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Pucksat Payload Carrier

There is an ever-expanding need to provide economical space launch opportunities for relatively small science payloads. To address this need, a team at NASA's Goddard Space Flight Center has designed the Pucksat. The Pucksat is a highly versatile payload carrier structure compatible for launching on a Delta II two-stage vehicle as a system co-manifested with a primary payload. It is also compatible for launch on the Air Force Medium Class EELV. Pucksat's basic structural architecture consists of six honeycomb panels attached to six longerons in a hexagonal manner and closed off at the top and bottom with circular rings. Users may configure a co-manifested Pucksat in a number of ways. As examples, co-manifested configurations can be designed to accommodate dedicated missions, multiple experiments, multiple small deployable satellites, or a hybrid of the preceding examples. The Pucksat has fixed lateral dimensions and a downward scaleable height. The dimension across the panel hexagonal flats is 62 in. and the maximum height configuration dimension is 38.5 in. Pucksat has been designed to support a 5000 lbm primary payload, with the center of gravity located no greater than 60 in. from its separation plane, and to accommodate a total co-manifested payload mass of 1275 lbm.

Milam, M. Bruce↗

Hypersonic airbreathing propulsion/airframe integration

Recent interest in airbreathing hypersonic flight has centered around the need to develop advanced space launch systems which can reduce the cost of inserting payloads in orbit and make space more accessible. An effect of the thermal environment is to require the vehicle to operate at high altitudes, in very thin air, to maintain aircraft structural load limits. The high altitudes at which the hypersonic vehicle must operate give rise to the concept of an airframe integrated propulsion system to provide a much larger inlet and nozzle to process the required volume of air at low density, atmospheric conditions. In the integrated system, the forward portion of the vehicle compresses the air flow and serves as the external portion of the inlet; the aftbody completes the expansion process for the nozzle. In addition, the engine, which is contained between the body and the forebody shock wave, lends itself to a modular integration of a number of separate engines. In this manner, a relatively small engine can be defined to allow engine development in existing ground facilities.

Weidner, John P.↗

Research and Technology: 2003 Annual Report of the John F Kennedy Space Center

The John F. Kennedy Space Center (KSC) is America's Spaceport Technology Center. The KSC technology development program encompasses the efforts of the entire KSC team, consisting of Government and contractor personnel, working in partnership with academic institutions and commercial industry. KSC's assigned mission areas are space launch operations and spaceport and range technologies. KSC's technology development customers include current space transportation programs, future space transportation programs / initiatives, and enabling technical programs. The KSC Research and Technology 2003 Annual Report encompasses the efforts of contributors to the KSC advanced technology development program and KSC technology transfer activities. Dr. Dave Bartine, KSC Chief Technologist, (321) 867-7069, is responsible for publication of this report and should be contacted for any desired information regarding KSC's research and technology development activities.

Source record↗

Kennedy Space Center Annual Report, FY 1997

The John F. Kennedy Space Center (KSC) has a nearly 40-year tradition of excellence in processing and launching space vehicles and their payloads. The Center's outstanding record of achievements in America's space program has earned it an honored place in history and an essential role in the present; KSC also intends to play a vital part in the future of space exploration.

John F. Kennedy space Center (KSC)↗

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel Part 1: 8-Ply In-Autoclave Facesheets: 8-Ply In-Autoclave Facesheets - Part 1

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10-m diameter barrel section of the heavy lift launch vehicle, were manufactured under the NASA Composites for Exploration program and the NASA Space Launch Systems program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: inautoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3.00- by 5.00-ft panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center. Furthermore, linear eigenvalue and geometrically nonlinear finite element analysis was performed to predict the compressive response of the 3.00- by 5.00-ft panels. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panel composed of 8-ply, IM7/977-3 facesheets (referred to Panel A). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yield good qualitative and quantitative predictions. Additionally, it was predicted correctly that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber misalignments, and three-dimensional (3 D) effects on the compressive response of the panel.

Myers, David E.↗

Integrated Modal Test of the Artmis I Launch Vehicle

The dynamic testing campaign for the Artemis I launch vehicle culminated in the Integrated Modal Test (IMT). The IMT consisted of the Space Launch System with a mass simulator of Orion (MSO) on top of the SLS stack, which rested on the deck of the mobile launcher (ML) and mount mechanisms. The modal testing met the goal to capture a set of target modes under 7Hz, in two test configurations, using 298 accelerometer locations and 472 accelerometer channels. Overall the model of the test matched very well with the data without tuning the model with the exception of the first torsion mode, which was measured at a much lower frequency than predicted at when excited at higher levels.

Dan Lazor↗

Fiber Optics Sensing System (FOSS) deployment on Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID)

Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) is a technology demonstration of an inflatable aeroshell to slow down and protect heavy and valuable payloads when entering atmospheres such as those of the Earth and Mars. The ultimate project goal is to enable future payload deliveries to Mars. The LOFTID is based on more than a decade of development of the hypersonic inflatable aerodynamic decelerator (HIAD) technology, which consists of a stack of the inflatable concentric rings that make up the inflatable structure that is covered with a Flexible Thermal Protection System (FTPS) and, when combined, form the inflatable aeroshell. The goal of the LOFTID demonstration was to verify that a flexible heat shield, packed into a small-volume payload, can be inflated exoatmospherically to sizes much larger than that of the launch vehicle fairing and survive re-entry into the Earth atmosphere while withstanding a temperature excess of 1,600 °C. The LOFTID is part of Technology Demonstration Missions (TDM) under the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD). The NASA Armstrong Flight Research Center (AFRC) (Edwards, California) is part of the LOFTID program, where a space-launch version of the fiber optic sensing system (FOSS) is integrated into the avionics bay of the re-entry vehicle to provide high-spatial-density temperature measurements in three strategic locations of the vehicle. The program is part of a partnership agreement between the NASA Launch Service Program (LSP) at Kennedy Space Center (KSC) (Merritt Island, Florida) and the main Center of the LOFTID program at NASA Langley Research Center (LaRC) (Hampton, Virginia). This paper will first give a brief introduction of the FOSS, then discuss how the FOSS was integrated into LOFTID, in terms of fiber sensor integration into various sections of the vehicle, as well as integration of the FOSS interrogator into the avionics bay. Finally, data analysis during the LOFTID re-entry will be discussed.

Allen R Parker↗

Passive Cooling in Aerogel-Based Insulation Systems for Liquid Hydrogen Upper Stage Launch Vehicle Tanks

Spray-On Foam Insulation (SOFI) is typically used to protect the windward-facing side of flight tanks for space launch vehicle liquid hydrogen (LH2) stages. SOFI is an excellent insulator in ambient pressure environments, however, its performance pales in comparison to reflective-type systems such as Multi-Layer Insulation in the thermal radiation dominated vacuum environment of space. If a windward insulation system employing radiation shields could be devised to replace or supplement SOFI, the on-orbit heat load could be drastically reduced, and the residual propellants could then be used to facilitate secondary missions. Such insulation systems, utilizing aerogel blanket insulation, have been explored by the Cryogenics Test Laboratory at NASA Kennedy Space Center. Owing to its nano-porous structure, aerogel is an excellent adsorbent as well as an insulator at cryogenic temperatures and will readily uptake condensable background gasses such as air when protecting a surface near LH2 temperatures. When an adsorbed blanket is rapidly exposed to a vacuum, such as during the ascent of a rocket, it will release the background gas, producing a passive cooling effect that could potentially reduce or eliminate the heat load on the propellant tank for a time. This work discusses the setup and results of a test program carried out to determine the effectiveness and impact of this cooling effect as it pertains to LH2 upper stage tanks. A vertical-cylindrical liquid nitrogen (LN2) calorimeter test instrument acted as the upper stage analog. The cold-mass was wrapped with two layers of 10 mm thick aerogel blanket material, with and without aluminum heat shields depending on the test, and interspersed with numerous thermocouple temperature sensors. Gaseous argon was used as a stand-in for air as the condensable background gas. The test procedure mimicked vehicle cryo-loading/stabilization, and ascent phases, with the ascent phase accomplished using parallel vacuum pumps. Results show that the desorption cooling effect was enough to not only eliminate the heat load on the LN2 cold-mass entirely, but further refrigerated the liquid below its boiling point.

A.M. Swanger↗

Command and Control System Automated Testing

To support the National Aeronautics and Space Administration’s (NASA) Space Launch System (SLS) rocket and the Orion capsule, designed to take humans back to the moon in 2024, Kennedy Space Center (KSC) has developed the Spaceport Command and Control System (SCCS) to monitor and control the launch. Within SCCS, the Launch Control System (LCS) is designed to allow console engineers to control and monitor the status of the launch and flight hardware, as well as issue commands to ground control systems and launch vehicles. The messaging software of LCS is responsible for handling the various data types that can be sent between the hardware and software components of the LCS. Since this system is interacting with numerous devices, controllers, and viewports in real time, the distribution of data across the system must be fast, but also reliable and accurate. To verify the accuracy and reliability of the system, developers on the project have created a set of tests to be performed that covers all operations allowed by the system. Given the extensive Application Programming Interface(API) provided by the messaging software, these unit tests are rather time-consuming and costly (in terms of man-hours) to perform. Therefore, an automated testing framework is used to perform supplemental tests automatically when updates are made to the code base.

Rebecca McFadden↗

Ares Launch Vehicles Overview: Space Access Society

America is returning to the Moon in preparation for the first human footprint on Mars, guided by the U.S. Vision for Space Exploration. This presentation will discuss NASA's mission, the reasons for returning to the Moon and going to Mars, and how NASA will accomplish that mission in ways that promote leadership in space and economic expansion on the new frontier. The primary goals of the Vision for Space Exploration are to finish the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return people to the Moon and go to Mars. The Vision commits NASA and the nation to an agenda of exploration that also includes robotic exploration and technology development, while building on lessons learned over 50 years of hard-won experience. NASA is building on common hardware, shared knowledge, and unique experience derived from the Apollo Saturn, Space Shuttle, and contemporary commercial launch vehicle programs. The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, which transports the Orion Crew Exploration Vehicle, and the Ares V Cargo Launch Vehicle, which transports the Lunar Surface Access Module. The architecture for the lunar missions will use one launch to ferry the crew into orbit, where it will rendezvous with the Lunar Module in the Earth Departure Stage, which will then propel the combination into lunar orbit. The imperative to explore space with the combination of astronauts and robots will be the impetus for inventions such as solar power and water and waste recycling. This next chapter in NASA's history promises to write the next chapter in American history, as well. It will require this nation to provide the talent to develop tools, machines, materials, processes, technologies, and capabilities that can benefit nearly all aspects of life on Earth. Roles and responsibilities are shared between a nationwide Government and industry team. The Exploration Launch Projects Office at the Marshall Space Flight Center manages the design, development, testing, and evaluation of both vehicles and serves as lead systems integrator. A little over a year after it was chartered, the Exploration Launch Projects team is testing engine components, refining vehicle designs, performing wind tunnel tests, and building hardware for the first flight test of Ares I-X, scheduled for spring 2009. The Exploration Launch Projects team conducted the Ares I System Requirements Review (SRR) at the end of 2006. In Ares' first year, extensive trade studies and evaluations were conducted to refine the design initially recommended by the Exploration Systems Architecture Study, conceptual designs were analyzed for fitness, and the contractual framework was assembled to enable a development effort unparalleled in American space flight since the Space Shuttle. Now, the project turns its focus to the Preliminary Design Review (PDR), scheduled for 2008. Taking into consideration the findings of the SRR, the design of the Ares I is being tightened and refined to meet the safety, operability, reliability, and affordability goals outlined by the Constellation Program. The Ares V is in the early design stage, focusing its activities on requirements validation and ways to develop this heavy-lift system so that synergistic hardware commonality between it and the Ares I can reduce the operational footprint and foster sustained exploration across the decades ahead.

Cook, Steve↗

Near Earth Asteroid Solar Sail Engineering Development Unit Test Program

The Near Earth Asteroid (NEA) Scout project is a 30x20x10cm (6U) cubesat reconnaissance mission to investigate a near Earth asteroid utilizing an 86m2 solar sail as the primary propulsion system. This will be the largest solar sail NASA will launch to date. NEA Scout is a secondary payload currently manifested on the maiden voyage of the Space Launch System in 2018. In development of the solar sail subsystem, design challenges were identified and investigated for packaging within a 6U form factor and deployment in cis-lunar space. Analysis furthered understanding of thermal, stress, and dynamics of the stowed system and matured an integrated sail membrane model for deployed flight dynamics. This paper will address design, fabrication, and lessons learned from the NEA Scout solar sail subsystem engineering development unit. From optical properties of the sail material to folding and spooling the single 86m2 sail, the team has developed a robust deployment system for the solar sail. This paper will also address expected and received test results from ascent vent, random vibration, and deployment tests.

Lockett, Tiffany Russell↗

NASA JSC EV2 Intern Spring 2016 - Jennie Chung

Exploration Mission 2 (EM-2) is a mission to resume the manned exploration of the Solar System. This mission is the first crewed mission of NASA’s Orion on the Space Launch System. The target for EM-2 is to perform a flyby of a captured asteroid in lunar orbit, which NASA plans to launch in 2023. As an intern working with EV-2 – Avionics Systems Division in Johnson Space Center, we are developing flight instrumentation systems for EM-2 (MISL & RFID). The Modular Integrated Stackable Layer (MISL) is a compact space-related computer system that is modular, scalable and reconfigurable. The RFID (radio frequency identification) sensors are used to take lower frequency (TC) type measurements and be able to stream data real-time to an RF (radio frequency) interrogator upon demand. Our job, in EV-2, is to certify, test, manufacture/assemble and deliver flight EM-2 DFI System (MISL & RFID). Our goal is to propose a development effort to design low-mass wire and wireless data acquisition and sensor solutions for EM-2 DFI (Development Flight Instrumentation). The team is tasked to provide the most effective use of 75 pounds to acquire DFI data and to collect sensor data for 100-200 high priority DFI channels (mass driven).

Chung, Jennie↗

Coherent launch-site atmospheric wind sounder - Theory and experiment

The coherent launch-site atmospheric wind sounder (CLAWS) is a lidar atmospheric wind sensor designed to measure the winds above space launch facilities to an altitude of 20 km. In our development studies, lidar sensor requirements are defined, a system to meet those requirements is defined and built, and the concept is evaluated, with recommendations for the most feasible and cost-effective lidar system for use as an input to a guidance and control system for missile or spacecraft launches. The ability of CLAWS to meet NASA goals for increased safety and launch/mission flexibility is evaluated in a field test program at Kennedy Space Center (KSC) in which we investigate maximum detection range, refractive turbulence, and aerosol backscattering efficiency. The Nd:YAG coherent lidar operating at 1.06 micron with 1-J energy per pulse is able to make real-time measurements of the 3D wind field at KSC to an altitude of 26 km, in good agreement with our performance simulations. It also shows the height and thickness of the volcanic layer caused by the volcanic eruption of Mount Pinatubo in the Philippines.

Hawley, James G.↗

Equuleus Launch Window Analysis and Mission Design

This paper presents the trajectory design process for EQUULEUS, a 6U CubeSat developed by JAXA and the University of Tokyo that is scheduled to launch as a piggyback of NASA’s Artemis 1. After separation from the upper stage of the Space Launch System, EQUULEUS will maneuver along a low-energy transfer to an Earth–Moon quasi-rectilinear halo orbit in 1-to-4 resonance with the lunar synodic period. As a secondary payload, the trajectory of EQUULEUS needs to be compatible with the requirements of the primary mission, but also robust against disturbances and potential changes in the deployment state. Realistic initial conditions spanning two years of potential launch windows are processed and the solution structure for optimal lunar transfers is analyzed. A host of candidate solutions is presented, compatibly with the fuel and power limitations of EQUULEUS. The global understanding of the solution space is shown to be insightful for the design of robust trajectories for limited control-authority spacecraft.

Kawakatsu, Yasuhiro↗

Aircraft measurements of electrified clouds at Kennedy Space Center, part 3

Flights made by the Special Purpose Test Vehicle for Atmospheric Research (SPTVAR) airplane during a second deployment to Florida during the summer of 1989 are discussed. The findings based on the data gathered are presented. The progress made during the second year of the project is discussed. The summer 1989 study was carried out with the support and guidance of Col. John Madura, Commander of Detachment 11, 2nd Weather Squadron, USAF, at Patrick Air Force Base (PAFB) and Cape Canaveral Air Force Station. The project goals were to develop and demonstrate techniques for measuring the electric field aloft and locating regions of charge during flight within and near clouds; to characterize the electric conditions that are presently identified as a threat to space launch vehicles; and to study the correlation between the electric field aloft and that at Kennedy Space Center's ground-based electric field mill array for a variety of electrified clouds.

Jones, J. J.↗

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

Following the cancellation of the Constellation program and retirement of the Space Shuttle, NASA initiated the Space Launch System (SLS) program to provide next-generation heavy lift cargo and crew access to space. A key constituent of the SLS architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). The RS-25 was selected to serve as the main propulsion system for the SLS core stage in conjunction with the solid rocket boosters. This selection was largely based on the maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle boat-tail and installing it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration details involving changes to significant areas such as the environments, interface conditions, technical performance requirements, operational constraints and so on, there were other challenges to be overcome in the area of replacing the obsolete engine control system (ECS). While the magnitude of accomplishing this effort was less than that needed to develop and field a new clean-sheet engine system, the path to the first flight of SLS has not been without unexpected challenges.

Ballard, Richard O.↗

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

Orbit Determination for the James Webb Space Telescope During Launch and Early Orbit

The NASA James Webb Space Telescope (JWST) mission successfully launched on December 25, 2021, at 12:20 UTC. This paper details several novel challenges encountered in the orbit determination (OD) of JWST during the launch and early orbit. The first OD solution used only 6.5 hours of tracking data, much less than the 24 hours of data usually required for libration orbiters on an outbound trajectory. In addition, the observatory area exposed to solar radiation pressure changed through a series of sunshield deployments while concurrent momentum unloads and attitude telemetry outages occurred. This paper covers how the Flight Dynamics Team (FDT) prepared for these challenges, how these challenges were handled on-orbit, and the performance of the resulting OD solutions.

Orbit Determination↗