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NASA NTRS2011

The Application of Lean Thinking Principles and Kaizen Practices for the Successful Development and Implementation of the Ares I-X Flight Test Rocket and Mission

On October 28, 2009 the Ares I-X flight test rocket launched from Kennedy Space Center and flew its suborbital trajectory as designed. The mission was successfully completed as data from the test, and associated development activities were analyzed, transferred to stakeholders, and well documented. A positive lesson learned from Ares I-X was that the application of lean thinking principles and kaizen practices was very effective in streamlining development activities. Ares I-X, like other historical rocket development projects, was hampered by technical, cost, and schedule challenges and if not addressed boldly could have resulted in cancellation of the test. The mission management team conducted nine major meetings, referred to as lean events, across its elements to assess plans, procedures, processes, requirements, controls, culture, organization, use of resources, and anything that could be changed to optimize schedule or reduce risk. The preeminent aspect of the lean events was the focus on value added activities and the removal or at least reduction in non-value added activities. Trained Lean Six Sigma facilitators assisted the Ares I-X developers in conducting the lean events. They indirectly helped formulate the mission s own unique methodology for assessing schedule. A core team was selected to lead the events and report to the mission manager. Each activity leveraged specialized participants to analyze the subject matter and its related processes and then recommended alternatives and solutions. Stakeholders were the event champions. They empowered and encouraged the team to succeed. The keys to success were thorough preparation, honest dialog, small groups, adherence to the Ares I-X ground rules, and accountability through disciplined reporting and tracking of actions. This lean event formula was game-changing as demonstrated by Ares I-X. It is highly recommended as a management tool to help develop other complex systems efficiently. The key benefits for Ares I-X were obtaining unambiguous schedule margin, defining enabling options for risk reduction, and most importantly a stronger more unified team.

Askins, B. R.↗

NASA NTRS2011

Solid Rocket Booster (SRB) Flight System Integration at Its Best

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Wood, T. David↗

NASA NTRS2011

National Institute for Rocket Propulsion Systems (NIRPS): Solutions Facilitator

National Institute for Rocket Propulsion Systems (NIRPS) "Solutions" plans to enable our nation's future in rocket propulsion systems by leveraging existing skills and capabilities to support industry's future needs

Brown, Tom↗

NASA NTRS2011

Low Cost Nuclear Thermal Rocket Cermet Fuel Element Environment Testing

Deep space missions with large payloads require high specific impulse (Isp) and relatively high thrust in order to achieve mission goals in reasonable time frames. Conventional, storable propellants produce average Isp. Nuclear thermal rockets (NTR) capable of high Isp thrust have been proposed. NTR employs heat produced by fission reaction to heat and therefore accelerate hydrogen which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000K) and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high temperature hydrogen exposure on fuel elements is limited. The primary concern is the mechanical failure of fuel elements which employ high-melting-point metals, ceramics or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. It is not necessary to include fissile material in test samples intended to explore high temperature hydrogen exposure of the structural support matrices. A small-scale test bed designed to heat fuel element samples via non-contact RF heating and expose samples to hydrogen is being developed to assist in optimal material and manufacturing process selection without employing fissile material. This paper details the test bed design and results of testing conducted to date.

Bradley, David E.↗

NASA NTRS2012

Automated and Manual Rocket Crater Measurement Software

An update has been performed to software designed to do very rapid automated measurements of craters created in sandy substrates by rocket exhaust on liftoff. The previous software was optimized for pristine lab geometry and lighting conditions. This software has been enhanced to include a section for manual measurements of crater parameters; namely, crater depth, crater full width at half max, and estimated crater volume. The tools provide a very rapid method to measure these manual parameters to ease the burden of analyzing large data sets. This software allows for rapid quantization of the rocket crater parameters where automated methods may not work. The progress of spreadsheet data is continuously saved so that data is never lost, and data can be copied to clipboards and pasted to other software for analysis. The volume estimation of a crater is based on the central max depth axis line, and the polygonal shape of the crater is integrated around that axis.

Metzger, Philip↗

NASA NTRS2011

Maturation of Structural Health Management Systems for Solid Rocket Motors

Concepts of an autonomous and automated space-compliant diagnostic system were developed for conditioned-based maintenance (CBM) of rocket motors for space exploration vehicles. The diagnostic system will provide real-time information on the integrity of critical structures on launch vehicles, improve their performance, and greatly increase crew safety while decreasing inspection costs. Using the SMART Layer technology as a basis, detailed procedures and calibration techniques for implementation of the diagnostic system were developed. The diagnostic system is a distributed system, which consists of a sensor network, local data loggers, and a host central processor. The system detects external impact to the structure. The major functions of the system include an estimate of impact location, estimate of impact force at impacted location, and estimate of the structure damage at impacted location. This system consists of a large-area sensor network, dedicated multiple local data loggers with signal processing and data analysis software to allow for real-time, in situ monitoring, and longterm tracking of structural integrity of solid rocket motors. Specifically, the system could provide easy installation of large sensor networks, onboard operation under harsh environments and loading, inspection of inaccessible areas without disassembly, detection of impact events and impact damage in real-time, and monitoring of a large area with local data processing to reduce wiring.

Quing, Xinlin↗

NASA NTRS2011

Current Closure in the Auroral Ionosphere: Results from the Auroral Current and Electrodynamics Structure Rocket Mission

The Auroral Current and Electrodynamics Structure (ACES) mission consisted of two sounding rockets launched nearly simultaneously from Poker Flat Research Range, AK on January 29, 2009 into a dynamic multiple-arc aurora. The ACES rocket mission was designed to observe electrodynamic and plasma parameters above and within the current closure region of the auroral ionosphere. Two well instrumented payloads were flown along very similar magnetic field footprints, at different altitudes, with small temporal separation between both payloads. The higher altitude payload (apogee 360 km), obtained in-situ measurements of electrodynamic and plasma parameters above the current closure region to determine the input signature. The low altitude payload (apogee 130 km), made similar observations within the current closure region. Results are presented comparing observations of the electric fields, magnetic components, and the differential electron energy flux at magnetic footpoints common to both payloads. In situ data is compared to the ground based all-sky imager data, which presents the evolution of the auroral event as the payloads traversed through magnetically similar regions. Current measurements derived from the magnetometers on the high altitude payload observed upward and downward field-aligned currents. The effect of collisions with the neutral atmosphere is investigated to determine it is a significant mechanism to explain discrepancies in the low energy electron flux. The high altitude payload also observed time-dispersed arrivals in the electron flux and perturbations in the electric and magnetic field components, which are indicative of Alfven waves.

Kaeppler, S. R.↗

NASA NTRS2012

Current Closure in the Auroral Ionosphere: Results from the Auroral Current and Electrodynamics Structure Rocket Mission

The Auroral Current and Electrodynamics Structure (ACES) mission consisted of two sounding rockets launched nearly simultaneously from Poker Flat Research Range, AK on January 29, 2009 into a dynamic multiple-arc aurora. The ACES rocket mission was designed to observe electrodynamic and plasma parameters above and within the current closure region of the auroral ionosphere. Two well instrumented payloads were flown along very similar magnetic field footprints, at different altitudes, with small temporal separation between both payloads. The higher altitude payload (apogee 360 km), obtained in-situ measurements of electrodynamic and plasma parameters above the current closure region to determine the input signature. The low altitude payload (apogee 130 km), made similar observations within the current closure region. Results are presented comparing observations of the electric fields, magnetic components, and the differential electron energy flux at magnetic footpoints common to both payloads. In situ data is compared to the ground based all-sky imager data, which presents the evolution of the auroral event as the payloads traversed through magnetically similar regions. Current measurements derived from the magnetometers on the high altitude payload observed upward and downward field-aligned currents. The effect of collisions with the neutral atmosphere is investigated to determine if it is a significant mechanism to explain discrepancies in the low energy electron flux. The high altitude payload also observed time-dispersed arrivals in the electron flux and perturbations in the electric and magnetic field components, which are indicative of Alfven waves.

Kaeppler, S. R.↗

NASA NTRS2012

The Transition-Edge-Sensor Array for the Micro-X Sounding Rocket

The Micro-X sounding rocket program will fly a 128-element array of transition-edge-sensor microcalorimeters to enable high-resolution X-ray imaging spectroscopy of the Puppis-A supernova remnant. To match the angular resolution of the optics while maximizing the field-of-view and retaining a high energy resolution (< 4 eV at 1 keV), we have designed the pixels using 600 x 600 sq. micron Au/Bi absorbers, which overhang 140 x 140 sq. micron Mo/Au sensors. The data-rate capabilities of the rocket telemetry system require the pulse decay to be approximately 2 ms to allow a significant portion of the data to be telemetered during flight. Here we report experimental results from the flight array, including measurements of energy resolution, uniformity, and absorber thermalization. In addition, we present studies of test devices that have a variety of absorber contact geometries, as well as a variety of membrane-perforation schemes designed to slow the pulse decay time to match the telemetry requirements. Finally, we describe the reduction in pixel-to-pixel crosstalk afforded by an angle-evaporated Cu backside heatsinking layer, which provides Cu coverage on the four sidewalls of the silicon wells beneath each pixel.

Eckart, M. E.↗

NASA NTRS2012

Five-Segment Solid Rocket Motor Development Status

In support of the National Aeronautics and Space Administration (NASA), Marshall Space Flight Center (MSFC) is developing a new, more powerful solid rocket motor for space launch applications. To minimize technical risks and development costs, NASA chose to use the Space Shuttle s solid rocket boosters as a starting point in the design and development. The new, five segment motor provides a greater total impulse with improved, more environmentally friendly materials. To meet the mass and trajectory requirements, the motor incorporates substantial design and system upgrades, including new propellant grain geometry with an additional segment, new internal insulation system, and a state-of-the art avionics system. Significant progress has been made in the design, development and testing of the propulsion, and avionics systems. To date, three development motors (one each in 2009, 2010, and 2011) have been successfully static tested by NASA and ATK s Launch Systems Group in Promontory, UT. These development motor tests have validated much of the engineering with substantial data collected, analyzed, and utilized to improve the design. This paper provides an overview of the development progress on the first stage propulsion system.

Priskos, Alex S.↗

NASA NTRS2012

A Sounding Rocket Mission Concept to Acquire High-Resolution Radiometric Spectra Spanning the 9 nm - 31 nm Wavelength Range

When studying Solar Extreme Ultraviolet (EUV) emissions, both single-wavelength, two- dimensional (2D) spectroheliograms and multi-wavelength, one-dimensional (1D) line spectra are important, especially for a thorough understanding of the complex processes in the solar magnetized plasma from the base of the chromosphere through the corona. 2D image data are required for a detailed study of spatial structures, whereas radiometric (i.e., spectral) data provide information on relevant atomic excitation/ionization state densities (and thus temperature). Using both imaging and radiometric techniques, several satellite missions presently study solar dynamics in the EUV, including the Solar Dynamics Observatory (SDO), Hinode, and the Solar-Terrestrial Relations Observatory (STEREO). The EUV wavelengths of interest typically span 9 nm to 31 nm, with the shorter wavelengths being associated with the hottest features (e.g., intense flares and bright points) and the longer wavelengths associated with cooler features (e.g., coronal holes and filaments). Because the optical components of satellite instruments degrade over time, it is not uncommon to conduct sounding rocket underflights for calibration purposes. The authors have designed a radiometric sounding rocket payload that could serve as both a calibration underflight for and a complementary scientific mission to the upcoming Solar Ultraviolet Imager (SUVI) mission aboard the GOES-R satellite (scheduled for a 2015 launch). The challenge to provide quality radiometric line spectra over the 9-31 nm range covered by SUVI was driven by the multilayer coatings required to make the optical components, including mirrors and gratings, reflective over the entire range. Typically, these multilayers provide useful EUV reflectances over bandwidths of a few nm. Our solution to this problem was to employ a three-telescope system in which the optical components were coated with multilayers that spanned three wavelength ranges to cover the three pairs of SUVI bands. The complete system was designed to fit within the Black Brandt-IX 22.-diameter payload skin envelope. The basic optical path is that of a simple parabolic telescope in which EUV light is focused onto a slit and shutter assembly and imaged onto a normal-incidence diffraction grating, which then disperses the light onto a 2048 2048 CCD sensor. The CCD thus records 1D spatial information along one axis and spectral information along the other. The slit spans 40 arc-minutes in length, thus covering a solar diameter out to +/- 1.3 solar radii. Our operations concept includes imaging at three distinct positions: the north-south meridian, the northeast-southwest diagonal, and real-time pointing at an active region. Six 10-second images will be obtained at each position. Fine pointing is provided by the SPARCS-VII attitude control system typically employed on Black Brandt solar missions. Both before and after launch, all three telescopes will be calibrated with the EUV line emission source and monochromater system at NASA's Stray Light Facility at Marshall Spaceflight Center. Details of the payload design, operations concept, and data application will be presented.

Krause, L. Habash↗

NASA NTRS2012

Formulation and Testing of Paraffin-Based Solid Fuels Containing Energetic Additives for Hybrid Rockets

Many approaches have been considered in an effort to improve the regression rate of solid fuels for hybrid rocket applications. One promising method is to use a fuel with a fast burning rate such as paraffin wax; however, additional performance increases to the fuel regression rate are necessary to make the fuel a viable candidate to replace current launch propulsion systems. The addition of energetic and/or nano-sized particles is one way to increase mass-burning rates of the solid fuels and increase the overall performance of the hybrid rocket motor.1,2 Several paraffin-based fuel grains with various energetic additives (e.g., lithium aluminum hydride (LiAlH4) have been cast in an attempt to improve regression rates. There are two major advantages to introducing LiAlH4 additive into the solid fuel matrix: 1) the increased characteristic velocity, 2) decreased dependency of Isp on oxidizer-to-fuel ratio. The testing and characterization of these solid-fuel grains have shown that continued work is necessary to eliminate unburned/unreacted fuel in downstream sections of the test apparatus.3 Changes to the fuel matrix include higher melting point wax and smaller energetic additive particles. The reduction in particle size through various methods can result in more homogeneous grain structure. The higher melting point wax can serve to reduce the melt-layer thickness, allowing the LiAlH4 particles to react closer to the burning surface, thus increasing the heat feedback rate and fuel regression rate. In addition to the formulation of LiAlH4 and paraffin wax solid-fuel grains, liquid additives of triethylaluminum and diisobutylaluminum hydride will be included in this study. Another promising fuel formulation consideration is to incorporate a small percentage of RDX as an additive to paraffin. A novel casting technique will be used by dissolving RDX in a solvent to crystallize the energetic additive. After dissolving the RDX in a solvent chosen for its compatibility with both paraffin and RDX, the mixture will be combined with the melted paraffin. With the melting point of the paraffin far below the decomposition temperature of the RDX, the solvent will be boiled off, leaving the crystallized RDX embedded in the paraffin. At low percentages of RDX additive and with crystallized RDX surrounded by paraffin, the fuel grains will remain inert, maintaining a key benefit of hybrids in the safety of the solid fuel.

Larson, Daniel B.↗

NASA NTRS2012

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

To support the on-going nuclear thermal propulsion effort, a state-of-the-art non nuclear experimental test setup has been constructed to evaluate the performance characteristics of candidate fuel element materials and geometries in representative environments. The facility to perform this testing is referred to as the Nuclear Thermal Rocket Element Environment Simulator (NTREES). This device can simulate the environmental conditions (minus the radiation) to which nuclear rocket fuel components will be subjected during reactor operation. Test articles mounted in the simulator are inductively heated in such a manner so as to accurately reproduce the temperatures and heat fluxes which would normally occur as a result of nuclear fission and would be exposed to flowing hydrogen. Initial testing of a somewhat prototypical fuel element has been successfully performed in NTREES and the facility has now been shutdown to allow for an extensive reconfiguration of the facility which will result in a significant upgrade in its capabilities

Emrich, William J. Jr.↗

NASA NTRS2012

Analyses of Noise from Reusable Solid Rocket Motor (RSRM) Firings

NASA s Space Launch Vehicle (SLS) program has chosen the Reusable Solid Rocket Motor V (RSRMV) as the booster system for initial flights. Lift off acoustics continue to be a consideration in overall vehicle vibroacoustic evaluations and launch pad modifications. Work started with the Ares program to understand solid rocket noise mechanisms is continuing through SLS program in conjunction with BYU/Blue Ridge Research Consulting.

Gee, Kent L.↗

NASA NTRS2006

Investigation of Post-Flight Solid Rocket Booster Thermal Protection System

After every Shuttle mission, the Solid Rocket Boosters (SRBs) are recovered and observed for missing material. Most of the SRB is covered with a cork-based thermal protection material (MCC-l). After the most recent shuttle mission, STS-114, the forward section of the booster appeared to have been impacted during flight. The darkened fracture surfaces indicated that this might have occurred early in flight. The scope of the analysis included microscopic observations to assess the degree of heat effects and locate evidence of the impact source as well as chemical analysis of the fracture surfaces and recovered foreign material using Fourier Transform Infrared Spectroscopy and Scanning Electron Microscopy/Energy Dispersive Spectroscopy. The amount of heat effects and presence of soot products on the fracture surface indicated that the material was impacted prior to SRB re-entry into the atmosphere. Fragments of graphite fibers found on these fracture surfaces were traced to slag inside the Solid Rocket Motor (SRM) that forms during flight as the propellant is spent and is ejected throughout the descent of the SRB after separation. The direction of the impact mark matches with the likely trajectory of SRBs tumbling prior to re-entry.

Nelson, Linda A.↗

NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Phase II Upgrade Activities

Emrich, William J.↗

NASA NTRS2007

Exploring the Solid Rocket Boosters and Properties of Matter

I worked for the United Space Alliance, LLC (USA) with the Solid Rocket Booster (SRB) Materials and Process engineers (M&P). I was assigned a project in which I needed to research and collect chemical and physical properties information, material safety data sheets (MSDS), and other product information from the vendor's websites and existing "inhouse" files for a select group of materials used in building and refurbishing the SRBs. This information was then compiled in a report that summarized the information collected. My work site was at the Kennedy Space Center (KSC). This allowed for many opportunities to visit and tour sites operated by NASA, by USA, and by the Air Force. This included the vehicle assembly building (VAB), orbital processing facilities (OPF), the crawler with the mobile launch pad (MLP), and the SRB assembly and refurbishment facility (ARF), to name a few. In addition, the launch, of STS- 117 took place within the first week of employment allowing a day by day following of that mission including post flight operations for the SRBs. Two Delta II rockets were also launched during these 7 weeks. The sights were incredible and the operations witnessed were amazing. I learned so many things I never knew about the entire program and the shuttle itself. The entire experience, especially my work with the SRB materials, inspired my plan for implementation into the classroom.

Moffett, Amy↗

NASA NTRS2014

Evaluation of Geopolymer Concrete for Rocket Test Facility Flame Deflectors

The current paper presents results from a combined research effort by Louisiana Tech University (LTU) and NASA Stennis Space Center (SSC) to develop a new alumina-silicate based cementitious binder capable of acting as a high performance refractory material with low heat ablation rate and high early mechanical strength. Such a binder would represent a significant contribution to NASA's efforts to develop a new generation of refractory 'hot face' liners for liquid or solid rocket plume environments. This project was developed as a continuation of on-going collaborations between LTU and SSC, where test sections of a formulation of high temperature geopolymer binder were cast in the floor and walls of Test Stand E-1 Cell 3, an active rocket engine test stand flame trench. Additionally, geopolymer concrete panels were tested using the NASA-SSC Diagnostic Test Facility (DTF) thruster, where supersonic plume environments were generated on a 1ft wide x 2ft long x 6 inch deep refractory panel. The DTF operates on LOX/GH2 propellants producing a nominal thrust of 1,200 lbf and the combustion chamber conditions are Pc=625psig, O/F=6.0. Data collected included high speed video of plume/panel area and surface profiles (depth) of the test panels measured on a 1-inch by 1-inch giving localized erosion rates during the test. Louisiana Tech conducted a microstructure analysis of the geopolymer binder after the testing program to identify phase changes in the material.

Allgood, Daniel C.↗