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NASA NTRS2012

Decision Gate Process for Assessment of a NASA Technology Development Portfolio

The NASA Dust Management Project (DMP) was established to provide technologies (to Technology Readiness Level (TRL) 6) required to address adverse effects of lunar dust to humans and to exploration systems and equipment, to reduce life cycle cost and risk, and to increase the probability of sustainable and successful lunar missions. The technology portfolio of DMP consisted of different categories of technologies whose final product was either a technology solution in itself, or one that contributes toward a dust mitigation strategy for a particular application. A Decision Gate Process (DGP) was developed to assess and validate the achievement and priority of the dust mitigation technologies as the technologies progress through the development cycle. The DGP was part of continuous technology assessment and was a critical element of DMP risk management. At the core of the process were technology-specific criteria developed to measure the success of each DMP technology in attaining the technology readiness levels assigned to each decision gate. The DGP accounts for both categories of technologies and qualifies the technology progression from technology development tasks to application areas. The process provided opportunities to validate performance, as well as to identify non-performance in time to adjust resources and direction. This paper describes the overall philosophy of the DGP and the methodology for implementation for DMP, and describes the method for defining the technology evaluation criteria. The process is illustrated by example of an application to a specific DMP technology.

Kohli, Rajiv↗
NASA NTRS2013

A Kinematic Calibration Process for Flight Robotic Arms

The Mars Science Laboratory (MSL) robotic arm is ten times more massive than any Mars robotic arm before it, yet with similar accuracy and repeatability positioning requirements. In order to assess and validate these requirements, a higher-fidelity model and calibration processes were needed. Kinematic calibration of robotic arms is a common and necessary process to ensure good positioning performance. Most methodologies assume a rigid arm, high-accuracy data collection, and some kind of optimization of kinematic parameters. A new detailed kinematic and deflection model of the MSL robotic arm was formulated in the design phase and used to update the initial positioning and orientation accuracy and repeatability requirements. This model included a higher-fidelity link stiffness matrix representation, as well as a link level thermal expansion model. In addition, it included an actuator backlash model. Analytical results highlighted the sensitivity of the arm accuracy to its joint initialization methodology. Because of this, a new technique for initializing the arm joint encoders through hardstop calibration was developed. This involved selecting arm configurations to use in Earth-based hardstop calibration that had corresponding configurations on Mars with the same joint torque to ensure repeatability in the different gravity environment. The process used to collect calibration data for the arm included the use of multiple weight stand-in turrets with enough metrology targets to reconstruct the full six-degree-of-freedom location of the rover and tool frames. The follow-on data processing of the metrology data utilized a standard differential formulation and linear parameter optimization technique.

Collins, Curtis L.↗
NASA NTRS2013

NASA Advanced Concepts Office, Earth-To-Orbit Team Design Process and Tools

The Earth-to-Orbit Team (ETO) of the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) is considered the pre-eminent "go-to" group for pre-phase A and phase A concept definition. Over the past several years the ETO team has evaluated thousands of launch vehicle concept variations for a significant number of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Augustine Report, Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS). The ACO ETO Team is called upon to address many needs in NASA's design community; some of these are defining extremely large trade-spaces, evaluating advanced technology concepts which have not been addressed by a large majority of the aerospace community, and the rapid turn-around of highly time critical actions. It is the time critical actions, those often limited by schedule or little advanced warning, that have forced the five member ETO team to develop a design process robust enough to handle their current output level in order to meet their customer's needs. Based on the number of vehicle concepts evaluated over the past year this output level averages to four completed vehicle concepts per day. Each of these completed vehicle concepts includes a full mass breakdown of the vehicle to a tertiary level of subsystem components and a vehicle trajectory analysis to determine optimized payload delivery to specified orbital parameters, flight environments, and delta v capability. A structural analysis of the vehicle to determine flight loads based on the trajectory output, material properties, and geometry of the concept is also performed. Due to working in this fast-paced and sometimes rapidly changing environment, the ETO Team has developed a finely tuned process to maximize their delivery capabilities. The objective of this paper is to describe the interfaces between the three disciplines used in the design process: weights and sizing, trajectory, and structural analysis. The tools used to perform such analysis are INtegrated Rocket Sizing (INTROS), Program to Optimize Simulated Trajectories (POST), and Launch Vehicle Analysis (LVA) respectively. The methods each discipline uses to streamline their particular part of the design process will also be discussed.

Waters, Eric D.↗
NASA NTRS2014

Computational Process Modeling for Additive Manufacturing

Computational Process and Material Modeling of Powder Bed additive manufacturing of IN 718. Optimize material build parameters with reduced time and cost through modeling. Increase understanding of build properties. Increase reliability of builds. Decrease time to adoption of process for critical hardware. Potential to decrease post-build heat treatments. Conduct single-track and coupon builds at various build parameters. Record build parameter information and QM Meltpool data. Refine Applied Optimization powder bed AM process model using data. Report thermal modeling results. Conduct metallography of build samples. Calibrate STK models using metallography findings. Run STK models using AO thermal profiles and report STK modeling results. Validate modeling with additional build. Photodiode Intensity measurements highly linear with power input. Melt Pool Intensity highly correlated to Melt Pool Size. Melt Pool size and intensity increase with power. Applied Optimization will use data to develop powder bed additive manufacturing process model.

Bagg, Stacey↗
NASA NTRS2014

Acoustic Data Processing and Transient Signal Analysis for the Hybrid Wing Body 14- by 22-Foot Subsonic Wind Tunnel Test

An advanced vehicle concept, the HWB N2A-EXTE aircraft design, was tested in NASA Langley's 14- by 22-Foot Subsonic Wind Tunnel to study its acoustic characteristics for var- ious propulsion system installation and airframe con gurations. A signi cant upgrade to existing data processing systems was implemented, with a focus on portability and a re- duction in turnaround time. These requirements were met by updating codes originally written for a cluster environment and transferring them to a local workstation while en- abling GPU computing. Post-test, additional processing of the time series was required to remove transient hydrodynamic gusts from some of the microphone time series. A novel automated procedure was developed to analyze and reject contaminated blocks of data, under the assumption that the desired acoustic signal of interest was a band-limited sta- tionary random process, and of lower variance than the hydrodynamic contamination. The procedure is shown to successfully identify and remove contaminated blocks of data and retain the desired acoustic signal. Additional corrections to the data, mainly background subtraction, shear layer refraction calculations, atmospheric attenuation and microphone directivity corrections, were all necessary for initial analysis and noise assessments. These were implemented for the post-processing of spectral data, and are shown to behave as expected.

Bahr, Christopher J.↗
NASA NTRS2014

Preparation Process and Dielectric Properties of Ba(0.5)Sr(0.5)TiO3-P(VDF-CTFE) Nanocomposites

Ceramic-polymer 0-3 nanocomposites, in which nanosized Ba(0.5)Sr(0.5)TiO3 (BST) powders were used as ceramic filler and P(VDF-CTFE) 88/12 mol% [poly(vinylidene fluoridechlorotrifluoroethylene)] copolymer was used as matrix, were studied over a concentration range from 0 to 50 vol.% of BST powders. It is found that the solution cast composites are porous and a hot-press process can eliminate the porosity, which results in a dense composite film. Two different configurations used in the hot-press process are studied. Although there is no clear difference in the uniformity and microstructure of the composites prepared using these two configurations, the composite prepared using one configuration exhibit a higher dielectric constant with a lower loss. For the composite with 40 vol. BST, a dielectric constant of 70 with a loss of 0.07 at 1 kHz is obtained at room temperature. The composites exhibit a lower dielectric loss than the polymer matrix at high frequency. However, at low frequency, the composites exhibit a higher loss than the polymer matrix due to a low frequency relaxation process that appears in the composites. It is believed that this relaxation process is related to the interfacial layer formed between BST particle and the polymer matrix. The temperature dependence of the dielectric property of the composites was studied. It is found that the dielectric constant of these composites is almost independent of the temperature over a temperature range from 20 to 120 C. Key words: A. Polymer-matrix composites (PMCs); B. Electrical Properties; E. Casting; E. Heat treatment; Dielectric properties.

Zhang, Lin↗
NASA NTRS2014

Microstructure and Macrosegregation Study of Directionally Solidified Al-7Si Samples Processed Terrestrially and Aboard the International Space Station

This talk reports research that has been carried out under the aegis of NASA as part of a collaboration between ESA and NASA for solidification experiments on the International Space Station (ISS). The focus has been on the effect of convection on the microstructural evolution and macrosegregation in hypoeutectic Al‐Si alloys during directional solidification (DS). The DS‐experiments have been carried out under 1‐g at Cleveland State University (CSU) and under low‐g on the International Space Station (ISS). The thermal processing‐history of the experiments is well defined for both the terrestrially‐processed samples and the ISS‐processed samples. We have observed that the primary dendrite arm spacings of two samples grown in the low‐g environment of the ISS show good agreement with a dendrite‐growth model based on diffusion controlled growth. The gravity‐driven convection (i.e., thermosolutal convection) in terrestrially grown samples has the effect of decreasing the primary dendrite arm spacings and causes macrosgregation. In order to process DS‐samples aboard the ISS, dendritic‐seed crystals have to partially remelted in a stationary thermal gradient before the DS is carried out. Microstructural changes and macrosegregation effects during this period are described.

Angart, Samuel↗
NASA NTRS2014

Novel Materials, Processing and Device Technologies for Space Exploration with Potential Dual-Use Applications

We highlight results of a broad spectrum of efforts on lower-temperature processing of nanomaterials, novel approaches to energy conversion, and environmentally rugged devices. Solution-processed quantum dots of copper indium chalcogenide semiconductors and multiwalled carbon nanotubes from lower-temperature spray pyrolysis are enabled by novel (precursor) chemistry. Metal-doped zinc oxide (ZnO) nanostructured components of photovoltaic cells have been grown in solution at low temperature on a conductive indium tin oxide substrate. Arrays of ZnO nanorods can be templated and decorated with various semiconductor and metallic nanoparticles. Utilizing ZnO in a more broadly defined energy conversion sense as photocatalysts, unwanted organic waste materials can potentially be repurposed. Current efforts on charge carrier dynamics in nanoscale electrode architectures used in photoelectrochemical cells for generating solar electricity and fuels are described. The objective is to develop oxide nanowire-based electrode architectures that exhibit improved charge separation, charge collection and allow for efficient light absorption. Investigation of the charge carrier transport and recombination properties of the electrodes will aid in the understanding of how nanowire architectures improve performance of electrodes for dye-sensitized solar cells. Nanomaterials can be incorporated in a number of advanced higher-performance (i.e. mass specific power) photovoltaic arrays. Advanced technologies for the deposition of 4H-silicon carbide are described. The use of novel precursors, advanced processing, and process studies, including modeling are discussed from the perspective of enhancing the performance of this promising material for enabling technologies such as solar electric propulsion. Potential impact(s) of these technologies for a variety of aerospace applications are highlighted throughout. Finally, examples are given of technologies with potential spin-offs for dual-use or terrestrial applications.

solid state devices↗
NASA NTRS2010

Probabilistic Round Trip Contamination Analysis of a Mars Sample Acquisition and Handling Process Using Markovian Decompositions

A method for evaluating the probability of a Viable Earth Microorganism (VEM) contaminating a sample during the sample acquisition and handling (SAH) process of a potential future Mars Sample Return mission is developed. A scenario where multiple core samples would be acquired using a rotary percussive coring tool, deployed from an arm on a MER class rover is analyzed. The analysis is conducted in a structured way by decomposing sample acquisition and handling process into a series of discrete time steps, and breaking the physical system into a set of relevant components. At each discrete time step, two key functions are defined: The probability of a VEM being released from each component, and the transport matrix, which represents the probability of VEM transport from one component to another. By defining the expected the number of VEMs on each component at the start of the sampling process, these decompositions allow the expected number of VEMs on each component at each sampling step to be represented as a Markov chain. This formalism provides a rigorous mathematical framework in which to analyze the probability of a VEM entering the sample chain, as well as making the analysis tractable by breaking the process down into small analyzable steps.

Hudson, Nicolas↗
NASA NTRS2008

Cassini's Maneuver Automation Software (MAS) Process: How to Successfully Command 200 Navigation Maneuvers

To keep Cassini on its complex trajectory, more than 200 orbit trim maneuvers (OTMs) have been planned from July 2004 to July 2010. With only a few days between many of these OTMs, the operations process of planning and executing the necessary commands had to be automated. The resulting Maneuver Automation Software (MAS) process minimizes the workforce required for, and maximizes the efficiency of, the maneuver design and uplink activities. The MAS process is a well-organized and logically constructed interface between Cassini's Navigation (NAV), Spacecraft Operations (SCO), and Ground Software teams. Upon delivery of an orbit determination (OD) from NAV, the MAS process can generate a maneuver design and all related uplink and verification products within 30 minutes. To date, all 112 OTMs executed by the Cassini spacecraft have been successful. MAS was even used to successfully design and execute a maneuver while the spacecraft was in safe mode.

Yang, Genevie Velarde↗
NASA NTRS2016

Normalized Temperature Contrast Processing in Flash Infrared Thermography

The paper presents further development in normalized contrast processing of flash infrared thermography method by the author given in US 8,577,120 B1. The method of computing normalized image or pixel intensity contrast, and normalized temperature contrast are provided, including converting one from the other. Methods of assessing emissivity of the object, afterglow heat flux, reflection temperature change and temperature video imaging during flash thermography are provided. Temperature imaging and normalized temperature contrast imaging provide certain advantages over pixel intensity normalized contrast processing by reducing effect of reflected energy in images and measurements, providing better quantitative data. The subject matter for this paper mostly comes from US 9,066,028 B1 by the author. Examples of normalized image processing video images and normalized temperature processing video images are provided. Examples of surface temperature video images, surface temperature rise video images and simple contrast video images area also provided. Temperature video imaging in flash infrared thermography allows better comparison with flash thermography simulation using commercial software which provides temperature video as the output. Temperature imaging also allows easy comparison of surface temperature change to camera temperature sensitivity or noise equivalent temperature difference (NETD) to assess probability of detecting (POD) anomalies.

Koshti, Ajay M.↗
NASA NTRS2016

Process for Upgrading Cognitive Assessment Capabilities Onboard the International Space Station

MOTIVATION: Spaceflight poses varied and unique risks to the brain and cognitive functioning including radiation exposure, sleep disturbance, fatigue, fluid shifts (increased intracranial pressure), toxin exposure, elevated carbon dioxide, and traumatic brain injury, among others. These potential threats to cognitive functioning are capable of degrading performance and compromising mission success. Furthermore, the threats may increase in severity, and new types of threats may emerge for longer duration exploration missions. This presentation will describe the process used to identify gaps in our current approach, evaluate best practices in cognitive assessment, and transition new cognitive assessment tools to operational use. OVERVIEW: Risks to brain health and performance posed by spaceflight missions require sensitive tools to assess cognitive functioning of astronauts in flight. The Spaceflight Cognitive Assessment Tool for Windows (WinSCAT) is the automated cognitive assessment tool currently deployed onboard the International Space Station (ISS). WinSCAT provides astronauts and flight surgeons with objective data to monitor neurocognitive functioning. WinSCAT assesses 5 discrete cognitive domains, is sensitive to changes in cognitive functioning, and was designed to be completed in less than 15 minutes. However, WinSCAT does not probe other areas of cognitive functioning that might be important to mission success. Researchers recently have developed batteries that may expand current capabilities, such as increased sensitivity to subtle fluctuations in cognitive functioning. Therefore, we engaged in a systematic process review in order to improve upon our current capabilities and incorporate new advances in cognitive assessment. This process included a literature review on newer measures of neurocognitive assessment, surveys of operational flight surgeons at NASA regarding needs and gaps in our capabilities, and expert panel review of candidate cognitive measures and assessment issues and procedures. SIGNIFICANCE: Our process and the results that flowed from it may be helpful to aeromedical professionals charged with transitioning research findings to operational use. Our specific findings regarding cognitive assessment tools are of significance to professionals who must assess readiness to perform in mission critical situations in environments involving threats to cognition and performance

Picano, J. J.↗
NASA NTRS2015

Novel Materials, Processing, and Device Technologies for Space Exploration with Potential Dual-Use Applications

We highlight results of a broad spectrum of efforts on lower-temperature processing of nanomaterials, novel approaches to energy conversion, and environmentally rugged devices. Solution-processed quantum dots of copper indium chalcogenide semiconductors and multi-walled carbon nanotubes from lower-temperature spray pyrolysis are enabled by novel (precursor) chemistry. Metal-doped zinc oxide (ZnO) nanostructured components of photovoltaic cells have been grown in solution at low temperature on a conductive indium tin oxide substrate. Arrays of ZnO nanorods can be templated and decorated with various semiconductor and metallic nanoparticles. Utilizing ZnO in a more broadly defined energy conversion sense as photocatalysts, unwanted organic waste materials can potentially be re-purposed. Current efforts on charge carrier dynamics in nanoscale electrode architectures used in photoelectrochemical cells for generating solar electricity and fuels are described. The objective is to develop oxide nanowire-based electrode architectures that exhibit improved charge separation, charge collection and allow for efficient light absorption. Investigation of the charge carrier transport and recombination properties of the electrodes will aid in the understanding of how nanowire architectures improve performance of electrodes for dye-sensitized solar cells. Nanomaterials can be incorporated in a number of advanced higher-performance (i.e. mass specific power) photovoltaic arrays. Advanced technologies for the deposition of 4H-silicon carbide are described. The use of novel precursors, advanced processing, and process studies, including modeling are discussed from the perspective of enhancing the performance of this promising material for enabling technologies such as solar electric propulsion. Potential impact(s) of these technologies for a variety of aerospace applications are highlighted throughout. Finally, examples are given of technologies with potential spin-offs for dual-use or terrestrial applications.

thin films↗
NASA NTRS2016

Resource Prospector Instrumentation for Lunar Volatiles Prospecting, Sample Acquisition and Processing

Data gathered from lunar missions within the last two decades have significantly enhanced our understanding of the volatile resources available on the lunar surface, specifically focusing on the polar regions. Several orbiting missions such as Clementine and Lunar Prospector have suggested the presence of volatile ices and enhanced hydrogen concentrations in the permanently shadowed regions of the moon. The Lunar Crater Observation and Sensing Satellite (LCROSS) mission was the first to provide direct measurement of water ice in a permanently shadowed region. These missions with other orbiting assets have laid the groundwork for the next step in the exploration of the lunar surface; providing ground truth data of the volatiles by mapping the distribution and processing lunar regolith for resource extraction. This next step is the robotic mission Resource Prospector (RP). Resource Prospector is a lunar mission to investigate 'strategic knowledge gaps' (SKGs) for in-situ resource utilization (ISRU). The mission is proposed to land in the lunar south pole near a permanently shadowed crater. The landing site will be determined by the science team with input from broader international community as being near traversable landscape that has a high potential of containing elevated concentrations of volatiles such as water while maximizing mission duration. A rover will host the Regolith & Environment Science and Oxygen & Lunar Volatile Extraction (RESOLVE) payload for resource mapping and processing. The science instruments on the payload include a 1-meter drill, neutron spectrometer, a near infrared spectrometer, an operations camera, and a reactor with a gas chromatograph-mass spectrometer for volatile analysis. After the RP lander safely delivers the rover to the lunar surface, the science team will guide the rover team on the first traverse plan. The neutron spectrometer (NS) and near infrared (NIR) spectrometer instruments will be used as prospecting tools to guide the traverse path. The NS will map the water-equivalent hydrogen concentration as low as 0.5% by weight to an 80 centimeter depth as the rover traverses the lunar landscape. The NIR spectrometer will measure surficial H2O/OH as well as general mineralogy. When the prospecting instruments identify a potential volatile-rich area during the course of a traverse, the prospect is then mapped out and the most promising location identified. An augering drill capable of sampling to a depth of 100 centimeters will excavate regolith for analysis. A quick assay of the drill cuttings will be made using an operations camera and NIR spectrometer. With the water depth confirmed by this first auguring activity, a regolith sample may be extracted for processing. The drill will deliver the regolith sample to a crucible that will be sealed and heated. Evolved volatiles will be measured by a gas chromatograph-mass spectrometer and the water will be captured and photographed. RP is a solar powered mission, which given the polar location translates to a relatively short mission duration on the order of 4-15 days. This short mission duration drives the concept of operations, instrumentation, and data analysis towards critical real time analysis and decision support. Previous payload field tests have increased the fidelity of the hardware, software, and mission operations. Current activities include a mission level field test to optimize interfaces between the payload and rover as well as better understand the interaction of the science and rover teams during the mission timeline. This paper will include the current status of the science instruments on the payload as well as the integrated field test occurring in fall of 2015. The concept of operations will be discussed, including the real time science and engineering decision-making process based on the critical data from the instrumentation. The path to flight will be discussed with the approach to this ambitious low cost mission.

ISRU↗
NASA NTRS2015

ExMC Work Prioritization Process

Last year, NASA's Human Research Program (HRP) introduced the concept of a "Path to Risk Reduction" (PRR), which will provide a roadmap that shows how the work being done within each HRP element can be mapped to reducing or closing exploration risks. Efforts are currently underway within the Exploration Medical Capability (ExMC) Element to develop a structured, repeatable process for prioritizing work utilizing decision analysis techniques and risk estimation tools. The goal of this effort is to ensure that the work done within the element maximizes risk reduction for future exploration missions in a quantifiable way and better aligns with the intent and content of the Path to Risk Reduction. The Integrated Medical Model (IMM) will be used to identify those conditions that are major contributors of medical risk for a given design reference mission. For each of these conditions, potential prevention, screening, diagnosis, and treatment methods will be identified. ExMC will then aim to prioritize its potential investments in these mitigation methods based upon their potential for risk reduction and other factors such as vehicle performance impacts, near term schedule needs, duplication with external efforts, and cost. This presentation will describe the process developed to perform this prioritization and inform investment discussions in future element planning efforts. It will also provide an overview of the required input information, types of process participants, figures of merit, and the expected outputs of the process.

Simon, Matthew↗
NASA NTRS1973

Inelastic Light Scattering Processes

Five different inelastic light scattering processes will be denoted by, ordinary Raman scattering (ORS), resonance Raman scattering (RRS), off-resonance fluorescence (ORF), resonance fluorescence (RF), and broad fluorescence (BF). A distinction between fluorescence (including ORF and RF) and Raman scattering (including ORS and RRS) will be made in terms of the number of intermediate molecular states which contribute significantly to the scattered amplitude, and not in terms of excited state lifetimes or virtual versus real processes. The theory of these processes will be reviewed, including the effects of pressure, laser wavelength, and laser spectral distribution on the scattered intensity. The application of these processes to the remote sensing of atmospheric pollutants will be discussed briefly. It will be pointed out that the poor sensitivity of the ORS technique cannot be increased by going toward resonance without also compromising the advantages it has over the RF technique. Experimental results on inelastic light scattering from I(sub 2) vapor will be presented. As a single longitudinal mode 5145 A argon-ion laser line was tuned away from an I(sub 2) absorption line, the scattering was observed to change from RF to ORF. The basis, of the distinction is the different pressure dependence of the scattered intensity. Nearly three orders of magnitude enhancement of the scattered intensity was measured in going from ORF to RF. Forty-seven overtones were observed and their relative intensities measured. The ORF cross section of I(sub 2) compared to the ORS cross section of N2 was found to be 3 x 10(exp 6), with I(sub 2) at its room temperature vapor pressure.

Fouche, Daniel G.↗
NASA NTRS2016

DebriSat Fragment Characterization System and Processing Status

The DebriSat project is a continuing effort sponsored by NASA and DoD to update existing break-up models using data obtained from hypervelocity impact tests performed to simulate on-orbit collisions. After the impact tests, a team at the University of Florida has been working to characterize the fragments in terms of their mass, size, shape, color and material content. The focus of the post-impact effort has been the collection of 2 mm and larger fragments resulting from the hypervelocity impact test. To date, in excess of 125K fragments have been recovered which is approximately 40K more than the 85K fragments predicted by the existing models. While the fragment collection activities continue, there has been a transition to the characterization of the recovered fragments. Since the start of the characterization effort, the focus has been on the use of automation to (i) expedite the fragment characterization process and (ii) minimize the effects of human subjectivity on the results; e.g., automated data entry processes were developed and implemented to minimize errors during transcription of the measurement data. At all steps of the process, however, there is human oversight to ensure the integrity of the data. Additionally, repeatability and reproducibility tests have been developed and implemented to ensure that the instrumentations used in the characterization process are accurate and properly calibrated.

Rivero, M.↗
NASA NTRS2016

Application of Design of Experiments and Surrogate Modeling within the NASA Advanced Concepts Office, Earth-to-Orbit Design Process

Decisions made during early conceptual design have a large impact upon the expected life-cycle cost (LCC) of a new program. It is widely accepted that up to 80% of such cost is committed during these early design phases.1 Therefore, to help minimize LCC, decisions made during conceptual design must be based upon as much information as possible. To aid in the decision making for new launch vehicle programs, the Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center (MSFC) provides rapid turnaround pre-phase A and phase A concept definition studies. The ACO team utilizes a proven set of tools to provide customers with a full vehicle mass breakdown to tertiary subsystems, preliminary structural sizing based upon worst-case flight loads, and trajectory optimization to quantify integrated vehicle performance for a given mission.2 Although the team provides rapid turnaround for single vehicle concepts, the scope of the trade space can be limited due to analyst availability and the manpower requirements for manual execution of the analysis tools. In order to enable exploration of a broader design space, the ACO team has implemented an Advanced Design Methods (ADM) based approach. This approach applies the concepts of Design of Experiments (DOE) and surrogate modeling to more exhaustively explore the trade space and provide the customer with additional design information to inform decision making. This paper will first discuss the automation of the ACO tool set, which represents a majority of the development e ort. In order to t a surrogate model within tolerable error bounds a number of DOE cases are needed. This number will scale with the number of variable parameters desired and the complexity of the system's response to those variables. For all but the smallest design spaces, the number of cases required cannot be produced within an acceptable timeframe using a manual process. Therefore, automation of the tools was a key enabler for the successful application of an ADM approach to an ACO design study. Following the overview of the tool set automation, an example problem will be given to illustrate the implementation of the ADM approach. The example problem will first cover the inclusion of Ground Rules and Assumptions (GR&A) for a study. The GR&A are very important to the study as they determine the constraints within which a trade study can be conducted. These trades must ultimately reconcile with the customer's desired output and any anticipated \what if" questions. The example problem will then illustrate the setup and execution of a DOE through the automated ACO tools. This process is accomplished more efficiently in this work by splitting the tools into two separate environments. The first environment encompasses the structural optimization and mass estimation tools, while the second is focused on trajectory optimization. Surrogate models are t to the outputs of each environment and are integrated via connection of the surrogate equations. Throughout this process, checks are implemented to compare the output of the surrogates to the output of manually run cases to ensure that the error of the final surrogates is at an acceptable level. The conclusion of the example problem demonstrates the utility of the ADM based approach. Using surrogate models gives the ACO team the ability to visualize vehicle sensitivities to various design parameters and identify regions of interest within the design space. The ADM approach can thus be used to inform concept down selection and isolate promising vehicle configurations to be explored in more detail through the manual design process. In addition it provides the customer with an almost instantaneous turnaround on any \what if" questions that may arise within the bounds of the surrogate model. This approach ultimately expands the ability of the ACO team to provide its customer with broad and rapid turnaround trade studies for launch vehicle conceptual design. The ability to identify a selection of designs which can meet the customer requirements will have the potential to lower LCC of launch vehicle designs originating from ACO.

Zwack, Mathew R.↗