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NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗

NASA NTRS2015

Attitude Ground System (AGS) for the Magnetospheric Multi-Scale (MMS) Mission

MMS Overview Recall from Conrads presentation earlier today MMS launch: March 13, 2015 on an Atlas V from Space Launch Complex 40, Cape Canaveral, Florida MMS Observatory Separation: five minute intervals spinning at 3 rpm approximately 1.5 hours after launch MMS Science Goals: study magnetospheric plasma physics and understand the processes that cause power grids, communication disruptions and Aurora formation Mission: 4 identical spacecraft in tetrahedral formation with variable size1.2 x 12 RE in Phase 1, with apogee on dayside to observe bow shock1.2 x 25 RE in Phase 2, with apogee on night side to observe magneto tail Challenges Tight attitude control box, orbit and formation maintenance requirements Maneuvers on thrusters every two weeks Delta-H Spin axis direction and spin rate maintenance Delta-V Orbit and Formation maintenance Mission phase transitions AGS support Smart targeting prediction of Spin-Axis attitude in the presence of environmental torques to stay within the science attitude Determination of the spacecraft attitude and spin rate (sensitive to knowledge of inertia tensor)Calibrations to improve attitude determination results and improve orbit maneuvers Mass properties (Center of Mass, and inertia tensor for nutation and coning) Accelerometer bias (sensitive to the accuracy of the rate estimates) Sensor alignments.

Estimation and Calibration Support↗

NASA NTRS2015

Loop Heat Pipe Temperature Oscillation Induced by Gravity Assist and Reservoir Heating

The Laser Thermal Control System (LCTS) for the Advanced Topographic Laser Altimeter System (ATLAS) to be installed on NASA's Ice, Cloud, and Land Elevation Satellite (ICESat-2) consists of a constant conductance heat pipe and a loop heat pipe (LHP) with an associated radiator. During the recent thermal vacuum testing of the LTCS where the LHP condenser/radiator was placed in a vertical position above the evaporator and reservoir, it was found that the LHP reservoir control heater power requirement was much higher than the analytical model had predicted. Even with the control heater turned on continuously at its full power, the reservoir could not be maintained at its desired set point temperature. An investigation of the LHP behaviors found that the root cause of the problem was fluid flow and reservoir temperature oscillations, which led to persistent alternate forward and reversed flow along the liquid line and an imbalance between the vapor mass flow rate in the vapor line and liquid mass flow rate in the liquid line. The flow and temperature oscillations were caused by an interaction between gravity and reservoir heating, and were exacerbated by the large thermal mass of the instrument simulator which modulated the net heat load to the evaporator, and the vertical radiator/condenser which induced a variable gravitational pressure head. Furthermore, causes and effects of the contributing factors to flow and temperature oscillations intermingled.

0000↗

NASA NTRS2015

Predicting the Mineral Composition of Dust Aerosols: Model Evaluation and Identification of Key Processes with Observations - Part 2

A global compilation of nearly sixty measurement studies is used to evaluate two methods of simulating the mineral composition of dust aerosols in an Earth system model. Both methods are based upon a Mean Mineralogical Table (MMT) that relates the soil mineral fractions to a global atlas of arid soil type. The Soil Mineral Fraction (SMF) method assumes that the aerosol mineral fractions match the fractions of the soil. The MMT is based upon soil measurements after wet sieving, a process that destroys aggregates of soil particles that would have been emitted from the original, undisturbed soil. The second method approximately reconstructs the emitted aggregates. This model is referred to as the Aerosol Mineral Fraction (AMF) method because the mineral fractions of the aerosols differ from those of the wet-sieved parent soil, partly due to reaggregation. The AMF method remedies some of the deficiencies of the SMF method in comparison to observations. Only the AMF method exhibits phyllosilicate mass at silt sizes, where they are abundant according to observations. In addition, the AMF quartz fraction of silt particles is in better agreement with measured values, in contrast to the overestimated SMF fraction. Measurements at distinct clay and silt particle sizes are shown to be more useful for evaluation of the models, in contrast to the sum over all particles sizes that is susceptible to compensating errors, as illustrated by the SMF experiment. Model errors suggest that allocation of the emitted silt fraction of each mineral into the corresponding transported size categories is an important remaining source of uncertainty. Evaluation of both models and the MMT is hindered by the limited number of size-resolved measurements of mineral content that sparsely sample aerosols from the major dust sources. The importance of climate processes dependent upon aerosol mineral composition shows the need for global and routine mineral measurements.

aerosols↗

NASA NTRS2013

Transfer Trajectory Design for the Mars Atmosphere and Volatile Evolution (MAVEN) Mission

The Mars Atmosphere and Volatile Evolution (MAVEN) mission will determine the history of the loss of volatiles from the Martian atmosphere from a highly inclined elliptical orbit. MAVEN will launch from Cape Canaveral Air Force Station on an Atlas-V 401 during an extended 36-day launch period opening November 18, 2013. The MAVEN Navigation and Mission Design team performed a Monte Carlo analysis of the Type-II transfer to characterize; dispersions of the arrival B-Plane, trajectory correction maneuvers (TCMs), and the probability of Mars impact. This paper presents detailed analysis of critical MOI event coverage, maneuver constraints, deltaV-99 budgets, and Planetary Protection requirements.

Folta, David↗

NASA NTRS2015

[Redesign of the Spacesuit Long Life Battery and the Personal Life Support System Battery]

This fall I was working on two different projects that culminated into a redesign of the spacesuit LLB (long life battery). I also did some work on the PLSS (personal life support system) battery with EC. My first project was redlining the work instruction for completing DPAs (destructive physical analysis) on battery cells in the department. The purpose of this document is to create a standard process and ensure that the data in the same way no matter who carries out the analysis. I observed three DPAs, conducted one with help, and conducted two on my own all while taking notes on the procedure. These notes were used to write the final work instruction that will become is the department standard. My second project continued the work of the summer co-op before me. I was testing aluminum heat sinks for their ability to provide good thermal conduction and structural support during a thermal runaway event. The heat sinks were designed by the summer intern but there was not much time for testing before he left. We ran tests with a heater on the bottom of a trigger cell to try to drive thermal runaway and ensure that it will not propagate to adjacent cells. We also ran heat-to-vent tests in an oven to see if the assembly provided structural support and prevented sidewall rupture during thermal runaway. These tests were carried out at ESTA (energy systems test area) and are providing very promising results that safe, high performing (greater than 180 Wh/kg) designs are possible. My main project was a redesign of the LLB battery. Another summer intern did some testing and concluded that there was no simple fix to mitigate thermal runaway propagation hazards in the current design. The only option was a clean sheet redesign of the battery. I was given a volume and ideal energy density and the rest of the design was up to me. First, I created new heat sink banks in Creo using the information gathered in the metal heat sink tests from the summer intern. After this, I made capture plates to hold the cells in place and I worked on nickel bussings for the electrical connections between the cells. Finally, I designed the test box enclosure that included sections for flame arresting materials. The battery brick design, which is the heart of the battery, promises to become the first for a manned spacecraft application to achieve greater than 180 Wh/kg. My work in redlining the DPA work instructions will also be used in selecting the cells for the battery. We had a few options of cells that would provide the necessary power output and needed to make a choice. We repeatedly charged and discharged cells for around a month until they went through 100 lifecycles. The plan is to compare the DPA results on fresh and cycled cells from each manufacturer to see if cycling introduces any differences. After the complete LLB design was approved, the parts were ordered and testing should begin the first week of December. Some of my side projects included working on the CAD data for the PLSS with EC and attending the NASA Aerospace Battery Workshop in Huntsville. I was also a member of the Tours and Lectures Committee for the USRA and Pathways interns. I coordinated Apollo Evening and was on the committee for touring KSC and seeing an Atlas 5 launch. I really enjoyed my time at JSC and I would like to continue working for NASA or another aerospace company in the future. I have worked other internships prior to this, but I think the heavy research and development focus is the best fit for me. I originally thought I would need to go to grad school to work in an environment like this, but I now see it is possible with a bachelor’s degree and hard work. I would like to go into the workforce and maybe continue my education with night classes.

Scharf, Stephanie↗

NASA NTRS2014

Self-Raman Nd:YVO4 Laser and Electro-Optic Technology for Space-Based Sodium Lidar Instrument

We are developing a laser and electro-optic technology to remotely measure Sodium (Na) by adapting existing lidar technology with space flight heritage. The developed instrumentation will serve as the core for the planning of an Heliophysics mission targeted to study the composition and dynamics of Earth's mesosphere based on a spaceborne lidar that will measure the mesospheric Na layer. We present performance results from our diode-pumped tunable Q-switched self-Raman c-cut Nd:YVO4 laser with intra-cavity frequency doubling that produces multi-watt 589 nm wavelength output. The c-cut Nd:YVO4 laser has a fundamental wavelength that is tunable from 1063-1067 nanometers. A CW (Continuous Wave) External Cavity diode laser is used as a injection seeder to provide single-frequency grating tunable output around 1066 nanometers. The injection-seeded self-Raman shifted Nd:VO4 laser is tuned across the sodium vapor D2 line at 589 nanometers. We will review technologies that provide strong leverage for the sodium lidar laser system with strong heritage from the Ice Cloud and Land Elevation Satellite-2 (ICESat-2) Advanced Topographic Laser Altimeter System (ATLAS). These include a space-qualified frequency-doubled 9 watts-at-532-nanometer wavelength Nd:YVO4 laser, a tandem interference filter temperature-stabilized fused-silica-etalon receiver and high-bandwidth photon-counting detectors.

Krainak, Michael A.↗

NASA NTRS2014

Self-Raman Nd:YVO4 Laser and Electro-Optic Technology for Space-Based Sodium Lidar Instrument

Krainak, Michael A.↗

NASA NTRS2016

HIAD on ULA (HULA) Orbital Reentry Flight Experiment Concept

This paper describes a proposed orbital velocity reentry flight test of a Hypersonic Inflatable Aerodynamic Decelerator (HIAD). The flight test builds upon ground development activities that continue to advance the materials, design, and manufacturing techniques for the inflatable structure and flexible thermal protection system (F-TPS) that comprise the inflatable heat shield. While certain aspects of material and system performance can be assessed using a variety of ground testing capabilities, only orbital velocity energy on a trajectory through the gradient density of the atmosphere can impart the combined aerodynamic and aeroheating design environments in real time. To achieve this at limited cost, the HIAD would be delivered to a spin-stabilized entry trajectory as a secondary payload on the Centaur stage of a United Launch Alliance (ULA) Atlas V launch vehicle. Initial trajectory studies indicate that the combination of launch vehicle capability and achievable reentry vehicle ballistic numbers make this a strategic opportunity for technology development. This 4 to 6 meter diameter scale aeroshell flight, referred to as HIAD on ULA (HULA), would also contribute to ULA asset recovery development. ULA has proposed that a HIAD be utilized as part of the Sensible, Modular, Autonomous Return Technology (SMART) initiative to enable recovery of the Vulcan launch vehicle booster main engines [1], including a Mid-Air Recovery (MAR) to gently return these assets for reuse. Whereas HULA will attain valuable aerothermal and structural response data toward advancing HIAD technology, it may also provide a largest-to-date scaled flight test of the MAR operation, which in turn would allow the examination of a nearly pristine post-entry aeroshell. By utilizing infrared camera imaging, HULA will also attain aft-side thermal response data, enhancing understanding of the aft side aerothermal environment, an area of high uncertainty. The aeroshell inflation will utilize a heritage design compressed gas system to minimize development costs. The data will be captured to both an onboard recorder and a recorder that is jettisoned and recovered separately from the reentry vehicle to mitigate risk. This paper provides an overview, including the architecture and flight concept of operations, for the proposed HULA flight experiment.

Dinonno, J. M.↗

NASA NTRS2016

Performance Efficient Launch Vehicle Recovery and Reuse

For decades, economic reuse of launch vehicles has been an elusive goal. Recent attempts at demonstrating elements of launch vehicle recovery for reuse have invigorated a debate over the merits of different approaches. The parameter most often used to assess the cost of access to space is dollars-per-kilogram to orbit. When comparing reusable vs. expendable launch vehicles, that ratio has been shown to be most sensitive to the performance lost as a result of enabling the reusability. This paper will briefly review the historical background and results of recent attempts to recover launch vehicle assets for reuse. The business case for reuse will be reviewed, with emphasis on the performance expended to recover those assets, and the practicality of the most ambitious reuse concept, namely propulsive return to the launch site. In 2015, United Launch Alliance (ULA) announced its Sensible, Modular, Autonomous Return Technology (SMART) reuse plan for recovery of the booster module for its new Vulcan launch vehicle. That plan employs a non-propulsive approach where atmospheric entry, descent and landing (EDL) technologies are utilized. Elements of such a system have a wide variety of applications, from recovery of launch vehicle elements in suborbital trajectories all the way to human space exploration. This paper will include an update on ULA's booster module recovery approach, which relies on Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and Mid-Air Retrieval (MAR) technologies, including its concept of operations (ConOps). The HIAD design, as well as parafoil staging and MAR concepts, will be discussed. Recent HIAD development activities and near term plans including scalability, next generation materials for the inflatable structure and heat shield, and gas generator inflation systems will be provided. MAR topics will include the ConOps for recovery, helicopter selection and staging, and the state of the art of parachute recovery systems using large parafoils for space asset recovery and high altitude deployment. The next proposed HIAD flight demonstration is called HULA (for HIAD on ULA), and will feature a 6m diameter HIAD. An update for the HULA concept will be provided in this paper. As proposed, this demonstration will fly as a secondary payload on an Atlas mission. The Centaur upper stage provides the reentry pointing, deorbit burn, and entry vehicle spin up. The flight test will culminate with a recovery of the HIAD using MAR. HULA will provide data from a Low Earth Orbit (LEO) return aeroheating environment that enables predictive model correlation and refinement. The resultant reduction in performance uncertainties should lead to design efficiencies that are increasingly significant at larger scales. Relevance to human scale Mars EDL using a HIAD will also be presented, and the applicability of the data generated from both HULA and SMART Vulcan flights, and its value for NASA's human exploration efforts will be discussed. A summary and conclusion will follow.

Reed, John G.↗

NASA NTRS2016

MABEL Photon-Counting Laser Altimetry Data in Alaska for ICESat-2 Simulations and Development

Multiple Altimeter Beam Experimental Lidar (MABEL) maps Alaskan crevasses in detail, using 50 of the expected along-track Advanced Topographic Laser Altimeter System (ATLAS) signal-photon densities over summer ice sheets. Ice, Cloud, and Land Elevation Satellite 2 (ICESat-2) along-track data density, and spatial data density due to the multiple-beam strategy, will provide a new dataset to mid-latitude alpine glacier researchers.

Landsat-8↗

NASA NTRS1959

Space Probes Program Status Report

Brief of Progress: A. Preparations for the 26 November launching of ABLE-4 ATLAS are proceeding as scheduled, with no problems apparent at this time. Many of the electrical tests and subsystems checks have been completed. Minor modifications have been made to the solar paddle tie-down and release mechanism, after an extensive testing program; B. Work toward the 10 December launching of ABLE-4 THOR is also progressing on schedule. Subsystem checks have been started, and mechanical fit checks have been completed; C. During the month of October, a total of 136 tests were performed on components and assemblies related to the ABLE program. These included acceptance tests, type tests, R&D tests, etc. Of this total, only three failures occurred, all of which have been corrected; D. The Space Physics Data Library, Los Angeles, California, is now in operation. Data reduction gear in the Library is in breadboard operation with completion of the installation expected by mid-November. Analysis of ABLE-3 data is progressing satisfactorily at the Library.

Source record↗

NASA NTRS2017

Inflight Performance of the SDO Fine Pointing Science Mode

The Solar Dynamics Observatory (SDO) was successfully launched and deployed from its Atlas V launch vehicle on February 11, 2010. Three months later, on May 14, 2010, the fully commissioned heliophysics laboratory was handed over to Space Systems Mission Operations to begin its science mission. SDO is an Explorer-class mission now operating in a geosynchronous orbit, sending data 24 hours per day to a dedicated ground station in White Sands, New Mexico. It carries a suite of instruments designed to observe the Sun in multiple wavelengths at unprecedented resolution. The Atmospheric Imaging Assembly (AIA) includes four telescopes with 4096x4096 focal plane CCDs that can image the full solar disk in seven extreme ultraviolet and three ultraviolet-visible wavelengths. The Extreme Ultraviolet Variability Experiment (EVE) collects time-correlated data on the activity of the Sun's corona. The Helioseismic and Magnetic Imager (HMI) enables study of pressure waves moving through the body of the Sun.

Control↗

NASA NTRS2017

Designing to Sample the Unknown: Lessons from OSIRIS-REx Project Systems Engineering

On September 8, 2016, the third NASA New Frontiers mission launched on an Atlas V 411. The Origins, Spectral Interpretation, Resource Identification, Security-Regolith Explorer (OSIRIS-REx) will rendezvous with asteroid Bennu in 2018, collect a sample in 2020, and return that sample to Earth in September 2023. The development team has overcome a number of challenges in order to design and build a system that will make contact with an unexplored, airless, low-gravity body. This paper will provide an overview of the mission, then focus in on the system-level challenges and some of the key system-level processes. Some of the lessons here are unique to the type of mission, like discussion of operating at a largely-unknown, low-gravity object. Other lessons, particularly from the build phase, have broad implications. The OSIRIS-REx risk management process was particularly effective in achieving an on-time and under-budget development effort. The systematic requirements management and verification and the system validation also helped identify numerous potential problems. The final assessment of the OSIRIS-REx performance will need to wait until the sample is returned in 2023, but this post-launch assessment will capture some of the key systems-engineering lessons from the development team.

Asteroid↗

NASA NTRS2016

Aerocapture Design Study for a Titan Polar Orbiter

In 2014 a team at NASA Goddard Space Flight Center (GSFC) studied the feasibility of using active aerocapture to reduce the chemical Delta V requirements for inserting a small scientific satellite into Titan polar orbit. The scientific goals of the mission would be multi-spectral imaging and active radar mapping of Titan's surface and subsurface. The study objectives were to: (i) identify and select from launch window opportunities and refine the trajectory to Titan; (ii) study the aerocapture flight path and refine the entry corridor; (iii) design a carrier spacecraft and systems architecture; (iv) develop a scientific and engineering plan for the orbital portion of the mission. Study results include: (i) a launch in October 2021 on an Atlas V vehicle, using gravity assists from Earth and Venus to arrive at Titan in January 2031; (ii) initial aerocapture via an 8-km wide entry corridor to reach an initial 350X6000 km orbit, followed by aerobraking to reach a 350X1500 km orbit, and a periapse raise maneuver to reach a final 1500 km circular orbit; (iii) a three-part spacecraft system consisting of a cruise stage, radiator module, and orbiter inside a heat shield; (iv) a 22-month mission including station keeping to prevent orbital decay due to Saturn perturbations, with 240 Gb of compressed data returned. High-level issues identified include: (i) downlink capability - realistic downlink rates preclude the desired multi-spectral, global coverage of Titan's surface; (ii) power - demise of the NASA ASRG (Advanced Stirling Radioisotope Generator) program, and limited availability at present of MMRTGs (Multi-Mission Radioisotope Generators) needed for competed outer planet missions; (iii) thermal - external radiators must be carried to remove 4 kW of waste heat from MMRTGs inside the aeroshell, requiring heat pipes that pass through the aeroshell lid, compromising shielding ability; (iv) optical navigation to reach the entry corridor; (v) the NASA requirement of continuous critical event coverage for the orbiter, especially during the peak heating of the aerocapture when the radio link will be broken. In conclusion, although Titan aerocapture allows for considerable savings in propellant mass, this comes at a cost of increased mission complexity. Further architecture study and refinement is required to reduce high-level mission risks and to elucidate the optimum architecture.

Nixon, Conor A.↗

NASA NTRS2017

Carbon-Carbon Nozzle Extension Development in Support of In-Space and Upper-Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. Due to the large size of such nozzles, and the related engine performance requirements, carbon-carbon (C-C) composite nozzle extensions are being considered to reduce weight impacts. Currently, the state-of-the-art is represented by the metallic and foreign composite nozzle extensions limited to approximately 2000 degrees F. used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles. NASA and industry partners are working towards advancing the domestic supply chain for C-C composite nozzle extensions. These development efforts are primarily being conducted through the NASA Small Business Innovation Research (SBIR) program in addition to other low level internal research efforts. This has allowed for the initial material development and characterization, subscale hardware fabrication, and completion of hot-fire testing in relevant environments. NASA and industry partners have designed, fabricated and hot-fire tested several subscale domestically produced C-C extensions to advance the material and coatings fabrication technology for use with a variety of liquid rocket and scramjet engines. Testing at NASA's Marshall Space Flight Center (MSFC) evaluated heritage and state-of-the-art C-C materials and coatings, demonstrating the initial capabilities of the high temperature materials and their fabrication methods. This paper discusses the initial material development, design and fabrication of the subscale carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work. The follow on work includes the fabrication of ultra-high temperature materials, larger C-C nozzle extensions, material characterization, sub-element testing and hot-fire testing at larger scale.

Gradl, Paul R.↗

NASA NTRS2017

Methodology for Assessing Reusability of Spaceflight Hardware

In 2011 the Space Shuttle, the only Reusable Launch Vehicle (RLV) in the world, returned to earth for the final time. Upon retirement of the Space Shuttle, the United States (U.S.) no longer possessed a reusable vehicle or the capability to send American astronauts to space. With the National Aeronautics and Space Administration (NASA) out of the RLV business and now only pursuing Expendable Launch Vehicles (ELV), not only did companies within the U.S. start to actively pursue the development of either RLVs or reusable components, but entities around the world began to venture into the reusable market. For example, SpaceX and Blue Origin are developing reusable vehicles and engines. The Indian Space Research Organization is developing a reusable space plane and Airbus is exploring the possibility of reusing its first stage engines and avionics housed in the flyback propulsion unit referred to as the Advanced Expendable Launcher with Innovative engine Economy (Adeline). Even United Launch Alliance (ULA) has announced plans for eventually replacing the Atlas and Delta expendable rockets with a family of RLVs called Vulcan. Reuse can be categorized as either fully reusable, the situation in which the entire vehicle is recovered, or partially reusable such as the National Space Transportation System (NSTS) where only the Space Shuttle, Space Shuttle Main Engines (SSME), and Solid Rocket Boosters (SRB) are reused. With this influx of renewed interest in reusability for space applications, it is imperative that a systematic approach be developed for assessing the reusability of spaceflight hardware. The partially reusable NSTS offered many opportunities to glean lessons learned; however, when it came to efficient operability for reuse the Space Shuttle and its associated hardware fell short primarily because of its two to four-month turnaround time. Although there have been several attempts at designing RLVs in the past with the X-33, Venture Star and Delta Clipper Experimental (DC-X), reusability within the spaceflight arena is still in its infancy. With unlimited resources (namely, time and money), almost any launch vehicle and its associated hardware can be made reusable. However, an endless supply of funds for space exploration is not the case in today's economy for neither government agencies nor their commercial counterparts. Therefore, any organization wanting to be a leader in space exploration and remain competitive in this unforgiving space faring industry must confront shrinking budgets with more cost conscious and efficient designs. Therefore, standards for developing reusable spaceflight hardware need to be established. By having standards available to existing and emerging companies, some of the potential roadblocks and limitations that plagued previous attempts at reuse may be minimized or completely avoided.

Childress-Thompson, Rhonda↗

NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗