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NASA NTRS2011

Advancing Systems Engineering Excellence: The Marshall Systems Engineering Leadership Development Program

As NASA undertakes increasingly complex projects, the need for expert systems engineers and leaders in systems engineering is becoming more pronounced. As a result of this issue, the Agency has undertaken an initiative to develop more systems engineering leaders through its Systems Engineering Leadership Development Program; however, the NASA Office of the Chief Engineer has also called on the field Centers to develop mechanisms to strengthen their expertise in systems engineering locally. In response to this call, Marshall Space Flight Center (MSFC) has developed a comprehensive development program for aspiring systems engineers and systems engineering leaders. This presentation will summarize the two-level program, which consists of a combination of training courses and on-the-job, developmental training assignments at the Center to help develop stronger expertise in systems engineering and technical leadership. In addition, it will focus on the success the program has had in its pilot year. The program hosted a formal kickoff event for Level I on October 13, 2009. The first class includes 42 participants from across MSFC and Michoud Assembly Facility (MAF). A formal call for Level II is forthcoming. With the new Agency focus on research and development of new technologies, having a strong pool of well-trained systems engineers is becoming increasingly more critical. Programs such as the Marshall Systems Engineering Leadership Development Program, as well as those developed at other Centers, help ensure that there is an upcoming generation of trained systems engineers and systems engineering leaders to meet future design challenges.

Hall, Philip↗
NASA NTRS2011

Analyses of Longitudinal Mode Combustion Instability in J-2X Gas Generator Development

The National Aeronautics and Space Administration (NASA) and Pratt & Whitney Rocketdyne are developing a liquid oxygen/liquid hydrogen rocket engine for future upper stage and trans-lunar applications. This engine, designated the J-2X, is a higher pressure, higher thrust variant of the Apollo-era J-2 engine. The contract for development was let to Pratt & Whitney Rocketdyne in 2006. Over the past several years, development of the gas generator for the J-2X engine has progressed through a variety of workhorse injector, chamber, and feed system configurations on the component test stand at the NASA Marshall Space Flight Center (MSFC). Several of the initial configurations resulted in combustion instability of the workhorse gas generator assembly at a frequency near the first longitudinal mode of the combustion chamber. In this paper, several aspects of these combustion instabilities are discussed, including injector, combustion chamber, feed system, and nozzle influences. To ensure elimination of the instabilities at the engine level, and to understand the stability margin, the gas generator system has been modeled at the NASA MSFC with two techniques, the Rocket Combustor Interaction Design and Analysis (ROCCID) code and a lumped-parameter MATLAB(TradeMark) model created as an alternative calculation to the ROCCID methodology. To correctly predict the instability characteristics of all the chamber and injector geometries and test conditions as a whole, several inputs to the submodels in ROCCID and the MATLAB(TradeMark) model were modified. Extensive sensitivity calculations were conducted to determine how to model and anchor a lumped-parameter injector response, and finite-element and acoustic analyses were conducted on several complicated combustion chamber geometries to determine how to model and anchor the chamber response. These modifications and their ramification for future stability analyses of this type are discussed.

Hulka, J. R.↗
NASA NTRS2011

FOD Prevention at NASA-Marshall Space Flight Center

NASA now requires all flight hardware projects to develop and implement a Foreign Object Damage (FOD) Prevention Program. With the increasing use of composite and bonded structures, NASA now also requires an Impact Damage Protection Plan for these items. In 2009, Marshall Space Flight Center released an interim directive that required all Center organizations to comply with FOD protocols established by on-site Projects, to include prevention of impact damage. The MSFC Technical Standards Control Board authorized the development of a new MSFC technical standard for FOD Prevention.

Lowrey, Nikki M.↗
NASA NTRS2011

Engineering the System and Technical Integration

Approximately 80% of the problems encountered in aerospace systems have been due to a breakdown in technical integration and/or systems engineering. One of the major challenges we face in designing, building, and operating space systems is: how is adequate integration achieved for the systems various functions, parts, and infrastructure? This Contractor Report (CR) deals with part of the problem of how we engineer the total system in order to achieve the best balanced design. We will discuss a key aspect of this question - the principle of Technical Integration and its components, along with management and decision making. The CR will first provide an introduction with a discussion of the Challenges in Space System Design and meeting the challenges. Next is an overview of Engineering the System including Technical Integration. Engineering the System is expanded to include key aspects of the Design Process, Lifecycle Considerations, etc. The basic information and figures used in this CR were presented in a NASA training program for Program and Project Managers Development (PPMD) in classes at Georgia Tech and at Marshall Space Flight Center (MSFC). Many of the principles and illustrations are extracted from the courses we teach for MSFC.

Blair, J. C.↗
NASA NTRS2011

Exploring the Use of Radar for a Physically Based Lightning Cessation Nowcasting Tool

NASA s Marshall Space Flight Center (MSFC) and the University of Alabama in Huntsville (UAHuntsville) are collaborating with the 45th Weather Squadron (45WS) at Cape Canaveral Air Force Station (CCAFS) to enable improved nowcasting of lightning cessation. This project centers on use of dual-polarimetric radar capabilities, and in particular, the new C-band dual-polarimetric weather radar acquired by the 45WS. Special emphasis is placed on the development of a physically based operational algorithm to predict lightning cessation. While previous studies have developed statistically based lightning cessation algorithms, we believe that dual-polarimetric radar variables offer the possibility to improve existing algorithms through the inclusion of physically meaningful trends reflecting interactions between in-cloud electric fields and hydrometeors. Specifically, decades of polarimetric radar research using propagation differential phase has demonstrated the presence of distinct phase and ice crystal alignment signatures in the presence of strong electric fields associated with lightning. One question yet to be addressed is: To what extent can these ice-crystal alignment signatures be used to nowcast the cessation of lightning activity in a given storm? Accordingly, data from the UAHuntsville Advanced Radar for Meteorological and Operational Research (ARMOR) along with the NASA-MSFC North Alabama Lightning Mapping Array are used in this study to investigate the radar signatures present before and after lightning cessation. Thus far, our case study results suggest that the negative differential phase shift signature weakens and disappears after the analyzed storms ceased lightning production (i.e., after the last lightning flash occurred). This is a key observation because it suggests that while strong electric fields may still have been present, the lightning cessation signature encompassed the period of the polarimetric negative phase shift signature. To the extent this behavior is repeatable in other cases, even if only in a substantial fraction of those cases, the case analyses suggests that differential propagation phase may prove to be a useful parameter for future lightning cessation algorithms. Indeed, analysis of 15+ cases has shown additional indications of the weakening and disappearance of this ice alignment signature with lightning cessation. A summary of results will be presented.

Schultz, Elise V.↗
NASA NTRS2011

Using Innovative Techniques for Manufacturing Rocket Engine Hardware

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using the Workhorse Gas Generator (WHGG) test setup at MSFC?s East Test Area test stand 116, the duct was subject to extreme J-2X gas generator environments and endured a total of 538 seconds of hot-fire time. The duct survived the testing and was inspected after the test. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Betts, Erin M.↗
NASA NTRS2011

Signal Processing Methods for Liquid Rocket Engine Combustion Stability Assessments

The J2X Gas Generator engine design specifications include dynamic, spontaneous, and broadband combustion stability requirements. These requirements are verified empirically based high frequency chamber pressure measurements and analyses. Dynamic stability is determined with the dynamic pressure response due to an artificial perturbation of the combustion chamber pressure (bomb testing), and spontaneous and broadband stability are determined from the dynamic pressure responses during steady operation starting at specified power levels. J2X Workhorse Gas Generator testing included bomb tests with multiple hardware configurations and operating conditions, including a configuration used explicitly for engine verification test series. This work covers signal processing techniques developed at Marshall Space Flight Center (MSFC) to help assess engine design stability requirements. Dynamic stability assessments were performed following both the CPIA 655 guidelines and a MSFC in-house developed statistical-based approach. The statistical approach was developed to better verify when the dynamic pressure amplitudes corresponding to a particular frequency returned back to pre-bomb characteristics. This was accomplished by first determining the statistical characteristics of the pre-bomb dynamic levels. The pre-bomb statistical characterization provided 95% coverage bounds; these bounds were used as a quantitative measure to determine when the post-bomb signal returned to pre-bomb conditions. The time for post-bomb levels to acceptably return to pre-bomb levels was compared to the dominant frequency-dependent time recommended by CPIA 655. Results for multiple test configurations, including stable and unstable configurations, were reviewed. Spontaneous stability was assessed using two processes: 1) characterization of the ratio of the peak response amplitudes to the excited chamber acoustic mode amplitudes and 2) characterization of the variability of the peak response's frequency over the test duration. This characterization process assists in evaluating the discreteness of a signal as well as the stability of the chamber response. Broadband stability was assessed using a running root-mean-square evaluation. These techniques were also employed, in a comparative analysis, on available Fastrac data, and these results are presented here.

Kenny, R. Jeremy↗
NASA NTRS2011

CFD Simulations of Supersonic Highly Swirling Flow Exiting a Turbine Vane Row Compared with Experimental Observations

Marshall Space Flight Center (MSFC) has been heavily involved in developing the J2-X engine. The Center has been testing a Work Horse Gas Generator (WHGG) to supply gas products to J2-X turbine components at realistic flight-like operating conditions. Three-dimensional time accurate CFD simulations and analytical fluid analysis have been performed to support WHGG tests at MSFC. The general purpose CFD program LOCI/Chem was utilized to simulate flow of products from the WHGG through a turbine manifold, a stationary row of turbine vanes, into a Can and orifice assembly used to control the back pressure at the turbine vane row and finally through an aspirator plate and flame bucket. Simulations showed that supersonic swirling flow downstream of the turbine imparted a much higher pressure on the Can wall than expected for a non-swirling flow. This result was verified by developing an analytical model that predicts wall pressure due to swirling flow. The CFD simulations predicted that the higher downstream pressure would cause the pressure drop across the nozzle row to be approximately half the value of the test objective. With CFD support, a redesign of the Can orifice and aspirator plate was performed. WHGG experimental results and observations compared well with pre-test and post-test CFD simulations. CFD simulations for both quasi-static and transient test conditions correctly predicted the pressure environment downstream of the turbine row and the behavior of the gas generator product plume as it exited the WHGG test article, impacted the flame bucket and interacted with the external environment.

West, Jeff S.↗
NASA NTRS2011

An Evaluation of Ultra-High Pressure Regulator for Robotic Lunar Landing Spacecraft

The Robotic Lunar Lander Development (RLLD) Project Office at NASA Marshall Space Flight Center (MSFC) has studied several lunar surface science mission concepts. These missions focus on spacecraft carrying multiple science instruments and power systems that will allow extended operations on the lunar surface. Initial trade studies of launch vehicle options for these mission concepts indicate that the spacecraft design will be significantly mass-constrained. To minimize mass and facilitate efficient packaging, the notional propulsion system for these landers has a baseline of an ultra-high pressure (10,000 psig) helium pressurization system that has been used on Defense missiles. The qualified regulator is capable of short duration use; however, the hardware has not been previously tested at NASA spacecraft requirements with longer duration. Hence, technical risks exist in using this missile-based propulsion component for spacecraft applications. A 10,000-psig helium pressure regulator test activity is being carried out as part of risk reduction testing for MSFC RLLD project. The goal of the test activity is to assess the feasibility of commercial off-the-shelf ultra-high pressure regulator by testing with a representative flight mission profile. Slam-start, gas blowdown, water expulsion, lock-up, and leak tests are also performed on the regulator to assess performance under various operating conditions. The preliminary test results indicated that the regulator can regulate helium to a stable outlet pressure of 740 psig within the +/- 5% tolerance band and maintain a lock-up pressure less than +5% for all tests conducted. Numerous leak tests demonstrated leakage less than 10-3 standard cubic centimeters per second (SCCS) for internal seat leakage at lock-up and less than10-5 SCCS for external leakage through the regulator ambient reference cavity. The successful tests have shown the potential for 10,000 psig helium systems in NASA spacecraft and have reduced risk associated with hardware availability and hardware ability to meet RLL mission requirements.

Burnside, Christopher↗
NASA NTRS2011

Using Innovative Technologies for Manufacturing Rocket Engine Hardware

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As the United States enters into the next space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, rapid manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on NASA s Space Launch System (SLS) upper stage engine, J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator (GG) discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using a workhorse gas generator (WHGG) test fixture at MSFC's East Test Area, the duct was subjected to extreme J-2X hot gas environments during 7 tests for a total of 537 seconds of hot-fire time. The duct underwent extensive post-test evaluation and showed no signs of degradation. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Betts, E. M.↗
NASA NTRS2011

Initial Results from the Miniature Imager for Neutral Ionospheric Atoms and Magnetospheric Electrons (MINI-ME) on the FASTSAT Spacecraft

The MINI-ME instrument is a collaborative effort between NASA's Goddard Space Flight Center (GSFC) and the U.S. Naval Academy, funded solely through GSFC Internal Research and Development (IRAD) awards. It detects neutral atoms from about 10 eV to about 700 eV (in 30 energy steps) in its current operating configuration with an approximately 10 degree by 360 degree field-of-view, divided into six sectors. The instrument was delivered on August 3, 2009 to Marshall Space Flight Center (MSFC) for integration with the FASTSAT-HSV01 small spacecraft bus developed by MSFC and a commercial partner, one of six Space Experiment Review Board (SERB) experiments on FASTSAT and one of three GSFC instruments (PISA and TTI being the other two). The FASTSAT spacecraft was launched on November 21, 2010 from Kodiak, Alaska on a Minotaur IV as a secondary payload and inserted into a 650 km, 72 degree inclination orbit, very nearly circular. MINI-ME has been collecting science data, as spacecraft resources would permit, in "optimal science mode" since January 20, 2011. In this presentation, we report initial science results including the potential first observations of neutral molecular ionospheric outflow. At the time of this abstract, we have identified 15 possible molecular outflow events. All these events occur between about 65 and 82 degrees geomagnetic latitude and most map to the auroral oval. The MINI-ME results provide an excellent framework for interpretation of the MILENA data, two instruments almost identical to MINI-ME that will launch on the VISIONS suborbital mission

Collier, Michael R.↗
NASA NTRS2012

Thermal and Fluid Modeling of the CRYogenic Orbital TEstbed (CRYOTE) Ground Test Article (GTA)

The purpose of this study was to anchor thermal and fluid system models to data acquired from a ground test article (GTA) for the CRYogenic Orbital TEstbed - CRYOTE. To accomplish this analysis, it was broken into four primary tasks. These included model development, pre-test predictions, testing support at Marshall Space Flight Center (MSFC} and post-test correlations. Information from MSFC facilitated the task of refining and correlating the initial models. The primary goal of the modeling/testing/correlating efforts was to characterize heat loads throughout the ground test article. Significant factors impacting the heat loads included radiative environments, multi-layer insulation (MLI) performance, tank fill levels, tank pressures, and even contact conductance coefficients. This paper demonstrates how analytical thermal/fluid networks were established, and it includes supporting rationale for specific thermal responses seen during testing.

Piryk, David↗
NASA NTRS2012

Nondestructive Evaluation of the J-2X Direct Metal Laser Sintered Gas Generator Discharge Duct

The J-2X program at NASA's Marshall Space Flight Center (MSFC) procured a direct metal laser sintered (DMLS) gas generator discharge duct from Pratt & Whitney Rocketdyne and Morris Technologies for a test program that would evaluate the material properties and durability of the duct in an engine-like environment. DMLS technology was pursued as a manufacturing alternative to traditional techniques, which used off nominal practices to manufacture the gas generator duct's 180 degree turn geometry. MSFC's Nondestructive Evaluation (NDE) Team performed radiographic, ultrasonic, computed tomographic, and fluorescent penetrant examinations of the duct. Results from the NDE examinations reveal some shallow porosity but no major defects in the as-manufactured material. NDE examinations were also performed after hot-fire testing the gas generator duct and yielded similar results pre and post-test and showed no flaw growth or development.

Esther, Elizabeth A.↗
NASA NTRS2012

Friction Pull Plug Welding in Aluminum Alloys

NASA's Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for the Space Shuttle fs External Tank. FPPW was easily selected as the primary weld process used to close out the termination hole on the Constellation Program's ARES I Upper Stage circumferential Self-Reacting Friction Stir Welds (SR-FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR-FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process's limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗
NASA NTRS2012

Regeneratively Cooled Liquid Oxygen/Methane Technology Development

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. NASA-Marshall Space Flight Center (MSFC) in concert with industry partner Pratt & Whitney Rocketdyne (PWR) utilized a Space Act Agreement to test an oxygen/methane engine system in the Summer of 2010. PWR provided a 5,500 lbf (24,465 N) LOX/LCH4 regenerative cycle engine to demonstrate advanced thrust chamber assembly hardware and to evaluate the performance characteristics of the system. The chamber designs offered alternatives to traditional regenerative engine designs with improvements in cost and/or performance. MSFC provided the test stand, consumables and test personnel. The hot fire testing explored the effective cooling of one of the thrust chamber designs along with determining the combustion efficiency with variations of pressure and mixture ratio. The paper will summarize the status of these efforts.

Robinson, Joel W.↗
NASA NTRS2012

Test Before You Fly - High Fidelity Planetary Environment Simulation

The lunar surface environment will present many challenges to the survivability of systems developed for long duration lunar habitation and exploration of the lunar, or any other planetary, surface. Obstacles will include issues pertaining especially to the radiation environment (solar plasma and electromagnetic radiation) and lunar regolith dust. The Planetary Environments Chamber is one piece of the MSFC capability in Space Environmental Effects Test and Analysis. Comprised of many unique test systems, MSFC has the most complete set of SEE test capabilities in one location allowing examination of combined space environmental effects without transporting already degraded, potentially fragile samples over long distances between tests. With this system, the individual and combined effects of the lunar radiation and regolith environment on materials, sub-systems, and small systems developed for the lunar return can be investigated. This combined environments facility represents a unique capability to NASA, in which tests can be tailored to any one aspect of the lunar environment (radiation, temperature, vacuum, regolith) or to several of them combined in a single test.

Craven, Paul↗
NASA NTRS2012

Extending the International Space Station Life and Operability

The International Space Station (ISS) is in an operational configuration with final assembly complete. To fully utilize ISS and extend the operational life, it became necessary to upgrade and extend the onboard systems with the Obsolescence Driven Avionics Redesign (ODAR) project. ODAR enabled a joint project between the Johnson Space Center (JSC) and Marshall Space Flight Center (MSFC) focused on upgrading the onboard payload and Ku-Band systems, expanding the voice and video capabilities, and including more modern protocols allowing unprecedented access for payload investigators to their on-orbit payloads. The MSFC Huntsville Operations Support Center (HOSC) was tasked with developing a high-rate enhanced Functionally Distributed Processor (eFDP) to handle 300Mbps Return Link data, double the legacy rate, and incorporate a Line Outage Recorder (LOR). The eFDP also provides a 25Mbps uplink transmission rate with a Space Link Extension (SLE) interface. HOSC also updated the Payload Data Services System (PDSS) to incorporate the latest Consultative Committee for Space Data Systems (CCSDS) protocols, most notably the use of the Internet Protocol (IP) Encapsulation, in addition to the legacy capabilities. The Central Command Processor was also updated to interact with the new onboard and ground capabilities of Mission Control Center -- Houston (MCC-H) for the uplink functionality. The architecture, implementation, and lessons learned, including integration and incorporation of Commercial Off The Shelf (COTS) hardware and software into the operational mission of the ISS, is described herein. The applicability of this new technology provides new benefits to ISS payload users and ensures better utilization of the ISS by the science community

Cecil, Andrew J.↗
NASA NTRS2012

Laboratory Studies of Charging Properties of Dust Grains in Astrophysical/Planetary Environments

Dust grains in various astrophysical environments are generally charged electrostatically by photoelectric emissions with UV/X-ray radiation, as well as by electron/ion impact. Knowledge of physical and optical properties of individual dust grains is required for understanding of the physical and dynamical processes in space environments and the role of dust in formation of stellar and planetary systems. In this paper we focus on charging of individual micron/submicron dust grains by processes that include: (a) UV photoelectric emissions involving incident photon energies higher than the work function of the material and b) electron impact, where low energy electrons are scattered or stick to the dust grains, thereby charging the dust grains negatively, and at sufficiently high energies the incident electrons penetrate the grain leading to excitation and emission of electrons referred to as secondary electron emission (SEE). It is well accepted that the charging properties of individual micron/submicron size dust grains are expected to be substantially different from the bulk materials. However, no viable models for calculation of the charging properties of individual micron size dust grains are available at the present time. Therefore, the photoelectric yields, and secondary electron emission yields of micron-size dust grains have to be obtained by experimental methods. Currently, very limited experimental data are available for charging of individual micron-size dust grains. Our experimental results, obtained on individual, micron-size dust grains levitated in an electrodynamic balance facility (at NASA-MSFC), show that: (1) The measured photoelectric yields are substantially higher than the bulk values given in the literature and indicate a particle size dependence with larger particles having order-of-magnitude higher values than for submicron-size grains; (2) dust charging by low energy electron impact is a complex process. Also, our measurements indicate that the electron impact may lead to charging or discharging of dust grains depending upon the grain size, surface potential, electron energy, electron flux, grain composition, and configuration (e.g. Abbas et al, 2010). Laboratory measurements on charging of analogs of the interstellar dust as well as Apollo 11 dust grains conducted at the NASA-MSFC Dusty Plasma Lab. are presented here

Tankosic, D.↗