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NASA NTRS2007

Development of Natural Flaw Samples for Evaluating Nondestructive Testing Methods for Foam Thermal Protection Systems

Low density polyurethane foam has been an important insulation material for space launch vehicles for several decades. The potential for damage from foam breaking away from the NASA External Tank was not realized until the foam impacts on the Columbia Orbiter vehicle caused damage to its Leading Edge thermal protection systems (TPS). Development of improved inspection techniques on the foam TPS is necessary to prevent similar occurrences in the future. Foamed panels with drilled holes for volumetric flaws and Teflon inserts to simulate debonded conditions have been used to evaluate and calibrate nondestructive testing (NDT) methods. Unfortunately the symmetric edges and dissimilar materials used in the preparation of these simulated flaws provide an artificially large signal while very little signal is generated from the actual defects themselves. In other words, the same signal are not generated from the artificial defects in the foam test panels as produced when inspecting natural defect in the ET foam TPS. A project to create more realistic voids similar to what actually occurs during manufacturing operations was began in order to improve detection of critical voids during inspections. This presentation describes approaches taken to create more natural voids in foam TPS in order to provide a more realistic evaluation of what the NDT methods can detect. These flaw creation techniques were developed with both sprayed foam and poured foam used for insulation on the External Tank. Test panels with simulated defects have been used to evaluate NDT methods for the inspection of the External Tank. A comparison of images between natural flaws and machined flaws generated from backscatter x-ray radiography, x-ray laminography, terahertz imaging and millimeter wave imaging show significant differences in identifying defect regions.

Workman, Gary L.↗

NASA NTRS2007

Magnetic Field Response Measurement Acquisition System

This paper presents a measurement acquisition method that alleviates many shortcomings of traditional measurement systems. The shortcomings are a finite number of measurement channels, weight penalty associated with measurements, electrical arcing, wire degradations due to wear or chemical decay and the logistics needed to add new sensors. Wire degradation has resulted in aircraft fatalities and critical space launches being delayed. The key to this method is the use of sensors designed as passive inductor-capacitor circuits that produce magnetic field responses. The response attributes correspond to states of physical properties for which the sensors measure. Power is wirelessly provided to the sensing element by using Faraday induction. A radio frequency antenna produces a time-varying magnetic field used to power the sensor and receive the magnetic field response of the sensor. An interrogation system for discerning changes in the sensor response frequency, resistance and amplitude has been developed and is presented herein. Multiple sensors can be interrogated using this method. The method eliminates the need for a data acquisition channel dedicated to each sensor. The method does not require the sensors to be near the acquisition hardware. Methods of developing magnetic field response sensors and the influence of key parameters on measurement acquisition are discussed. Examples of magnetic field response sensors and the respective measurement characterizations are presented. Implementation of this method on an aerospace system is discussed.

Woodard, Stanley E.↗

NASA NTRS2009

NASA Composite Materials Development: Lessons Learned and Future Challenges

Composite materials have emerged as the materials of choice for increasing the performance and reducing the weight and cost of military, general aviation, and transport aircraft and space launch vehicles. Major advancements have been made in the ability to design, fabricate, and analyze large complex aerospace structures. The recent efforts by Boeing and Airbus to incorporate composite into primary load carrying structures of large commercial transports and to certify the airworthiness of these structures is evidence of the significant advancements made in understanding and use of these materials in real world aircraft. NASA has been engaged in research on composites since the late 1960 s and has worked to address many development issues with these materials in an effort to ensure safety, improve performance, and improve affordability of air travel for the public good. This research has ranged from synthesis of advanced resin chemistries to development of mathematical analyses tools to reliably predict the response of built-up structures under combined load conditions. The lessons learned from this research are highlighted with specific examples to illustrate the problems encountered and solutions to these problems. Examples include specific technologies related to environmental effects, processing science, fabrication technologies, nondestructive inspection, damage tolerance, micromechanics, structural mechanics, and residual life prediction. The current state of the technology is reviewed and key issues requiring additional research identified. Also, grand challenges to be solved for expanded use of composites in aero structures are identified.

Tenney, Darrel R.↗

NASA NTRS2010

A Historical Systems Study of Liquid Rocket Engine Throttling Capabilities

This is a comprehensive systems study to examine and evaluate throttling capabilities of liquid rocket engines. The focus of this study is on engine components, and how the interactions of these components are considered for throttling applications. First, an assessment of space mission requirements is performed to determine what applications require engine throttling. A background on liquid rocket engine throttling is provided, along with the basic equations that are used to predict performance. Three engines are discussed that have successfully demonstrated throttling. Next, the engine system is broken down into components to discuss special considerations that need to be made for engine throttling. This study focuses on liquid rocket engines that have demonstrated operational capability on American space launch vehicles, starting with the Apollo vehicle engines and ending with current technology demonstrations. Both deep throttling and shallow throttling engines are discussed. Boost and sustainer engines have demonstrated throttling from 17% to 100% thrust, while upper stage and lunar lander engines have demonstrated throttling in excess of 10% to 100% thrust. The key difficulty in throttling liquid rocket engines is maintaining an adequate pressure drop across the injector, which is necessary to provide propellant atomization and mixing. For the combustion chamber, cooling can be an issue at low thrust levels. For turbomachinery, the primary considerations are to avoid cavitation, stall, surge, and to consider bearing leakage flows, rotordynamics, and structural dynamics. For valves, it is necessary to design valves and actuators that can achieve accurate flow control at all thrust levels. It is also important to assess the amount of nozzle flow separation that can be tolerated at low thrust levels for ground testing.

Betts, Erin M.↗

NASA NTRS2001

Potential Future Shuttle Improvements

NASA has just recently completed the 104th flight of the Space Shuttle. Each of the four Orbiters in the Shuttle fleet have a design life of 100 flights each. Thus the fleet is capable of almost 300 more flights, and at current flight rates could potentially operate well past 2020 if necessary. This paper addresses some of the potential Shuttle system improvements that could be considered if the decision is made to continue operations of this vehicle for such an extended period. The national space transportation policy envisions a decision around 2005-2006 concerning readiness to start development of a Shuttle replacement system. Leading up to that decision point NASA is investing in the Space Launch Initiative (SLI) to reduce the development risks associated with key technologies needed for the next generation reusable launch vehicle (RLV). The Shuttle replacement could be a new design RLV or could be based on a Shuttle derived design: i.e., a vehicle based on the current Shuttle but with major design changes. The technology investment strategy of SLI is supportive of either approach. However, if NASA and industry are not ready to develop a replacement vehicle in the 2006-2012 timeframe, then another option would be to continue to make important, but evolutionary changes, to the existing Shuttle fleet. The overall strategy for next generation RLV planning, including possible Shuttle evolution, is captured in Figure 1.

Henderson, Edward↗

NASA NTRS2010

A Method to Estimate the Probability That Any Individual Lightning Stroke Contacted the Surface Within Any Radius of Any Point

A technique has been developed to calculate the probability that any nearby lightning stroke is within any radius of any point of interest. In practice, this provides the probability that a nearby lightning stroke was within a key distance of a facility, rather than the error ellipses centered on the stroke. This process takes the current bivariate Gaussian distribution of probability density provided by the current lightning location error ellipse for the most likely location of a lightning stroke and integrates it to get the probability that the stroke is inside any specified radius. This new facility-centric technique will be much more useful to the space launch customers and may supersede the lightning error ellipse approach discussed in [5], [6].

Huddleston, Lisa L.↗

NASA NTRS2011

CLVTOPS Liftoff and Separation Analysis Validation Using Ares I-X Flight Data

CLVTOPS is a multi-body time domain flight dynamics simulation tool developed by NASA s Marshall Space Flight Center (MSFC) for a space launch vehicle and is based on the TREETOPS simulation tool. CLVTOPS is currently used to simulate the flight dynamics and separation/jettison events of the Ares I launch vehicle including liftoff and staging separation. In order for CLVTOPS to become an accredited tool, validation against other independent simulations and real world data is needed. The launch of the Ares I-X vehicle (first Ares I test flight) on October 28, 2009 presented a great opportunity to provide validation evidence for CLVTOPS. In order to simulate the Ares I-X flight, specific models were implemented into CLVTOPS. These models include the flight day environment, reconstructed thrust, reconstructed mass properties, aerodynamics, and the Ares I-X guidance, navigation and control models. The resulting simulation output was compared to Ares I-X flight data. During the liftoff region of flight, trajectory states from the simulation and flight data were compared. The CLVTOPS results were used to make a semi-transparent animation of the vehicle that was overlaid directly on top of the flight video to provide a qualitative measure of the agreement between the simulation and the actual flight. During ascent, the trajectory states of the vehicle were compared with flight data. For the stage separation event, the trajectory states of the two stages were compared to available flight data. Since no quantitative rotational state data for the upper stage was available, the CLVTOPS results were used to make an animation of the two stages to show a side-by-side comparison with flight video. All of the comparisons between CLVTOPS and the flight data show good agreement. This paper documents comparisons between CLVTOPS and Ares I-X flight data which serve as validation evidence for the eventual accreditation of CLVTOPS.

Burger, Ben↗

NASA NTRS2011

Kennedy Space Center - "America's Gateway to Space"

KSC fits into the overall NASA vision and mission by moving forward so that what we do and learn will benefit all here on Earth. In January of last year, KSC revised its Mission and Vision statements to articulate our identity as we align with this new direction the Agency is heading. Currently KSC is endeavoring to form partnerships with industry, , Government, and academia, utilizing institutional assets and technical capabilities to support current and future m!issions. With a goal of safe, low-cost, and readily available access to space, KSC seeks to leverage emerging industries to initiate development of a new space launch system, oversee the development of a multipurpose crew vehicle, and assist with the efficient and timely evolution of commercial crew transportation capabilities. At the same time, KSC is pursuing modernizing the Center's infrastructure and creating a multi-user launch complex with increased onsite processing and integration capabilities.

Petro, Janet↗

NASA NTRS2011

Computational Fluid Dynamics Demonstration of Rigid Bodies in Motion

The Design Analysis Branch (NE-Ml) at the Kennedy Space Center has not had the ability to accurately couple Rigid Body Dynamics (RBD) and Computational Fluid Dynamics (CFD). OVERFLOW-D is a flow solver that has been developed by NASA to have the capability to analyze and simulate dynamic motions with up to six Degrees of Freedom (6-DOF). Two simulations were prepared over the course of the internship to demonstrate 6DOF motion of rigid bodies under aerodynamic loading. The geometries in the simulations were based on a conceptual Space Launch System (SLS). The first simulation that was prepared and computed was the motion of a Solid Rocket Booster (SRB) as it separates from its core stage. To reduce computational time during the development of the simulation, only half of the physical domain with respect to the symmetry plane was simulated. Then a full solution was prepared and computed. The second simulation was a model of the SLS as it departs from a launch pad under a 20 knot crosswind. This simulation was reduced to Two Dimensions (2D) to reduce both preparation and computation time. By allowing 2-DOF for translations and 1-DOF for rotation, the simulation predicted unrealistic rotation. The simulation was then constrained to only allow translations.

Camarena, Ernesto↗

NASA NTRS2011

Ram booster

The present invention is a space launch system and method to propel a payload bearing craft into earth orbit. The invention has two, or preferably, three stages. The upper stage has rocket engines capable of carrying a payload to orbit and provides the capability of releasably attaching to the lower, or preferably, middle stage. Similar to the lower stage, the middle stage is a reusable booster stage that employs all air breathing engines, is recoverable, and can be turned-around in a short time between missions.

Brand, Vance D.↗

NASA NTRS2011

Comprehensive Forced Response Analysis of J2X Turbine Bladed-Discs with 36- Degree Variation in CFD Loading

At NASA/MSFC, Structural Dynamics personnel continue to perform advanced analysis for the turbomachinery in the J2X Rocket Engine, which is under consideration for the new Space Launch System. One of the most challenging analyses in the program is predicting turbine blade structural capability. Resonance was predicted by modal analysis, so comprehensive forced response analyses using high fidelity cyclic symmetric finite element models were initiated as required. Analysis methodologies up to this point have assumed the flow field could be fully described by a sector, so the loading on every blade would be identical as it travelled through it. However, in the J2X the CFD flow field varied over the 360 deg of a revolution because of the flow speeds and tortuous axial path. MSFC therefore developed a complex procedure using Nastran Dmap's and Matlab scripts to apply this circumferentially varying loading onto the cyclically symmetric structural models to produce accurate dynamic stresses for every blade on the disk. This procedure is coupled with static, spin, and thermal loading to produce high cycle fatigue safety factors resulting in much more accurate analytical assessments of the blades.

Elrod, David↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishment, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor (RSRM) represents the largest solid rocket motor (SRM) ever flown and the only human-rated solid motor. High reliability of the RSRM has been the result of challenges addressed and lessons learned. Advancements have resulted by applying attention to process control, testing, and postflight through timely and thorough communication in dealing with all issues. A structured and disciplined approach was taken to identify and disposition all concerns. Careful consideration and application of alternate opinions was embraced. Focus was placed on process control, ground test programs, and postflight assessment. Process control is mandatory for an SRM, because an acceptance test of the delivered product is not feasible. The RSRM maintained both full-scale and subscale test articles, which enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. RSRM reusability offered unique opportunities to learn about the hardware. NASA is moving forward with the Space Launch System that incorporates propulsion systems that takes advantage of the heritage Shuttle and Ares solid motor programs. These unique challenges, features of the RSRM, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, D. R.↗

NASA NTRS2012

Testing of the NASA Hypersonics Project Combined Cycle Engine Large Scale Inlet Mode Transition Experiment (CCE LlMX)

Status on an effort to develop Turbine Based Combined Cycle (TBCC) propulsion is described. This propulsion technology can enable reliable and reusable space launch systems. TBCC propulsion offers improved performance and safety over rocket propulsion. The potential to realize aircraft-like operations and reduced maintenance are additional benefits. Among most the critical TBCC enabling technologies are: 1) mode transition from turbine to scramjet propulsion, 2) high Mach turbine engines and 3) TBCC integration. To address these TBCC challenges, the effort is centered on a propulsion mode transition experiment and includes analytical research. The test program, the Combined-Cycle Engine Large Scale Inlet Mode Transition Experiment (CCE LIMX), was conceived to integrate TBCC propulsion with proposed hypersonic vehicles. The goals address: (1) dual inlet operability and performance, (2) mode-transition sequences enabling a switch between turbine and scramjet flow paths, and (3) turbine engine transients during transition. Four test phases are planned from which a database can be used to both validate design and analysis codes and characterize operability and integration issues for TBCC propulsion. In this paper we discuss the research objectives, features of the CCE hardware and test plans, and status of the parametric inlet characterization testing which began in 2011. This effort is sponsored by the NASA Fundamental Aeronautics Hypersonics project

Saunders, J. D.↗

NASA NTRS2012

Dual-Doppler Feasibility Study

When two or more Doppler weather radar systems are monitoring the same region, the Doppler velocities can be combined to form a three-dimensional (3-D) wind vector field thus providing for a more intuitive analysis of the wind field. A real-time display of the 3-D winds can assist forecasters in predicting the onset of convection and severe weather. The data can also be used to initialize local numerical weather prediction models. Two operational Doppler Radar systems are in the vicinity of Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS); these systems are operated by the 45th Space Wing (45 SW) and the National Weather Service Melbourne, Fla. (NWS MLB). Dual-Doppler applications were considered by the 45 SW in choosing the site for the new radar. Accordingly, the 45th Weather Squadron (45 WS), NWS MLB and the National Aeronautics and Space Administration tasked the Applied Meteorology Unit (AMU) to investigate the feasibility of establishing dual-Doppler capability using the two existing systems. This study investigated technical, hardware, and software requirements necessary to enable the establishment of a dual-Doppler capability. Review of the available literature pertaining to the dual-Doppler technique and consultation with experts revealed that the physical locations and resulting beam crossing angles of the 45 SW and NWS MLB radars make them ideally suited for a dual-Doppler capability. The dual-Doppler equations were derived to facilitate complete understanding of dual-Doppler synthesis; to determine the technical information requirements; and to determine the components of wind velocity from the equation of continuity and radial velocity data collected by the two Doppler radars. Analysis confirmed the suitability of the existing systems to provide the desired capability. In addition, it is possible that both 45 SW radar data and Terminal Doppler Weather Radar data from Orlando International Airport could be used to alleviate any radar geometry issues at the NWS MLB radar, such as the "cone of silence" or beam blockage. In the event of a radar outage at one of the sites, the multi-radar algorithms would provide continuing coverage of the area through use of the data from the remaining operational radar sites. There are several options to collect, edit, synthesize and display dual-Doppler data sets. These options include commercial packages available for purchase and a variety of freeware packages available from the National Center for Atmospheric Research (NCAR) for processing raw radar data. However, evaluation of the freeware packages revealed that they do not have sufficient documentation and configuration control to be certified for 45 SW use. Additionally, a TI data line must be installed/leased from the NWS MLB office and CCAFS to enable the receipt of NWS MLB raw radar data to use in the dual-Doppler synthesis. Integration of the TI data line into the Eastern Range infrastructure that will meet the security requirements necessary for 45 SW use is time-consuming and costly. Overall evaluation indicates that establishment of the dual-Doppler capability using the existing operational radar systems is desirable and feasible with no technical concerns. Installation of such a system represents a significant enhancement to forecasting capabilities at the 45 WS and at NWS MLB. However, data security and cost considerations must be evaluated in light of current budgetary constraints. In any case, gaining the dual-Doppler capability will provide opportunities for better visualization of the wind field and better forecasting of the onset of convection and severe weather events to support space launch operations at KSC and CCAFS.

Huddleston, Lisa L.↗

NASA NTRS2012

Elastic Plastic Fracture Analysis of an Aluminum COPV Liner

Onboard any space-launch vehicle, composite over-wrapped pressure vessels (COPVs) may be utilized by propulsion or environmental control systems. The failure of a COPV has the potential to be catastrophic, resulting in the loss of vehicle, crew or mission. The latest COPV designs have reduced the wall-thickness of the metallic liner to the point where the material strains plastically during operation. At this time, the only method to determine the damage tolerance lifetime (safe-life) of a plastically responding metallic liner is through full-scale COPV testing. Conducting tests costs substantially more and can be far more time consuming than performing an analysis. As a result of this cost, there is a need to establish a qualifying process through the use of a crack growth analysis tool. This paper will discuss fracture analyses of plastically responding metallic liners in COPVs. Uni-axial strain tests have been completed on laboratory specimens to collect elastic-plastic crack growth data. This data has been modeled with the crack growth analysis tool, NASGRO 6.20 to predict the response of laboratory specimens and subsequently the complexity of a COPV.

Forth, Scott↗

NASA NTRS2012

Cryogenic Propulsion Stage (CPS) Configuration in Support of NASA's Multiple Design Reference Missions (DRMs)

In support of the National Aeronautics and Space Administration's (NASA) Human Exploration and Operations Mission Directorate (HEOMD), the Space Launch System (SLS) is being designed for safe, affordable, and sustainable human and scientific exploration missions beyond Earth's or-bit (BEO). The SLS Team is tasked with developing a system capable of safely and repeatedly lofting a new fleet of spaceflight vehicles beyond Earth orbit. The Cryogenic Propulsion Stage (CPS) is a key enabler for evolving the SLS capability for BEO missions. This paper reports on the methodology and initial recommendations relative to the CPS, giving a brief retrospective of early studies on this promising propulsion hardware. This paper provides an overview of the requirements development and CPS configuration in support of NASA's multiple Design Reference Missions (DRMs).

Hanna, Stephen G.↗

NASA NTRS2012

Analytical Approaches to Guide SLS Fault Management (FM) Development

Extensive analysis is needed to determine the right set of FM capabilities to provide the most coverage without significantly increasing the cost, reliability (FP/FN), and complexity of the overall vehicle systems. Strong collaboration with the stakeholders is required to support the determination of the best triggers and response options. The SLS Fault Management process has been documented in the Space Launch System Program (SLSP) Fault Management Plan (SLS-PLAN-085).

Patterson, Jonathan D.↗

NASA NTRS2012

Contamination Control and Hardware Processing Solutions at Marshall Space Flight Center

The Contamination Control Team of Marshall Space Flight Center's Materials and Processes Laboratory supports many Programs/ Projects that design, manufacture, and test a wide range of hardware types that are sensitive to contamination and foreign object damage (FOD). Examples where contamination/FOD concerns arise include sensitive structural bondline failure, critical orifice blockage, seal leakage, and reactive fluid compatibility (liquid oxygen, hydrazine) as well as performance degradation of sensitive instruments or spacecraft surfaces such as optical elements and thermal control systems. During the design phase, determination of the sensitivity of a hardware system to different types or levels of contamination/FOD is essential. A contamination control and FOD control plan must then be developed and implemented through all phases of ground processing, and, sometimes, on-orbit use, recovery, and refurbishment. Implementation of proper controls prevents cost and schedule impacts due to hardware damage or rework and helps assure mission success. Current capabilities are being used to support recent and on-going activities for multiple Mission Directorates / Programs such as International Space Station (ISS), James Webb Space Telescope (JWST), Space Launch System (SLS) elements (tanks, engines, booster), etc. The team also advances Green Technology initiatives and addresses materials obsolescence issues for NASA and external customers, most notably in the area of solvent replacement (e.g. aqueous cleaners containing hexavalent chrome, ozone depleting chemicals (CFC s and HCFC's), suspect carcinogens). The team evaluates new surface cleanliness inspection and cleaning technologies (e.g. plasma cleaning), and maintains databases for processing support materials as well as outgassing and optical compatibility test results for spaceflight environments.

Burns, DeWitt H.↗