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NASA NTRS1991

Large liquid rocket engine transient performance simulation system

A simulation system, ROCETS, was designed and developed to allow cost-effective computer predictions of liquid rocket engine transient performance. The system allows a user to generate a simulation of any rocket engine configuration using component modules stored in a library through high-level input commands. The system library currently contains 24 component modules, 57 sub-modules and maps, and 33 system routines and utilities. FORTRAN models from other sources can be operated in the system upon inclusion of interface information on comment cards. Operation of the simulation is simplified for the user by run, execution, and output processors. The simulation system makes available steady-state trim balance, transient operation, and linear partial generation. The system utilizes a modern equation solver for efficient operation of the simulations. Transient integration methods include integral and differential forms for the trapezoidal, first order Gear, and second order Gear corrector equations. A detailed technology test bed engine (TTBE) model was generated to be used as the acceptance test of the simulation system. The general level of model detail was that reflected in the Space Shuttle Main Engine DTM. The model successfully obtained steady-state balance in main stage operation and simulated throttle transients, including engine starts and shutdown. A NASA FORTRAN control model was obtained, ROCETS interface installed in comment cards, and operated with the TTBE model in closed-loop transient mode.

Mason, J. R.↗
NASA NTRS2000

A Characterization of the Terrestrial Environment of Kodiak Island, Alaska for the Design, Development and Operation of Launch Vehicles

A quantitative characterization of the terrestrial environment is an important component in the success of a launch vehicle program. Environmental factors such as winds, atmospheric thermodynamics, precipitation, fog, and cloud characteristics are among many parameters that must be accurately defined for flight success. The National Aeronautics and Space Administration (NASA) is currently coordinating weather support and performing analysis for the launch of a NASA payload from a new facility located at Kodiak Island, Alaska in late 2001 (NASA, 1999). Following the first launch from the Kodiak Launch Complex, an Air Force intercontinental ballistic missile on November 5, 1999, the site's developer, the Alaska Aerospace Development Corporation (AADC), is hoping to acquire a sizable share of the many launches that will occur over the next decade. One such customer is NASA, which is planning to launch the Vegetation Canopy Lidar satellite aboard an Athena I rocket, the first planned mission to low earth orbit from the new facility. To support this launch, a statistical model of the atmospheric and surface environment for Kodiak Island, AK has been produced from rawinsonde and surface-based meteorological observations for use as an input to future launch vehicle design and/or operations. In this study, the creation of a "reference atmosphere" from rawinsonde observations is described along with comparisons between the reference atmosphere and existing model representations for Kodiak. Meteorological conditions that might result in a delay on launch day (cloud cover, visibility, precipitation, etc.) are also explored and described through probabilities of launch by month and hour of day. This atmospheric "mission analysis" is also useful during the early stages of a vehicle program, when consideration of the climatic characteristics of a location can be factored into vehicle designs. To be most beneficial, terrestrial environment definitions should a) be available at the inception of the program and based on the desired operational performance of the launch vehicle, b) be issued under the signature of the program manager and be part of the controlled program definition and requirements documentation, and c) specify the terrestrial environment for all phases of activity including prelaunch, launch, ascent, on-orbit, decent, and landing. Since the beginning of the space era, NASA has utilized some of the most detailed assessments of the terrestrial climatic environment in design, development, and operations of both expendable and reusable launch vehicles.

Rawlins, Michael A.↗
NASA NTRS2007

An IEEE 1451.1 Architecture for ISHM Applications

The IEEE 1451.1 Standard for a Smart Transducer Interface defines a common network information model for connecting and managing smart elements in control and data acquisition networks using network-capable application processors (NCAPs). The Standard is a network-neutral design model that is easily ported across operating systems and physical networks for implementing complex acquisition and control applications by simply plugging in the appropriate network level drivers. To simplify configuration and tracking of transducer and actuator details, the family of 1451 standards defines a Transducer Electronic Data Sheet (TEDS) that is associated with each physical element. The TEDS contains all of the pertinent information about the physical operations of a transducer (such as operating regions, calibration tables, and manufacturer information), which the NCAP uses to configure the system to support a specific transducer. The Integrated Systems Health Management (ISHM) group at NASA's John C. Stennis Space Center (SSC) has been developing an ISHM architecture that utilizes IEEE 1451.1 as the primary configuration and data acquisition mechanism for managing and collecting information from a network of distributed intelligent sensing elements. This work has involved collaboration with other NASA centers, universities and aerospace industries to develop IEEE 1451.1 compliant sensors and interfaces tailored to support health assessment of complex systems. This paper and presentation describe the development and implementation of an interface for the configuration, management and communication of data, information and knowledge generated by a distributed system of IEEE 1451.1 intelligent elements monitoring a rocket engine test system. In this context, an intelligent element is defined as one incorporating support for the IEEE 1451.x standards and additional ISHM functions. Our implementation supports real-time collection of both measurement data (raw ADC counts and converted engineering units) and health statistics produced by each intelligent element. The handling of configuration, calibration and health information is automated by using the TEDS in combination with other electronic data sheets extensions to convey health parameters. By integrating the IEEE 1451.1 Standard for a Smart Transducer Interface with ISHM technologies, each element within a complex system becomes a highly flexible computation engine capable of self-validation and performing other measures of the quality of information it is producing.

Morris, Jon A.↗
NASA NTRS2004

Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment

Type 304L stainless steel (304L SS) tubing is currently used in various supply lines that service the Orbiter at NASA's John F. Kennedy Space Center Launch Pads in Florida (USA). The atmosphere at the Space Shuffle launch site is very corrosive due to a combination of factors, such as the proximity of the Atlantic Ocean and the concentrated hydrochloric acid produced by the fuel combustion reaction in the solid rocket boosters. The acidic chloride environment is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as 304L SS. Stainless steel tubing is susceptible to pitting corrosion that can cause cracking and rupture of both high-pressure gas and fluid systems. Outages in the systems where failures occur can impact the normal operation of the shuttle and launch schedules. The use of a more corrosion resistant tubing alloy for launch pad applications would greatly reduce the probability of failure, improve safety, lessen maintenance costs, and reduce downtime. A study which included ten alloys was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. The study included atmospheric exposure at NASA's John F. Kennedy Space Center outdoor corrosion test site near the launch pads and electrochemical measurements in the laboratory which included DC techniques and electrochemical impedance spectroscopy (EIS). This paper presents the results from EIS measurements on three of the alloys: AL6XN (UN N08367), 254SMO (UNS S32l54), and 304L SS (UNS S30403). Type 304L SS was included in the study as a control. The alloys were tested in three electrolyte solutions which consisted of neutral 3.55% NaC1, 3.55% NaCl in O.1N HC1, and 3.55% NaCl in 1.ON HC1. The solutions were chosen to simulate environments that were expected to be less, similar, and more aggressive, respectively, than those present at the Space Shuttle launch pads. The results from the EIS measurements were analyzed to evaluate the corrosion susceptibility of the alloys and to predict the long-term corrosion performance of the subject materials. The results from the EIS measurements for the three alloys indicated that the higher-alloyed 254SMO and AL6XN exhibited a significantly improved resistance to corrosion than the 304L SS as the concentration of hydrochloric acid in the 3.55% NaC1 solution was increased. The polarization resistance values obtained from the EIS measurements were consistent with those from linear polarization measurements, and were indicative of the actual long-term corrosion performance of the alloys during a two-year atmospheric exposure study.

Calle, L. M.↗
NASA NTRS2006

Cold Flow Testing for Liquid Propellant Rocket Injector Scaling and Throttling

Scaling and throttling of combustion devices are important capabilities to demonstrate in development of liquid rocket engines for NASA's Space Exploration Mission. Scaling provides the ability to design new injectors and injection elements with predictable performance on the basis of test experience with existing injectors and elements, and could be a key aspect of future development programs. Throttling is the reduction of thrust with fixed designs and is a critical requirement in lunar and other planetary landing missions. A task in the Constellation University Institutes Program (CUIP) has been designed to evaluate spray characteristics when liquid propellant rocket engine injectors are scaled and throttled. The specific objectives of the present study are to characterize injection and primary atomization using cold flow simulations of the reacting sprays. These simulations can provide relevant information because the injection and primary atomization are believed to be the spray processes least affected by the propellant reaction. Cold flow studies also provide acceptable test conditions for a university environment. Three geometric scales - 1/4- scale, 1/2-scale, and full-scale - of two different injector element types - swirl coaxial and shear coaxial - will be designed, fabricated, and tested. A literature review is currently being conducted to revisit and compile the previous scaling documentation. Because it is simple to perform, throttling will also be examined in the present work by measuring primary atomization characteristics as the mass flow rate and pressure drop of the six injector element concepts are reduced, with corresponding changes in chamber backpressure. Simulants will include water and gaseous nitrogen, and an optically accessible chamber will be used for visual and laser-based diagnostics. The chamber will include curtain flow capability to repress recirculation, and additional gas injection to provide independent control of the backpressure. This paper provides a short review of the appropriate literature, as well as descriptions of plans for experimental hardware, test chamber instrumentation, diagnostics, and testing.

Kenny, Jeremy R.↗
NASA NTRS2001

Thermal Analysis of a Carbon Fiber Rope Barrier for Use in the Reusable Solid Rocket Motor Nozzle Joint-2

This study provides for development and verification of analysis methods used to assess performance of a carbon fiber rope (CFR) thermal barrier system that is currently being qualified for use in Reusable Solid Rocket Motor (RSRM) nozzle joint-2. Modeled geometry for flow calculations considers the joint to be vented with the porous CFR barriers placed in the "open' assembly gap. Model development is based on a 1-D volume filling approach where flow resistances (assembly gap and CFRs) are defined by serially connected internal flow and the porous media "Darcy" relationships. Combustion gas flow rates are computed using the volume filling code by assuming a lumped distribution total joint fill volume on a per linear circumferential inch basis. Gas compressibility, friction and heat transfer are included in the modeling. Gas-to-wall heat transfer is simulated by concurrent solution of the compressible flow equations and a large thermal 2-D finite element (FE) conduction grid. The derived numerical technique loosely couples the FE conduction matrix with the compressible gas flow equations, Free constants that appear in the governing equations are calibrated by parametric model comparison to hot fire subscale test results. The calibrated model is then used to make full-scale motor predictions using RSRM aft dome environments. Model results indicate that CFR thermal barrier systems will provide a thermally benign and controlled pressurization environment for the RSRM nozzle joint-2 primary seal activation.

Clayton, J. Louie↗
NASA NTRS2002

Thermal Analysis of a Carbon Fiber Rope Barrier for Use in the Reusable Solid Rocket Motor Nozzle Joint-2

This study provides development and verification of analysis methods used to assess performance of a carbon fiber rope (CFR) thermal barrier system that is currently being qualified for use in Reusable Solid Rocket Motor (RSRM) nozzle joint-2. Modeled geometry for flow calculations considers the joint to be vented with the porous CFR barriers placed in the 'open' assembly gap. Model development is based on a 1-D volume filling approach where flow resistances (assembly gap and CFRs) are defined by serially connected internal flow and the porous media 'Darcy' relationships. Combustion gas flow rates are computed using the volume filling code by assuming a lumped distribution total joint fill volume on a per linear circumferential inch basis. Gas compressibility, friction and heat transfer are included in the modeling. Gas-to-wall heat transfer is simulated by concurrent solution of the compressible flow equations and a large thermal 2-D finite element (FE) conduction grid. The derived numerical technique loosely couples the FE conduction matrix with the compressible gas flow equations. Free constants that appear in the governing equations are calibrated by parametric model comparison to hot fire subscale test results. The calibrated model is then used to make full-scale motor predictions using RSRM aft dome environments. Model results indicate that CFR thermal barrier systems will provide a thermally benign and controlled pressurization environment for the RSRM nozzle joint-2 primary seal activation.

Clayton, J. Louie↗
NASA NTRS2014

Design Concepts for a Small Space-Based GEO Relay Satellite for Missions Between Low Earth and near Earth Orbits

The main purpose of the Small Space-Based Geosynchronous Earth orbiting (GEO) satellite is to provide a space link to the user mission spacecraft for relaying data through ground networks to user Mission Control Centers. The Small Space Based Satellite (SSBS) will provide services comparable to those of a NASA Tracking Data Relay Satellite (TDRS) for the same type of links. The SSBS services will keep the user burden the same or lower than for TDRS and will support the same or higher data rates than those currently supported by TDRS. At present, TDRSS provides links and coverage below GEO; however, SSBS links and coverage capability to above GEO missions are being considered for the future, especially for Human Space Flight Missions (HSF). There is also a rising need for the capability to support high data rate links (exceeding 1 Gbps) for imaging applications. The communication payload on the SSBS will provide S/Ka-band single access links to the mission and a Ku-band link to the ground, with an optical communication payload as an option. To design the communication payload, various link budgets were analyzed and many possible operational scenarios examined. To reduce user burden, using a larger-sized antenna than is currently in use by TDRS was considered. Because of the SSBS design size, it was found that a SpaceX Falcon 9 rocket could deliver three SSBSs to GEO. This will greatly reduce the launch costs per satellite. Using electric propulsion was also evaluated versus using chemical propulsion; the power system size and time to orbit for various power systems were also considered. This paper will describe how the SSBS will meet future service requirements, concept of operations, and the design to meet NASA users' needs for below and above GEO missions. These users' needs not only address the observational mission requirements but also possible HSF missions to the year 2030. We will provide the trade-off analysis of the communication payload design in terms of the number of links looking above and below GEO; the detailed design of a GEO SSBS spacecraft bus and its accommodation of the communication payload, and a summary of the trade study that resulted in the selection of the Falcon 9 launch vehicle to deploy the SSBS and its impact on cost reductions per satellite. ======================================================================== Several initiatives have taken place within NASA1 and international space agencies2 to create a human exploration strategy for expanding human presence into the solar system; these initiatives have been driven by multiple factors to benefit Earth. Of the many elements in the strategy one stands out: to send robotic and human missions to destinations beyond Low Earth Orbit (LEO), including cis-lunar space, Near-Earth Asteroids (NEAs), the Moon, and Mars and its moons.3, 4 The time frame for human exploration to various destinations, based on the public information available,1,4 is shown in Figure 1. Advance planning is needed to define how future space communications services will be provided in the new budget environment to meet future space communications needs. The spacecraft for these missions can be dispersed anywhere from below LEO to beyond GEO, and to various destinations within the solar system. NASA's Space Communications and Navigation (SCaN) program office provides communication and tracking services to space missions during launch, in-orbit testing, and operation phases. Currently, SCaN's space networking relay satellites mainly provide services to users below GEO, at Near Earth Orbit (NEO), below LEO, and in deep space. The potential exists for using a space-based relay satellite, located in the vicinity of various solar system destinations, to provide communication space links to missions both below and above its orbit. Such relays can meet the needs of human exploration missions for maximum connectivity to Earth locations and for reduced latency. In the past, several studies assessed the ability of satellite-based relays working above GEO in conjunction with Earth ground stations. Many of these focused on the trade between space relay and direct-to-Earth station links5,6,7. Several others focused on top-level architecture based on relays at various destinations8,9,10,11,12. Much has changed in terms of microwave and optical technology since the publication of the referenced papers; Ka-band communication systems are being deployed, optical communication is being demonstrated, and spacecraft buses are becoming increasingly more functional and operational. A design concept study was undertaken to access the potential for deploying a Small Space-Based Satellite (SSBS) relay capable of serving missions between LEO and NEO. The needs of future human exploration missions were analyzed, and a notional relay-based architecture concept was generated as shown in Fig. 1. Relay satellites in Earth through cis-Lunar orbits are normally located in stable orbits requiring low fuel consumption. Relay satellites for Mars orbit are normally selected based on the mission requirement and projected fuel consumption. Relay satellites have extreme commonalities of functions between them, differing only in the redundancy and frequencies used; therefore, the relay satellite in GEO was selected for further analysis since it will be the first step in achieving a relay-based architecture for human exploration missions (see Fig.Figure 2). The mission design methodology developed by the Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) team13 was used to produce the satellite relay design and to perform various design trades. At the start of the activity, the team was provided with the detailed concept of the notional architecture and the system and communication payload drivers.

Relay Satellites↗
NASA NTRS2004

Nonlinear Longitudinal Mode Instability in Liquid Propellant Rocket Engine Preburners

Nonlinear pressure oscillations have been observed in liquid propellant rocket instability preburner devices. Unlike the familiar transverse mode instabilities that characterize primary combustion chambers, these oscillations appear as longitudinal gas motions with frequencies that are typical of the chamber axial acoustic modes. In several respects, the phenomenon is similar to longitudinal mode combustion instability appearing in low-smoke solid propellant motors. An important feature is evidence of steep-fronted wave motions with very high amplitude. Clearly, gas motions of this type threaten the mechanical integrity of associated engine components and create unacceptably high vibration levels. This paper focuses on development of the analytical tools needed to predict, diagnose, and correct instabilities of this type. For this purpose, mechanisms that lead to steep-fronted, high-amplitude pressure waves are described in detail. It is shown that such gas motions are the outcome of the natural steepening process in which initially low amplitude standing acoustic waves grow into shock-like disturbances. The energy source that promotes this behavior is a combination of unsteady combustion energy release and interactions with the quasi-steady mean chamber flow. Since shock waves characterize the gas motions, detonation-like mechanisms may well control the unsteady combustion processes. When the energy gains exceed the losses (represented mainly by nozzle and viscous damping), the waves can rapidly grow to a finite amplitude limit cycle. Analytical tools are described that allow the prediction of the limit cycle amplitude and show the dependence of this wave amplitude on the system geometry and other design parameters. This information can be used to guide corrective procedures that mitigate or eliminate the oscillations.

Sims, J. D.↗
NASA NTRS2001

TT and C - First TDRSS, Then Commercial GEO and Big LEO and Now through LEO

The advent of low earth orbit (LEO) commercial communications satellites provides an opportunity to dramatically reduce Telemetry Tracking and Control (TT&C) costs of launch vehicles and Unpiloted Aerial Vehicles (UAVs) by reducing or eliminating ground infrastructure. Personnel from the Goddard Space Flight Center Wallops Flight Facility (GSFC/WFF) in Virginia have successfully used commercial GEO & Big LEO communications satellites for Long Duration Balloon flight TT&C. In addition, TDRSS capability for these balloons has been developed by WFF for the Ultra Long Duration Balloons with the first test flight launch in January 2001 for one global circumnavigation at 120,000 feet altitude launched from Alice Springs. Australia. Numerous other low cost applications can new utilize the commercial LEO satellites for TT&C. The Flight Modern became a GSFC/WFF Advanced Range Technology Initiative (ARTI) in an effort to streamline TT&C capability to the user community at low cost. Phase I ground tests of The Flight Modem verified downlink communications quality of service and measured transmission latencies. These tests were completed last year, Phase II consisting of aircraft flight tests provide much of the data presented in this paper. Phase III of the Flight Modern baseline test program is a demonstration of the ruggedized version of the WFF Flight Modem flown on one sounding rocket launched from Sweden. Flights of opportunity have been and are being actively pursued with other centers, ranges and users at universities. The WFF goal is to reduce TT&C costs by providing a low cost COTS Flight Modem with a User Handbook containing system capability and limitation descriptions. Additionally, since data transmission is by packetized Internet Protocol (IP), data can be received and commands initialed from practically any location with no infrastructure. The WFF, like most ranges, has been using GPS receivers on sounding rockets and long duration balloons for several years, The WFF Flight Modem contains a GPS receiver to provide vehicle position for tracking and vehicle recovery. The system architecture which integrates antennas, GPS receiver, commercial satellite packet data modem. and a single board computer with custom software is described and a number of technical challenges are discussed along with the plan for their resolution. These include antenna development, high Doppler rates, reliability, environmental ruggedness, hand over between satellites and data security. An aggressive test plan is included which in addition to environmental Testing measures bit error rate latency and antenna patterns. Additional flight tests are planned far the near future on aircraft, long duration balloons and sounding rockets and these results as well as the current status of the project arc reported. Use of the WFF Flight Modem on small satellites is also being pursued. The LEO satellite constellation altitude above 1400 km is not an obstacle because most spacecraft do not require continuous Communications. The challenge is scheduling where store and forward techniques for command are required and downlink when the communications link allows connection (above 60 percent of the time depending on the satellite altitude). Sophisticated scheduling techniques utilizing 2-line orbital element sets available on the NASA/NORAD Internet site could be implemented for rare special cases. The current 9600 baud rate of the LEO communications link may be increased With special techniques that are planned for development in the WFF Flight Modem project.

Morgan, Dwayne↗
NASA NTRS2008

System Engineering on the Use for Ares I,V - the Simpler, the Better

The Ares I and Ares V Vehicles will utilize the J-2X rocket engine developed for NASA by the Pratt & Whitney Rocketdyne Company. The J-2X is an improved higher power version of the original J-2 engine used during the Apollo program. With higher power and updated requirements for safety and performance, the J-2X becomes a new engine using state-of-the-art design methodology, materials and manufacturing processes. The implementation of Systems Engineering (SE) principles enables the rapid J-2X development program to remain aligned with the ARES I and V vehicle programs, Meeting the aggressive development schedule is a challenge. Coordinating the best expertise thai NASA and PWR have to offer requires effectively utilizing resources at multiple sites. This presents formidable communication challenges. SE allows honest and open discussions of issues and problems. This simple idea is often overlooked in large and complex SE programs. Regular and effective meetings linking SE objectives to component designs are used to voice differences of opinions with customer and contractor in attendance so that the best mutual decisions can be made on the shortest possible schedule. Regular technical interchange meetings on secure program wide computer networks and CM processes are effective,in the "Controlled Change" process that exemplifies good SE. Good communication is a key effective SE implementation. The System of Systems approach is the vision of the Orion program which facilitates the establishment of dynamic SE processes at all levels including the engine. SE enables requirements evolution by facilitating organizational and process agility. Flow down and distribution of requirements is controlled by Allocation Reports which breakdown numerical design objectives (weight, reliability, etc.) into quanta goals for each component area. Linked databases of design and verification requirements helps eliminate redundancy and potential mistakes inherent m separated systems. Another tool, the Architecture Design Description, is being used to control J-2X system architecture and effectively communicate configuration changes to those involved in the design process. But the proof is in successful program accomplishment. The SE is the methodology being used to meet the challenge of completing J-2X engine certification 2 years ahead of any engine program ever developed at PWR. The Ares I SE system of systems has delivered according to expectations thus far. All major design reviews (SRR. PDR, CDR) have been successfully conducted to satisfy overall program objectives using SE as the basis for accomplishment. The paper describes SE tools and techniques utilized to achieve this success.

Kelly, William↗
NASA NTRS2024

Revisiting Optimal Guidance Solution for Vertical Landing and Take-Off

The vertical landing and take-off are crucial phases of a rocket-powered spacecraft's powered descent and ascent trajectories, during which its motion is confined to a single (vertical) axis. It is well-known that the minimum-propellant guidance solutions for vertical landing and take-off in a vacuum, consist of only one coast and one full-thrust arc and no singular arc exists in these problems. However, an exact solution for the vertical descent problem is not found in the literature. In the present work, exact guidance solutions for the optimal vertical landing and take-off are presented that are valid for arbitrary boundary conditions. The time-based and switching function-based guidance law implementations are discussed and their performance is compared using lunar descent and ascent simulations.

powered descent↗
NASA NTRS1989

Space shuttle Production Verification Motor 1 (PV-1) static fire

All inspection and instrumentation data indicate that the PV-1 static test firing conducted 18 Aug. 1988 was successful. With the exception of the intentionally flawed joints and static test modifications, PV-1 was flight configuration. Fail-safe flaws guaranteeing pressure to test the sealing capability of primary O-rings were included in the aft field joint, case-to-nozzle joint, and nozzle internal Joint 5. The test was conducted at ambient conditions, with the exception of the field joints and case/nozzle joints which were maintained at a minimum of 75 F. Ballistics performance values were within specification requirements. The PV-1 motor exhibited chamber pressure oscillations similar to previously tested Space Shuttle redesigned solid rocket motors, particularly QM-7. The first longitudinal mode oscillations experienced by PV-1 were the strongest ever measured in a Space Shuttle motor. Investigation into this observation is being conducted. Joint insulation performed as designed with no evidence of gas flow within unflawed forward field joints. The intentionally flawed center and aft case field joint insulation performance was excellent. There was no evidence of hot gas past the center field joint capture feature O-ring, the case-to-nozzle joint primary O-ring, or the aft field joint primary O-ring. O-ring seals and barriers with assured pressure at the flaws showed erosion and heat effect, but all sealed against passage of hot gases with the exception of the aft field joint capture feature O-ring. There was no evidence of erosion, heat effect, or blowby on any O-ring seals or barriers at the unflawed joints. Nozzle performance was nominal with typical erosion. Post-test examination revealed that the forward nose ring was of the old high performance motor design configuration with the 150-deg ply angle. All nozzle components remained intact for post-test evaluation. The thrust vector control system operated correctly. The water deluge system, CO2 quench, and other test equipment performed as planned during all required test operations.

Source record↗
NASA NTRS1992

STS-52 Space Shuttle mission report

The STS-52 Space Shuttle Program Mission Report provides a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle main engine (SSME) subsystem performance during the fifty-first flight of the Space Shuttle Program, and the thirteenth flight of the Orbiter vehicle Columbia (OV-102). In addition to the Orbiter, the flight vehicle consisted of the following: an ET (designated as ET-55/LWT-48); three SSME's, which were serial numbers 2030, 2015, and 2034 in positions 1, 2, and 3, respectively; and two SRB's, which were designated BI-054. The lightweight RSRM's that were installed in each SRB were designated 360L027A for the left SRB and 360Q027B for the right SRB. The primary objectives of this flight were to successfully deploy the Laser Geodynamic Satellite (LAGEOS-2) and to perform operations of the United States Microgravity Payload-1 (USMP-1). The secondary objectives of this flight were to perform the operations of the Attitude Sensor Package (ASP), the Canadian Experiments-2 (CANEX-2), the Crystals by Vapor Transport Experiment (CVTE), the Heat Pipe Performance Experiment (HPP), the Commercial Materials Dispersion Apparatus Instrumentation Technology Associates Experiments (CMIX), the Physiological System Experiment (PSE), the Commercial Protein Crystal Growth (CPCG-Block 2), the Shuttle Plume Impingement Experiment (SPIE), and the Tank Pressure Control Experiment (TPCE) payloads.

Fricke, Robert W., Jr.↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
NASA NTRS2013

Earth Observation from Space - The Issue of Environmental Sustainability

Remote sensing scientists work under assumptions that should not be taken for granted and should, therefore, be challenged. These assumptions include the following: 1. Space, especially Low Earth Orbit (LEO), will always be available to governmental and commercial space entities that launch Earth remote sensing missions. 2. Space launches are benign with respect to environmental impacts. 3. Minimization of Type 1 error, which provides increased confidence in the experimental outcome, is the best way to assess the significance of environmental change. 4. Large-area remote sensing investigations, i.e. national, continental, global studies, are best done from space. 5. National space missions should trump international, cooperative space missions to ensure national control and distribution of the data products. At best, all of these points are arguable, and in some cases, they're wrong. Development of observational space systems that are compatible with sustainability principles should be a primary concern when Earth remote sensing space systems are envisioned, designed, and launched. The discussion is based on the hypothesis that reducing the environmental impacts of thedata acquisition step,which is at the very beginning of the information streamleading to decision and action, will enhance coherence in the information streamand strengthen the capacity of measurement processes to meet their stated functional goal, i.e. sustainable management of Earth resources. We suggest that unconventional points of view should be adopted and when appropriate, remedial measures considered that could help to reduce the environmental footprint of space remote sensing and of Earth observation and monitoring systems in general. This article discusses these five assumptions inthe contextof sustainablemanagementof Earth's resources. Takingeachassumptioninturn,we find the following: (1) Space debris may limit access to Low Earth Orbit over the next decades. (2) Relatively speaking, given that they're rare event, space launches may be benign, but study is merited on upper stratospheric and exospheric layers given the chemical activity associated with rocket combustion by-products. (3) Minimization of Type II error should be considered in situations where minimization of Type I error greatly hampers or precludes our ability to correct the environmental condition being studied. (4) In certain situations, airborne collects may be less expensive and more environmentally benign, and comparative studies should be done to determine which path is wisest. (5) International cooperation and data sharing will reduce instrument and launch costs and mission redundancy. Given fiscal concerns of most of the major space agencies e e.g. NASA, ESA, CNES e it seems prudent to combine resources.

Earth observation systems↗
NASA NTRSDate not supplied

Planetary Protection at Marshall Space Flight Center

Introduction: NASA Marshall Space Flight Center (MSFC) is historically known for its role in propulsion. While this is still the mainstay of MSFC’s expertise, many unique capabilities exist at MSFC which pertain to Planetary Protection (PP), including 1) identifying PP threats, and 2) developing novel methods to neutralize those threats. Furthermore, because these capabilities exist among diverse groups at MSFC, this work promotes collaboration both within and outside MSFC to expand and develop PP studies related to a full spectrum of NASA research, design, manufacture, and test interests. This abstract describes the PP research ongoing at MSFC and describes how it contributes to NASA’s overall PP objectives. Microbial Identification in Cleanrooms: One of the greatest threats to successful implementation of PP requirements is recontamination post bioburden reduction. One method to prevent recontamination is to keep the spacecraft in clean environments (i.e. cleanrooms) as much as possible during assembly and integration. However, cleanrooms are not without their own sources of contamination, which is why NASA is interested in monitoring the cleanliness of cleanrooms and characterizing the microbial species present. Such information allows a greater understanding of the resistance of these microbes to cleaning methods, as well as the risk of their contaminating the targeted planetary body of a given mission. MSFC has multiple cleanrooms of various ISO cleanliness levels onsite. We sampled the air and surfaces of three of these rooms, isolated microbes, and then sequenced the 16S rRNA gene or ITS region of the 18S rRNA gene for bacterial and fungal isolates, respectively. This has resulted in a microbial library which currently includes nearly 100 isolates. Microbial Enumeration of Spacecraft Materials: Currently, there are only a couple bioburden reduction methods approved by NASA, and often the harshness of these methods presents additional concerns or risks related to material properties. The goal of this research is to assess the microbial content of solid rocket motor (SRM) materials potentially used for lander missions. This work aims to more accurately define the risk of planetary contamination by providing empirical data associated with commonly used SRM raw materials. In this study, we pulverized nonmetallic SRM materials using a cryogenic grinder, then analyzed the resulting substrate for microbial colony forming units (CFU). We found that many SRM nonmetallic materials do not harbor detectable bioburden, though a range existed depending on the material. The results from this work provide quantitative data to potentially reduce concerns of contamination, while also providing a foundation for follow up studies into additional sterilization methods and molecular identification of contaminating microbes. Space Environmental Effects on Microbial Survival: One potential area of microbial reduction is the space environment. Understanding the survivability of hardy microbes in space-like conditions is a crucial first step in answering how space may reduce bioburden and if it can be relied upon for adherence to PP requirements. This work studied the effects of ultraviolet (UV) and ionizing radiation on survival of Bacillus atrophaeus spores. Microbes were dried on relevant polymeric materials then exposed to space environmental stressors. Coupons were submerged in water, diluted, and plated to determine survival compared with controls. We found that both UV and ionizing radiation were capable of reducing viability by nearly 99%, but there were still survivors, some with changed morphology indicating resistance mechanisms within certain cells. Manufacturing credit: Finally, given the above-mentioned limitations of the NASA-approved bioburden reduction methods, there is interest in understanding if manufacturing processes may provide enough bioburden reduction without additional PP-specific bakeouts. For instance, some material additives may be antimicrobial. Given this, we investigated the effects of several commonly used rubber additives on the growth of B. atrophaeus spores. We found that some of the materials inhibited growth of the spores, possibly supporting the use of these additives on missions with PP constraints. Future work into manufacturing credit for bioburden reduction includes inoculation of green insulation with B. atrophaeus spores, followed by a typical cure. Thermal profiles will be verified for appropriate temperature and durations to meet PP requirements, and cured samples will be analyzed using a cryogenic grinder to determine survivability of spores.

Chelsi D. Cassilly↗
NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗