 9 km/s, and the findings of the influence of material equation-of-state on the simulation of the impact event to characterize the ballistic performance of these materials. These results will be compared with heritage models1 for these materials developed from testing at lower velocities. Assessments of predicted spacecraft risk based upon these tests and simulations will also be discussed.

Christiansen, E. L.↗
NASA NTRS2009

Ballistic Performance of Porous Ceramic Thermal Protection Systems at 9 km/s

Porous-ceramic, thermal-protection-systems are used heavily in current reentry vehicles like the Orbiter, and they are currently being proposed for the next generation of manned spacecraft, Orion. These materials insulate the structural components and sensitive electronic components of a spacecraft against the intense thermal environments of atmospheric reentry. Furthermore, these materials are also highly exposed to space environmental hazards like meteoroid and orbital debris impacts. This paper discusses recent impact testing up to 9 km/s on ceramic tiles similar to those used on the Orbiter. These tiles have a porous-batting of nominally 8 lb/cubic ft alumina-fiber-enhanced-thermal-barrier (AETB8) insulating material coated with a damage-resistant, toughened-unipiece-fibrous-insulation (TUFI) layer.

Miller, Joshua E.↗
NASA NTRS2009

Compartment Venting Analyses of Ares I First Stage Systems Tunnel

Compartment venting analyses have been performed for the Ares I first stage systems tunnel using both the lumped parameter method and the three-dimensional (31)) transient computational fluid dynamics (CFD) approach. The main objective of venting analyses is to predict the magnitudes of differential pressures across the skin so the integrity of solid walls can be evaluated and properly designed. The lumped parameter method assumes the gas pressure and temperature inside the systems tunnel are spatially uniform, which is questionable since the tunnel is about 1,700 in. long and 4 in. wide. Therefore, 31) transient CFD simulations using the commercial CFD code FLUENT are performed in order to examine the gas pressure and temperature variations inside the tunnel. It was found that the uniform pressure and temperature assumptions inside the systems tunnel are valid during ascent. During reentry, the uniform pressure assumption is also reasonable but the uniform temperature assumption is not valid. Predicted pressure and temperature inside the systems tunnel using CFD are also compared with those from the lumped parameter method using the NASA code CHCHVENT. In general, the average pressure and temperature inside the systems tunnel from CFD are between the burst and crush results from CHCHVENT during both ascent and reentry. The skin differential pressure and pressure inside the systems tunnel relative to freestream pressure from CHCHVENT as well as velocity vectors and streamlines are also discussed in detail.

Wang, Qunzhen↗
NASA NTRS2010

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗
NASA NTRS2010

Overview of the Orion Thermal Protection System

The Orion spacecraft is being developed as part of the Constellation Exploration Program and will serve as the United States crewed transportation system to the International Space Station after the retirement of the Space Shuttle in 2010 and as the eventual means to return U.S. astronauts to the Moon. Therefore, Orion is being designed for reentry missions from both low Earth orbit and from Lunar-return trajectories. This presentation will provide an overview of the development of the Orion TPS, a critical component in the development of the spacecraft. The thermal protection system (TPS) that protects the crew module from the extreme environments associated with Earth atmospheric reentry consists of a forward heatshield and an aft backshell. The requirements that drive the design of the TPS will be discussed, including several key requirements that establish a precedent for U.S. human-rated spacecraft. For the first time in U.S. human spaceflight, a vehicle s TPS is being designed with a specific, derived requirement for reliability. Also, due to the increased presence of spacecraft in Earth s orbit in recent decades, requirements for micro-meteoroid/orbital debris damage tolerance are also a driving requirement that has affected the selection of portions of the TPS. The efforts to select materials and to define a preliminary design for both the heatshield and the backshell will be described. This will include a discussion of the design challenges presented by the numerous penetrations on both the backshell and the heatshield. Finally, the verification and validation plan which is currently under development to certify the TPS for human-rated missions will be outlined. To support the execution of this plan, a ground test campaign for both thermal and structural performance is being designed. This test campaign will directly support thermal and thermal/structural analyses that also are fundamental to the certification effort.

Kowal, T. John↗
NASA NTRS2009

Recent Developments in Ultra High Temperature Ceramics at NASA Ames

NASA Ames is pursuing a variety of approaches to modify and control the microstructure of UHTCs with the goal of improving fracture toughness, oxidation resistance and controlling thermal conductivity. The overall goal is to produce materials that can perform reliably as sharp leading edges or nose tips in hypersonic reentry vehicles. Processing approaches include the use of preceramic polymers as the SiC source (as opposed to powder techniques), the addition of third phases to control grain growth and oxidation, and the use of processing techniques to produce high purity materials. Both hot pressing and field assisted sintering have been used to make UHTCs. Characterization of the mechanical and thermal properties of these materials is ongoing, as is arcjet testing to evaluate performance under simulated reentry conditions. The preceramic polymer approach has generated a microstructure in which elongated SiC grains grow in the form of an in-situ composite. This microstructure has the advantage of improving fracture toughness while potentially improving oxidation resistance by reducing the amount and interconnectivity of SiC in the material. Addition of third phases, such as Ir, results in a very fine-grained microstructure, even in hot-pressed samples. The results of processing and compositional changes on microstructure and properties are reported, along with selected arcjet results.

Johnson, Sylvia M.↗
NASA NTRS2009

Collaborative Approaches in Developing Environmental and Safety Management Systems for Commercial Space Transportation

The Federal Aviation Administration (FAA), Office of Commercial Space Transportation (AST) licenses and permits U.S. commercial space launch and reentry activities, and licenses the operation of non-federal launch and reentry sites. ASTs mission is to ensure the protection of the public, property, and the national security and foreign policy interests of the United States during commercial space transportation activities and to encourage, facilitate, and promote U.S. commercial space transportation. AST faces unique challenges of ensuring the protection of public health and safety while facilitating and promoting U.S. commercial space transportation. AST has developed an Environmental Management System (EMS) and a Safety Management System (SMS) to help meet its mission. Although the EMS and SMS were developed independently, the systems share similar elements. Both systems follow a Plan-Do-Act-Check model in identifying potential environmental aspects or public safety hazards, assessing significance in terms of severity and likelihood of occurrence, developing approaches to reduce risk, and verifying that the risk is reduced. This paper will describe the similarities between ASTs EMS and SMS elements and how AST is building a collaborative approach in environmental and safety management to reduce impacts to the environment and risks to the public.

Federal Aviation Administration (FAA)↗