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NASA NTRS2016

Ultrasonic Nondestructive Evaluation of Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) During Large-Scale Load Testing and Rod Push-Out Testing

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept developed by the Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration. The HWB has long been a focus of NASA's environmentally responsible aviation (ERA) project, following a building block approach to structures development, culminating with the testing of a nearly full-scale multi-bay box (MBB), representing a segment of the pressurized, non-circular fuselage portion of the HWB. PRSEUS is an integral structural concept wherein skins, frames, stringers and tear straps made of variable number of layers of dry warp-knit carbon-fiber stacks are stitched together, then resin-infused and cured in an out-of-autoclave process. The PRSEUS concept has the potential for reducing the weight and cost and increasing the structural efficiency of transport aircraft structures. A key feature of PRSEUS is the damage-arresting nature of the stitches, which enables the use of fail-safe design principles. During the load testing of the MBB, ultrasonic nondestructive evaluation (NDE) was used to monitor several sites of intentional barely-visible impact damage (BVID) as well as to survey the areas surrounding the failure cracks after final loading to catastrophic failure. The damage-arresting ability of PRSEUS was confirmed by the results of NDE. In parallel with the large-scale structural testing of the MBB, mechanical tests were conducted of the PRSEUS rod-to-overwrap bonds, as measured by pushing the rod axially from a short length of stringer.

Johnston, Patrick H.↗
NASA NTRS2002

SMEX-Lite Modular Solar Array Architecture

For the most part, Goddard solar arrays have been custom designs that are unique to each mission. The solar panel design has been frozen prior to issuing an RFP for their procurement. There has typically been 6-9 months between RFP release and contract award, followed by an additional 24 months for performance of the contract. For Small Explorer (SMEX) missions, with three years between mission definition and launch, this has been a significant problem. The SMEX solar panels have been sufficiently small that the contract performance period has been reduced to 12-15 months. The bulk of this time is used up in the final design definition and fabrication of flight solar cell assemblies. Even so, it has been virtually impossible to have the spacecraft design at a level of maturity sufficient to freeze the solar panel geometry and release the RFP in time to avoid schedule problems with integrating the solar panels to the spacecraft. With that in mind, the SMEX-Lite project team developed a modular architecture for the assembly of solar arrays to greatly reduce the cost and schedule associated with the development of a mission- specific solar array. In the modular architecture, solar cells are fabricated onto small substrate panels. This modular panel (approximately 8.5" x 17" in this case) becomes the building block for constructing solar arrays for multiple missions with varying power requirements and geometrical arrangements. The mechanical framework that holds these modules together as a solar array is the only mission-unique design, changing in size and shape as required for each mission. There are several advantages to this approach. First, the typical solar array development cycle requires a mission unique design, procurement, and qualification including a custom qualification panel. With the modular architecture, a single qualification of the SMEX-Lite modules and the associated mechanical framework in a typical configuration provided a qualification by similarity to multiple missions. It then becomes possible to procure solar array modules in advance of mission definition and respond quickly and inexpensively to a selected mission's unique requirements. The solar array modular architecture allows the procurement of solar array modules before the array geometry has been frozen. This reduces the effect of procurement lead-time on the mission integration and test flow by as much as 50%. Second, by spreading the non-recurring costs over multiple missions, the cost per unit area is also reduced. In the case of the SMEX-Lite procurement, this reduction was by about one third of the cost per unit area compared to previous SMEX mission-unique procurements. Third, the modular architecture greatly facilitates the infusion of new solar cell technologies into flight programs as these technologies become available. New solar cell technologies need only be fabricated onto a standard-sized module to be incorporated into the next available mission. The modular solar array can be flown in a mixed configuration with some new and some standard cell technologies. Since each module has its own wiring terminals, the array can be arranged as desired electrically with little impact to cost and schedule. The solar array modular architecture does impose some additional constraints on systems and subsystem engineers. First, they must work with discrete solar array modules rather than size the array to fit exactly within an available envelope. The array area is constrained to an integer multiple of the module area. Second, the modular design is optimized for space radiation and thermal environments not greatly different from a typical SMEX LEO environment. For example, a mission with a highly elliptical orbit (e.g., Polar, SMEX/FAST) would require thicker coverglasses to protect the solar cells from the more intense radiation environment.

Lyons, John↗
NASA NTRS2008

Low-Light-Shift Cesium Fountain without Mechanical Shutters

A new technique for reducing errors in a laser-cooled cesium fountain frequency standard provides for strong suppression of the light shift without need for mechanical shutters. Because mechanical shutters are typically susceptible to failure after operating times of the order of months, the elimination of mechanical shutters could contribute significantly to the reliability of frequency standards that are required to function continuously for longer time intervals. With respect to the operation of an atomic-fountain frequency standard, the term "light shift" denotes an undesired relative shift in the two energy levels of the atoms (in this case, cesium atoms) in the atomic fountain during interrogation by microwaves. The shift in energy levels translates to a frequency shift that reduces the precision and possibly accuracy of the frequency standard. For reasons too complex to describe within the space available for this article, the light shift is caused by any laser light that reaches the atoms during the microwave- interrogation period, but is strongest for near-resonance light. In the absence of any mitigating design feature, the light shift, expressed as a fraction of the standard fs frequency, could be as large as approx. 2 x 10(exp -11), the largest error in the standard. In a typical prior design, to suppress light shift, the intensity of laser light is reduced during the interrogation period by using a single-pass acoustooptic modulator to deflect the majority of light away from the main optical path. Mechanical shutters are used to block the remaining undeflected light to ensure complete attenuation. Without shutters, this remaining undeflected light could cause a light shift of as much as .10.15, which is unacceptably large in some applications. The new technique implemented here involves additionally shifting the laser wavelength off resonance by a relatively large amount (typically of the order of nanometers) during microwave interrogation. In this design, when microwave interrogation is not underway, the atoms are illuminated by a slave laser locked to the lasing frequency of a lower power master laser.

Enzer, Daphna↗
NASA NTRS2012

Design, Analysis and Testing of a PRSEUS Pressure Cube to Investigate Assembly Joints

Due to its potential to significantly increase fuel efficiency, the current focus of NASA's Environmentally Responsible Aviation Program is the hybrid wing body (HWB) aircraft. Due to the complex load condition that exists in HWB structure, as compared to traditional aircraft configurations, light-weight, cost-effective and manufacturable structural concepts are required to enable the HWB. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is one such structural concept. A building block approach for technology development of the PRSEUS concept is being conducted. As part of this approach, a PRSEUS pressure cube was developed as a risk reduction test article to examine a new integral cap joint concept. This paper describes the design, analysis and testing of the PRSEUS pressure cube test article. The pressure cube was required to withstand a 2P, 18.4 psi, overpressure load requirement. The pristine pressure cube was tested to 2.2P with no catastrophic failure. After the addition of barely visible impact damage, the cube was pressure loaded to 48 psi where catastrophic failure occurred, meeting the scale-up requirement. Comparison of pretest and posttest analyses with the cube test response agree well, and indicate that current analysis methods can be used to accurately analyze PRSEUS structure for initial failure response.

Yovanof, Nicolette↗
NASA NTRS2015

NASA Manufacturing and Test Requirements for Normally Closed Pyrovalves for Hazardous Flight Systems Applications

Pyrovalves (figure 1, Basic Pyrovalve Design and Features,) are typically lighter, more reliable, and in most cases less expensive than other types of valves. They also consume less electrical power. They are single-use devices that are used in propulsion systems to isolate propellants or pressurant gases. These fluids may be hazardous because of their toxicity, reactivity, temperature, or high pressure. Note that in the simplified block diagram below not all detail features are shown so that those of major interest are more prominent. The diagram is provided to point out the various features that are discussed in this Specification. Features of some NC parent metal valve designs may differ. In 2013, the NESC concluded an extensive study of the reliability and safety of NC parent metal valves used in payloads carried aboard ELVs. The assessment successfully evaluated technical data to determine the risk of NC parent metal valve leakage or inadvertent activation in ELV payloads. The study resulted in numerous recommendations to ensure personnel and hardware/facility safety during ground processing of ELV payloads. One of those recommendations was to establish a NASA specification for NC parent metal valves. This Specification is a result of that recommendation, which is documented in NESC-RP-10-00614.

McDougle, Stephen H.↗
NASA NTRS2018

NASA's Space Launch System Moves into Testing and Integration

NASA's Space Launch System (SLS) has moved from design and manufacturing into testing and integration for its first flight as early as December 2019. In 2017, the NASA/industry team completed manufacturing of all major structural elements for the launch vehicle for Exploration Mission-I (EM-1 ). That work included shipping the first major flight hardware element to the launch site. The team processed all four RS-25 engines for stage integration, cast all 10 booster flight motor segments, and manufactured all five major sections of the core stage. The program also completed major structural work on the B-2 test stand at Stennis Space Center, which will be used for the core stage "green run" test; delivered the core stage and engine simulators used for training; and much of the transportation equipment for the core stage. Engineers completed structural testing on the upper stage/payload section of the vehicle as well as the engine section test article. In 2018, the program will deliver the Orion Stage Adapter (OSA) to Exploration Ground Systems (EGS) at KSC and send the test articles for the core stage liquid hydrogen tank, liquid oxygen tank, and intertank to NASA's Marshall Space Flight center for structural testing. Additionally, workers will begin the challenging process of integrating the major sections of the 212-foot EM-1 core stage. This work is focused on the initial Block 1 variant of SLS, capable of launching more than 70 metric tons (t) to low Earth orbit (LEO). However, work concurrently is underway on the Block lB variant, which will enable 105 t to LEO and more than 37t to trans-lunar injection (TLI). Block lB will be the workhorse vehicle of NASA's lunar exploration plans. As the needs of the nation's deep space exploration program grow, SLS performance is designed to evolve to a payload mass of 130 t to LEO and up to 45t to TLI. The advantages of this mass - as well as volume- are critical to the entire exploration architecture for deep space exploration. They translate to greater capability, greater infrastructure and operational simplicity, less overall mission risk, and opportunities to accomplish unprecedented exploration and discovery. This paper will discuss SLS progress to date and planned future work.

Honeycutt, John↗
NASA NTRS2011

High-Speed Generation of Illumination Spectra for a Stereoscopic Endoscope

Traditional stereoscopic vision (3D) is achieved through use of two separate cameras, arranged to emulate human eyes. This method works well on most projects, but becomes impractical on small scale designs, such as surgical endoscopes. This project is focused on developing a stereoscopic endoscope, using a single camera and Conjugated Multiple?Bandpass Filters (CMBF) to produce stereoscopic vision. Each half of filter is built to allow a distinct spectrum to pass through, while blocking the complimentary spectrum. A system with complimentary filters can produce stereoscopic images. To accomplish this, the light must be filtered at the source to match the filters at the camera. Additionally, the light source and camera must be synchronized in a way that each image will show only one filter spectrum. In this paper, I will describe the design and characterization of the prototype electro?optical system, including optical throughput measurements and video produced using this method.

Conjugated Multiple?Bandpass Filters (CMBF)↗
NASA NTRS1976

The unified data system - A distributed processing network for control and data handling on a spacecraft

This paper presents the results obtained in a continuing investigation of real-time distributed processing systems which is being conducted at the Jet Propulsion Laboratory. A distributed processor architecture has been developed for control and data handling on a planetary spacecraft. This system, designated the Unified Data System, has been implemented in a feasibility breadboard. The following aspects of the Unified Data System are described: (1) standardized building block elements and their configuration into microprocessor modules, (2) a highly redundant bus structure which connects the various modules and facilitates intercommunications with minimal software support, (3) the structure of software within the individual modules and its coordination between modules, and (4) the mechanisms by which fault-tolerance can be implemented within the network. Through the attributes of multilevel standardization, simplicity, and flexibility, this system is expected to result in significant cost savings to future spacecraft missions.

Rennels, D. A.↗
NASA NTRS1992

The data acquisition system for the Anglo-Australian Observatory 2-degree field project

The Anglo-Australian Observatory (AAO) is building a system that will provide a two-degree field of view at prime focus. A robot positioner will be used to locate up to 400 optical fibers at pre-determined positions in this field. While observations are being made using one set of 400 fibers, the robot will be positioning a second set of fibers in a background field that can be moved in to replace the first when the telescope is moved to a new position. The fibers feed two spectrographs each with a 1024 square CCD detector. The software system being produced to control this involves Vaxes for overall control and data recording, UNIX workstations for fiber configuration calculations and on-line data reduction, and VME systems running VxWorks for real-time control of critical parts such as the positioner robot. The system has to be able to interact with the observatory's present data acquisition systems, which use the ADAM system. As yet, the real-time parts of ADAM have not been ported to Unix, and so we are having to produce a smaller-scale system that is similar but inherently distributed (which ADAM is not). We are using this system as a testbed for ideas that we hope may eventually influence an ADAM II system. The system we are producing is based on a message system that is designed to be able to handle inter-process and inter-processor messages of any length, efficiently, and without ever requiring a task to block (i.e., be unresponsive to 'cancel' messages, enquiry messages), other than when deliberately waiting for external input - all of which will be through such messages. The essential requirement is that a message 'send' operation should never be able to block. The messages will be hierarchical, self-defining, machine-independent data structures. This allows us to provide very simple monitoring of messages for diagnostic purposes, and allows general purpose interface programs to be written without needing to share precise byte by byte message format definitions. Programs in this system have interfaces defined simply in terms of named actions and their parameters. Real-time control programs are required to be able to handle a number of such actions concurrently; data reduction programs will normally only need to handle one action at a time ('process an image', 'display a spectrum', etc).

Shortridge, K.↗
NASA NTRS1995

Advanced flight computer. Special study

This report documents a special study to define a 32-bit radiation hardened, SEU tolerant flight computer architecture, and to investigate current or near-term technologies and development efforts that contribute to the Advanced Flight Computer (AFC) design and development. An AFC processing node architecture is defined. Each node may consist of a multi-chip processor as needed. The modular, building block approach uses VLSI technology and packaging methods that demonstrate a feasible AFC module in 1998 that meets that AFC goals. The defined architecture and approach demonstrate a clear low-risk, low-cost path to the 1998 production goal, with intermediate prototypes in 1996.

Coo, Dennis↗
NASA NTRS1972

HELIOS Critical Design Review: Reliability

This paper presents Helios Critical Design Review Reliability form October 16-20, 1972. The topics include: 1) Reliability Requirement; 2) Reliability Apportionment; 3) Failure Rates; 4) Reliability Assessment; 5) Reliability Block Diagram; and 5) Reliability Information Sheet.

Benoehr, H. C.↗
NASA NTRS2003

Initial SVS Integrated Technology Evaluation Flight Test Requirements and Hardware Architecture

This document presents the flight test requirements for the Initial Synthetic Vision Systems Integrated Technology Evaluation flight Test to be flown aboard NASA Langley's ARIES aircraft and the final hardware architecture implemented to meet these requirements. Part I of this document contains the hardware, software, simulator, and flight operations requirements for this light test as they were defined in August 2002. The contents of this section are the actual requirements document that was signed for this flight test. Part II of this document contains information pertaining to the hardware architecture that was realized to meet these requirements as presented to and approved by a Critical Design Review Panel prior to installation on the B-757 Airborne Research Integrated Experiments Systems (ARIES) airplane. This information includes a description of the equipment, block diagrams of the architecture, layouts of the workstations, and pictures of the actual installations.

Harrison, Stella V.↗
NASA NTRS2004

The In-Flight Calibration Program for the XRS on Astro-E2

The X-Ray Spectrometer (XRS) will be launched in February 2005 as part of the Astro-E2 mission. It will provide unprecedented throughput and resolving powers particularly at high energies. In this presentation we will describe the in-flight calibration program. The energy scale of the XRS is a complex, non-linear function of the noise and power conditions on the array. It will be calibrated empirically using the bright point sources, Capella and GX301-2. Ground calibration of the line spread function show it to be almost perfectly Gaussian. The in-flight calibration is designed to verify this using the energy scale targets. The effective area curve of the XRS contains discreet edge structure from the mirrors, the optical blocking filters, and the microcalorimeter HgTe absorbers. The effective area Calibration program will simultaneously measure these absorption edges and the global effective area properties using the relatively featureless sources 3C273 and Mrk421. Additional monitoring of any ice build-up on the filters will be conducted using observations of the supernova remnants N132D and E0102.

Cottam, J.↗
NASA NTRS2012

Radiation-Hard SpaceWire/Gigabit Ethernet-Compatible Transponder

A radiation-hard transponder was developed utilizing submicron/nanotechnology from IBM. The device consumes low power and has a low fabrication cost. This device utilizes a Plug-and-Play concept, and can be integrated into intra-satellite networks, supporting SpaceWire and Gigabit Ethernet I/O. A space-qualified, 100-pin package also was developed, allowing space-qualified (class K) transponders to be delivered within a six-month time frame. The novel, optical, radiation-tolerant transponder was implemented as a standalone board, containing the transponder ASIC (application specific integrated circuit) and optical module, with an FPGA (field-programmable gate array) friendly parallel interface. It features improved radiation tolerance; high-data-rate, low-power consumption; and advanced functionality. The transponder utilizes a patented current mode logic library of radiation-hardened-by-architecture cells. The transponder was developed, fabricated, and radhard tested up to 1 MRad. It was fabricated using 90-nm CMOS (complementary metal oxide semiconductor) 9 SF process from IBM, and incorporates full BIT circuitry, allowing a loop back test. The low-speed parallel LVCMOS (lowvoltage complementary metal oxide semiconductor) bus is compatible with Actel FPGA. The output LVDS (low-voltage differential signaling) interface operates up to 1.5 Gb/s. Built-in CDR (clock-data recovery) circuitry provides robust synchronization and incorporates two alarm signals such as synch loss and signal loss. The ultra-linear peak detector scheme allows on-line control of the amplitude of the input signal. Power consumption is less than 300 mW. The developed transponder with a 1.25 Gb/s serial data rate incorporates a 10-to-1 serializer with an internal clock multiplication unit and a 10-1 deserializer with internal clock and data recovery block, which can operate with 8B10B encoded signals. Three loop-back test modes are provided to facilitate the built-in-test functionality. The design is based on a proprietary library of differential current switching logic cells implemented in the standard 90-nm CMOS 9SF technology from IBM. The proprietary low-power LVDS physical interface is fully compatible with the SpaceWire standard, and can be directly connected to the SFP MSA (small form factor pluggable Multiple Source Agreement) optical transponder. The low-speed parallel interfaces are fully compatible with the standard 1.8 V CMOS input/output devices. The utilized proprietary annular CMOS layout structures provide TID tolerance above 1.2 MRad. The complete chip consumes less than 150 mW of power from a single 1.8-V positive supply source.

Katzman, Vladimir↗
NASA NTRS2018

Mission Concept for a Europa Lander

A NASA HQ-directed study team led by the Jet Propulsion Laboratory (JPL) with partners including Applied Physics Lab, Marshall Space Flight Center, Goddard Space Flight Center, Langley Research Center and Sandia National Laboratory has recently presented a mission concept for a Europa Lander that would search for bio-signatures and signs of life in the near-subsurface of the Jovian moon. The mission would follow the Europa Clipper multiple-flyby mission, planned for launch in June of 2022, which would provide reconnaissance imagery and other data to the Lander for use in selecting a scientifically compelling site and certifying it for engineering safety. The Europa Lander concept accommodates the Model Payload identified by the Europa Lander Science Definition Team (SDT) and documented in the Europa Lander Study 2016 Report released in February of 2017. The currently envisioned Europa Lander would launch on an SLS Block 1B as early as October of 2025 into a VEGA trajectory, arriving in the Jovian system as early as July of 2030. The baseline design of the integrated flight system includes a dedicated Carrier and Relay Stage, a Deorbit Vehicle composed of a Deorbit Stage consisting of a solid rocket motor (SRM), an MSL-like sky-crane Descent Stage, and a Lander which accommodates the instrument suite. The Lander would be powered by primary batteries over a 20-day surface mission. The science goals envisioned by the SDT require five samples taken from a depth of 10cm, a depth chosen to ensure minimal radiation processing of the potential biomarkers. Mission challenges include the large launch mass, unknown terrain topography, surface composition and materials properties, the high radiation environment, and complying with stringent planetary protection requirements. The mission concept uses a strategy of early risk reduction and overlapping requirements to provide robustness to harsh and uncertain environments. Early risk reduction efforts are aimed at maturing technologies associated with the sampling system, the intelligent landing system, high specific energy batteries, low mass and power motor controllers, and a thermal sterilization system.

Dooley, Jennifer↗
NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗
NASA NTRS2004

Atlas V Launch Incorporated NASA Glenn Thermal Barrier

In the Spring of 2002, Aerojet experienced a major failure during a qualification test of the solid rocket motor that they were developing for the Atlas V Enhanced Expendable Launch Vehicle. In that test, hot combustion gas reached the O-rings in the nozzle-to-case joint and caused a structural failure that resulted in loss of the nozzle and aft dome sections of the motor. To improve the design of this joint, Aerojet decided to incorporate three braided carbon-fiber thermal barriers developed at the NASA Glenn Research Center. The thermal barriers were used to block the searing-hot 5500 F pressurized gases from reaching the temperature-sensitive O-rings that seal the joint. Glenn originally developed the thermal barriers for the nozzle joints of the space shuttle solid rocket motors, and Aerojet decided to use them on the basis of the results of several successful ground tests of the thermal barriers in the shuttle rockets. Aerojet undertook an aggressive schedule to redesign the rocket nozzle-to-case joint with the thermal barriers and to qualify it in time for a launch planned for the middle of 2003. They performed two successful qualification tests (Oct. and Dec. 2002) in which the Glenn thermal barriers effectively protected the O-rings. These qualification tests saved hundreds of thousands of dollars in development costs and put the Lockheed-Martin/Aerojet team back on schedule. On July 17, 2003, the first flight of an Atlas V boosted with solid rocket motors successfully launched a commercial satellite into orbit from Cape Canaveral Air Force Station. Aero-jet's two 67-ft solid rocket boosters performed flawlessly, with each providing thrust in excess of 250,000 lbf. Both motors incorporated three Glenn-developed thermal barriers in their nozzle-to-case joints. The Cablevision satellite launched on this mission will be used to provide direct-to-home satellite television programming for the U.S. market starting in late 2003. The Atlas V is a product of the military's Enhanced Expendable Launch Vehicle program designed to provide assured military access to space. It can lift payloads up to 19,100 lb to geosynchronous transfer orbit and was designed to meet Department of Defense, commercial, and NASA needs. The Atlas V and Delta IV are two launch systems being considered by NASA to launch the Orbital Space Plane/Crew Exploration Vehicle. The launch and rocket costs of this mission are valued at $250 million. Successful application of the Glenn thermal barrier to the Atlas V program was an enormous breakthrough for the program's technical and schedule success.

Dunlap, Patrick H., Jr.↗