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A conceptual design of a multi-stage aerospace craft is presented. Two perspective views of the vehicle are developed to show the two component configuration with delta wing, four vertical tail surfaces, tricycle landing gear, and two rocket exhaust nozzles at the rear of the fuselage. Engines for propulsion in the atmosphere are mounted on the fuselage in front of the wing root attachment.
The necessity of performance augmentation for the Space Shuttle to assure its capability of delivering a 32,000 pound payload to a 150 nautical mile circular orbit at an inclination of 98 deg and to then retrieve a 25,000 pound spacecraft from that orbit is discussed. The performance augmented Space Shuttle must meet all design mission requirements and will offer potential payload growth to accommodate new payloads and new concepts. The performance augmentation program includes the uprating of the Space Shuttle main engines to the range of 115% of rated power level for nominal operations, the development of solid rocket motor filament-wound case segments, and the use of a liquid boost module.
The postflight reports of each of the Principal Investigators of three selected science payloads are presented in addition to the engineering report as documented by the Marshall Space Flight Center (MSFC). Pertinent portions of ground-based research leading to the ultimate selection of the flight sample composition are described including design, fabrication and testing. Containerless processing technology, containerless processing bubble dynamics, and comparative alloy solidification are the experiments discussed.
Many high temperature aircraft and rocket engine components experience large mechanical loads as well as severe thermal gradients and transients. These nonisothermal conditions are often large enough to cause inelastic deformations, which are the ultimate cause for failure in those parts. A way to alleviate this problem is through improved engine designs based on better predictions of thermomechanical material behavior. To address this concern, an experimental effort was recently initiated within the Hot Section Technology (HOST) program at Lewis. As part of this effort, two new test systems were added to the Fatigue and Structures Lab., which allowed thermomechanical tests to be conducted under closely controlled conditions. These systems are now being used for thermomechanical testing for the Space Station Receiver program, and will be used to support development of metal matrix composites.
The STS-51 Space Shuttle Program Mission Report summarizes the payloads as well as the orbiter, external tank (ET), solid rocket booster (SRB), redesigned solid rocket motor (RSRM), and the space shuttle main engine (SSME) systems performance during the fifty-seventh flight of the space shuttle program and seventeenth flight of the orbiter vehicle Discovery (OV-103). In addition to the orbiter, the flight vehicle consisted of an ET designated as ET-59; three SSME's, which were designated as serial numbers 2031, 2034, and 2029 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-060. The lightweight RSRM's that were installed in each SRB were designated as 360W033A for the left SRB and 360L033B for the right SRB.
The STS-59 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the sixty-second flight of the Space Shuttle Program and sixth flight of the Orbiter vehicle Endeavor (OV-105). In addition to the Orbiter, the flight vehicle consisted of an ET designated as ET-63; three SSME's which were designated as serial numbers 2028, 2033, and 2018 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-065. The RSRM's that were installed in each SRB were designated as 360W037A (welterweight) for the left SRB, and 360H037B (heavyweight) for the right SRB. This STS-59 Space Shuttle Program Mission Report fulfills the Space Shuttle Program requirement as documented in NSTS 07700, Volume 8, Appendix E. That document requires that each major organizational element supporting the Program report the results of its hardware evaluation and mission performance plus identify all related in-flight anomalies. The primary objective of the STS-59 mission was to successfully perform the operations of the Space Radar Laboratory-1 (SRL-1). The secondary objectives of this flight were to perform the operations of the Space Tissue Loss-A (STL-A) and STL-B payloads, the Visual Function Tester-4 (VFT-4) payload, the Shuttle Amateur Radio Experiment-2 (SAREX-2) experiment, the Consortium for Materials Development in Space Complex Autonomous Payload-4 (CONCAP-4), and the three Get-Away Special (GAS) payloads.
The STS-62 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSHE) systems performance during the sixty-first flight of the Space Shuttle Program and sixteenth flight of the Orbiter vehicle Columbia (OV-102). In addition to the Orbiter, the flight vehicle consisted of an ET designated as ET-62; three SSME's which were designated as serial numbers 2031, 2109, and 2029 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-064. The RSRM's that were installed in each SRB were designated as 360L036A (lightweight) for the left SRB, and 36OWO36B (welterweight) for the right SRB. This STS-62 Space Shuttle Program Mission Report fulfills the Space Shuttle Program requirement as documented in NSTS 07700, Volume 8, Appendix E. That document requires that each major organizational element supporting the Program report the results of its hardware evaluation and mission performance plus identify all related in-flight anomalies. The primary objectives of the STS-62 mission were to perform the operations of the United States Microgravity Payload-2 (USMP-2) and the Office of Aeronautics and Space Technology-2 (OAST-2) payload. The secondary objectives of this flight were to perform the operations of the Dexterous End Effector (DEE), the Shuttle Solar Backscatter Ultraviolet/A (SSBUV/A), the Limited Duration Space Environment Candidate Material Exposure (LDCE), the Advanced Protein Crystal Growth (APCG), the Physiological Systems Experiments (PSE), the Commercial Protein Crystal Growth (CPCG), the Commercial Generic Bioprocessing Apparatus (CGBA), the Middeck Zero-Gravity Dynamics Experiment (MODE), the Bioreactor Demonstration System (BDS), the Air Force Maui Optical Site Calibration Test (AMOS), and the Auroral Photography Experiment (APE-B).
The STS-61 Space Shuttle Program Mission Report summarizes the Hubble Space Telescope (HST) servicing mission as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Redesigned Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the fifty-ninth flight of the Space Shuttle Program and fifth flight of the Orbiter vehicle Endeavour (OV-105). In addition to the Orbiter, the flight vehicle consisted of an ET designated as ET-60; three SSME's which were designated as serial numbers 2019, 2033, and 2017 in positions 1, 2, and 3, respectively; and two SRB's which were designated BI-063. The RSRM's that were installed in each SRB were designated as 360L023A (lightweight) for the left SRB, and 360L023B (lightweight) for the right SRB. This STS-61 Space Shuttle Program Mission Report fulfills the Space Shuttle Program requirement as documented in NSTS 07700, Volume 8, Appendix E. That document requires that each major organizational element supporting the Program report the results of its hardware evaluation and mission performance plus identify all related in-flight anomalies. The primary objective of the STS-61 mission was to perform the first on-orbit servicing of the Hubble Space Telescope. The servicing tasks included the installation of new solar arrays, replacement of the Wide Field/Planetary Camera I (WF/PC I) with WF/PC II, replacement of the High Speed Photometer (HSP) with the Corrective Optics Space Telescope Axial Replacement (COSTAR), replacement of rate sensing units (RSU's) and electronic control units (ECU's), installation of new magnetic sensing systems and fuse plugs, and the repair of the Goddard High Resolution Spectrometer (GHRS). Secondary objectives were to perform the requirements of the IMAX Cargo Bay Camera (ICBC), the IMAX Camera, and the Air Force Maui Optical Site (AMOS) Calibration Test.
An advanced Cu-8(at.%)Cr-4%Nb alloy developed at NASA's Glenn Research Center, and designated as GRCop-84, is currently being considered for use as liners in combustor chambers and nozzle ramps in NASA s future generations of reusable launch vehicles (RLVs). However, past experience has shown that unprotected copper alloys undergo an environmental attack called "blanching" in rocket engines using liquid hydrogen as fuel and liquid oxygen as the oxidizer. Potential for sulfidation attack of the liners in hydrocarbon-fueled engines is also of concern. As a result, protective overlay coatings alloys are being developed for GRCop-84. The oxidation behavior of several new coating alloys has been evaluated. GRCop-84 specimens were coated with several copper and nickel-based coatings, where the coatings were deposited by either vacuum plasma spraying or cold spraying techniques. Coated and uncoated specimens were thermally cycled in a furnace at different temperatures in order to evaluate the performance of the coatings. Additional studies were conducted in a high pressure burner rig using a hydrocarbon fuel and subjected to a high heat flux hydrogen-oxygen combustion flame in NASA s Quick Access Rocket Exhaust (QARE) rig. The performance of these coatings are discussed.
Significant hardware and software for NASA's Space Launch System (SLS) began rolling off assembly lines in 2016, setting the stage for critical testing in 2017 and the launch of new capability for deep-space human exploration. (Figure 1) At NASA's Michoud Assembly Facility (MAF) near New Orleans, LA, full-scale test articles are being joined by flight hardware. Structural test stands are nearing completion at NASA's Marshall Space Flight Center (MSFC), Huntsville, AL. An SLS booster solid rocket motor underwent test firing, while flight motor segments were cast. An RS-25 and Engine Control Unit (ECU) for early SLS flights were tested at NASA's Stennis Space Center (SSC). The upper stage for the first flight was completed, and NASA completed Preliminary Design Review (PDR) for a new, powerful upper stage. The pace of production and testing is expected to increase in 2017. This paper will discuss the technical and programmatic highlights and challenges of 2016 and look ahead to plans for 2017.
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.
America has begun the development of a new heavy lift rocket which will enable humans to return to the moon and reach even farther destinations. Five decades ago, the National Aeronautics and Space Administration designed a system (called Saturn/Apollo) to carry men to the moon and back; the rocket which boosted them to the moon was the Saturn V. Saturn V was huge relative to contemporary rockets and is still the largest rocket ever launched. The new moon rocket is called Ares V. It will insert 40% more payload into low earth orbit than Saturn V; and after docking with the crew spacecraft, it will insert 50% more payload onto the translunar trajectory than Saturn V. The current design of Ares V calls for two liquid-fueled stages and 2 "strap-on" solid rockets. The solid rockets are extended-length versions of the solid rockets used on the Shuttle. The diameter of the liquid stages is at least as large as the first stage of the Saturn V; the height of the lower liquid stage (called the core stage) is longer than the external tank of the Shuttle. Huge rockets require huge infrastructure and, during the Saturn/Apollo era, America invested significantly in manufacturing, assembly and launch facilities which are still in use today. Since the Saturn/Apollo era, America has invested in additional infrastructure for the Shuttle program. Ares V must utilize this existing infrastructure, with reasonable modifications. Building a rocket with 50% more capability in the same buildings, testing it in the same test stands, shipping on the same canals under the same bridges, assembling it in the same building, rolling it to the pad on the same crawler, and launching it from the same launch pad is an engineering and logistics challenge which goes hand-in-hand with designing the structure, tanks, turbines, engines, software, etc. necessary to carry such a large payload to earth orbit and to the moon. This paper quantitatively discusses the significant "tight fits" that are constraining Ares V. The engineers designing and building the infrastructure for the Saturn/Apollo program usually added margins and growth capability; sometimes the size of existing facilities (such as the width of a draw bridge) was not a constraint. Ares V may utilize the "extra" space in the existing facilities and expand other tight fits. Some of the tight fits cannot be overcome without great expense; raising the roof on the Vertical Assembly Building for example. Other tight fits are easily overcome; the transporter at the manufacturing facility for the core stage can pass under low ceilings and later over a dike (without dragging the middle) by retracting or extending the struts which support the stage. Tight fits discussed in this paper include manufacturing (jigs, widths, heights, and local transportation), testing (test stand sizes and crane capability), transportation to the test stands and the launch site (barge, waterway, and rail), assembly (VAB internal dimensions and door size), roll-out limits, and launch pad size.
NASA’s Chemical Equilibrium with Applications (CEA) code is a foundational tool for propulsion system analysis. It provides equilibrium chemistry, rocket performance, shock, and detonation calculations used across NASA and the broader aerospace community. NASA Engineering and Safety Center (NESC) Activity TI-22-01730 modernized the legacy CEA2 Fortran code into CEA v3, a Fortran 2008, object-oriented software package with expanded interface support, updated thermochemical data, improved maintainability, and substantially improved workflow integration. The modernized code preserves backward compatibility with legacy CEA input workflows while enabling direct use from modern analysis environments, including Python, C, MATLAB, and automated design studies.
The objective of this effort is t o develop an efficient and accurate thermo-fluid computational methodology to predict environments for hypothetical thrust chamber design and analysis. The current task scope is to perform multidimensional, multiphysics analysis of thrust performance and heat transfer analysis for a hypothetical solid-core, nuclear thermal engine including thrust chamber and nozzle. The multiphysics aspects of the model include: real fluid dynamics, chemical reactivity, turbulent flow, and conjugate heat transfer. The model will be designed to identify thermal, fluid, and hydrogen environments in all flow paths and materials. This model would then be used to perform non- nuclear reproduction of the flow element failures demonstrated in the Rover/NERVA testing, investigate performance of specific configurations and assess potential issues and enhancements. A two-pronged approach will be employed in this effort: a detailed analysis of a multi-channel, flow-element, and global modeling of the entire thrust chamber assembly with a porosity modeling technique. It is expected that the detailed analysis of a single flow element would provide detailed fluid, thermal, and hydrogen environments for stress analysis, while the global thrust chamber assembly analysis would promote understanding of the effects of hydrogen dissociation and heat transfer on thrust performance. These modeling activities will be validated as much as possible by testing performed by other related efforts.
The failure mode analysis (FMA) is described as a design tool to predict and improve product reliability. The objectives of the failure mode analysis are presented as they influence component design, configuration selection, the product test program, the quality assurance plan, and engineering analysis priorities. The detailed mechanics of performing a failure mode analysis are discussed, including one suggested format. Some practical difficulties of implementation are indicated, drawn from experience with preparing FMAs on the nuclear rocket engine program.
The STS-49 Space Shuttle Program Mission Report contains a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and Space Shuttle main engine (SSME) subsystem performance during the forty-seventh flight of the Space Shuttle Program and the first flight of the Orbiter vehicle Endeavor (OV-105). In addition to the Endeavor vehicle, the flight vehicle consisted of an ET designated as ET-43 (LWT-36); three SSME's which were serial numbers 2030, 2015, and 2017 in positions 1, 2, and 3, respectively; and two SRB's designated as BI-050. The lightweight RSRM's installed in each SRB were designated as 360L022A for the left RSRM and 360L022B for the right RSRM.
Historically, advances in aerospace engine performance and durability have been linked to improvements in materials. Recent developments in ceramic matrix composites (CMCs) have led to increased interest in CMCs to achieve revolutionary gains in engine performance. The use of CMCs promises many advantages for advanced turbomachinery engine development and may be especially beneficial for aerospace engines. The most beneficial aspects of CMC material may be its ability to maintain its strength to over 2500 F, its internal material damping, and its relatively low density. Ceramic matrix composites reinforced with two-dimensional woven and braided fabric preforms are being considered for NASA s next-generation reusable rocket turbomachinery applications (for example, see the preceding figure). However, the architecture of a textile composite is complex, and therefore, the parameters controlling its strength properties are numerous. This necessitates the development of engineering approaches that combine analytical methods with limited testing to provide effective, validated design analyses for the textile composite structures development.
Additive Manufacturing (AM) is an emerging technology with a focus on complex metallic component fabrication: Enables complex shapes and internal features that were not possibly with traditional manufacturing techniques, and significant schedule and overall lifecycle cost reductions. To date at the NASA Marshall Space Flight Center (MSFC), combustion devices component hardware ranging in size from 100 - 35,000 lbf has been designed and manufactured using AM and many of these pieces have been hot-fire tested.