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At least 1,783 records · Page 99

Space Transportation System (STS)-133/External Tank (ET)-137 Intertank (IT) Stringer Cracking Issue and Repair Assessment: Proximate Cause Determination and Material Characterization Study

Several cracks were detected in stringers located beneath the foam on the External Tank (ET) following the launch scrub of Space Transportation System (STS)-133 on November 5, 2010. The stringer material was aluminum-lithium (AL-Li) 2090-T83 fabricated from sheets that were nominally 0.064 inches thick. The mechanical properties of the stringer material were known to vary between different material lots, with the stringers from ET-137 (predominately lots 620853 and 620854) having the highest yield and ultimate stresses. Subsequent testing determined that these same lots also had the lowest fracture toughness properties. The NASA Engineering and Safety Center (NESC) supported the Space Shuttle Program (SSP)-led investigation. The objective of this investigation was to develop a database of test results to provide validation for structural analysis models, independently confirm test results obtained from other investigators, and determine the proximate cause of the anomalous low fracture toughness observed in stringer lots 620853 and 620854. This document contains the outcome of the investigation.

Piascik, Robert S.↗

Comparison of Orion Vision Navigation Sensor Performance from STS-134 and the Space Operations Simulation Center

The Orion Multi-Purpose Crew Vehicle is a new spacecraft being designed by NASA and Lockheed Martin for future crewed exploration missions. The Vision Navigation Sensor is a Flash LIDAR that will be the primary relative navigation sensor for this vehicle. To obtain a better understanding of this sensor's performance, the Orion relative navigation team has performed both flight tests and ground tests. This paper summarizes and compares the performance results from the STS-134 flight test, called the Sensor Test for Orion RelNav Risk Mitigation (STORRM) Development Test Objective, and the ground tests at the Space Operations Simulation Center.

Christian, John A.↗

STS-133/ET-137 Tanking Test Photogrammetry Assessment

Following the launch scrub of Space Shuttle mission STS-133 on November 5, 2010, an anomalous condition of cracked and raised thermal protection system (TPS) foam was observed on the External Tank (ET). Subsequent dissection of the affected TPS region revealed cracks in the feet of two Intertank (IT) metallic stringers. An extensive investigation into the cause(s) and corrective action(s) for the cracked stringers was initiated, involving a wide array of material and structural tests and nondestructive evaluations, with the intent to culminate into the development of flight rational. One such structural test was the instrumented tanking test performed on December 17, 2010. The tanking test incorporated two three-dimensional optical displacement measurement systems to measure full-field outer surface displacements of the TPS surrounding the affected region that contained the stringer cracks. The results showed that the radial displacement and rotation of the liquid oxygen (LO2) tank flange changed significantly as the fluid level of the LO2 approached and passed the LO2 tank flange.

Oliver, Stanley T.↗

STS-133 Space Shuttle External Tank Intertank Stringer Crack Investigation Stress Analysis

The first attempt to launch the STS-133 Space Shuttle mission in the fall of 2010 was halted due to indications of a gaseous hydrogen leak at the External Tank ground umbilical carrier plate seal. Subsequent inspection of the external tank (figure 1) hardware and recorded video footage revealed that the foam insulation covering the forward end of the intertank near the liquid oxygen tank had cracked severely enough to have been cause for halting the launch attempt on its own (figure 2). An investigation into the cause of the insulation crack revealed that two adjacent hat-section sheet metal stringers (figure 3) had cracks up to nine inches long in the forward ends of the stringer flanges, or feet, near the fasteners that attach the stringer to the skin of the intertank (figure 4). A repair of those two stringers was implemented and the investigation effort widened to understand the root cause of the stringer cracks and to determine whether there was sufficient flight rationale to launch with the repairs and the other installed stringers.

Steeve, Brian E.↗

STS-114: Engine Cut-Off Sensors Are a No-Go: Teaching Notes for NASA Case Study

This case study format is intended to simulate the experience of facing the same difficult challenges and making the same critical decisions as managers, engineers, and scientists in the Space Shuttle Program. It has been designed for use in the classroom setting to help students develop skills related to decision-making. Students will read about the engine cut-off sensor anomaly which created challenges during the STS-114 mission and have the opportunity to make decisions as lead NASA engineers and Mission Management Team members. Included within this document are three case study presentation options - class discussion, group activity, and open-ended research. Please read the full case prior to in-class presentation to allow ample time for students' analysis and reflection, as well as to prepare additional questions. activities or exercises, material selection, etc. Depending upon the setting of your presentation and the number of participants, please choose at least one presentation format beforehand and plan accordingly. You may expect the following learning objectives by using the proposed formats. Learning Objectives: To enable students to experience the responsibilities of NASA management, engineers, and analysis; to discover possible procedures for investigating system anomalies; to become familiar with the liquid hydrogen low level engine cut-off sensor, including its function, connecting components, and location within the Space Shuttle; and to encourage critical analysis and stimulating discussion of Space Shuttle mission challenges.

Ransom, Khadijah S.↗

STS-41 Voice Command System Flight Experiment Report

This report presents the results of the Voice Command System (VCS) flight experiment on the five-day STS-41 mission. Two mission specialists,Bill Shepherd and Bruce Melnick, used the speaker-dependent system to evaluate the operational effectiveness of using voice to control a spacecraft system. In addition, data was gathered to analyze the effects of microgravity on speech recognition performance.

Salazar, George A.↗

Comparison of the Integrated Medical Model Predictions to Real World ISS and STS Observations

The Human Research Program funded the development of the integrated medical model (IMM) to quantify the medical component of overall mission risk. The IMM uses Monte Carlo methodology to integrate space flight and ground medical data to assess the probability of mission medical outcomes and resource utilization. To determine the credibility of IMM output the IMM project team completed two validation studies that compare IMM output to observed medical events from a selection of Shuttle Transportation System (STS) and International Space Station (ISS) missions.

validation↗

STS-1 Forward RCS Oxidizer Tank Subsystem Failure Assessment

The launch of the Space Shuttle Columbia on STS-1 in April 1981 marked the beginning of a new era in American spaceflight. It was the only crewed first flight of a launch vehicle, and was also among the first vehicles to use large solid rockets as primary propulsion. A potential disaster was narrowly averted at liftoff when ignition overpressure waves pulse swept up the Shuttle stack. The frequency of this transient shock wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. Among the results of this unexpected loading was failure of an oxidizer tank support strut in the orbiter’s forward reaction control system module, which could have led to loss of the mission, crew and vehicle. This particular incident is investigated in more detail using classical structural mechanics, and the results are discussed to provide additional insight.

Space Shuttle↗

STS-1 Forward RCS Oxidizer Tank Subsystem Failure Assessment

The launch of the Space Shuttle Columbia on STS-1 marked the beginning of a new era in American spaceflight. It was the only crewed first flight of a launch vehicle to date, and was also the first crewed system to use large solid rockets as primary propulsion. A potential disaster was narrowly averted at liftoff when an ignition overpressure pulse swept up the Shuttle stack. The frequency of this transient shock wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. Among the results of this unexpected loading was failure of an oxidizer tank support strut in the orbiter’s forward reaction control system module, which could have led to loss of the mission, crew, and vehicle. This particular incident is investigated in more detail using classical structural mechanics, and the results are discussed to provide additional insight.

Space Shuttle↗

Short Circuiting the Controller –Missteps in Maintenance and Inspection of Process and Wiring in STS-93

During the launch of the Chandra X-Ray Observatory in 1999, an in-flight anomaly occurred a few seconds after liftoff. A power fluctuation caused two Main Engine controllers to drop offline. Fortunately, due to redundancy, the Space Shuttle Columbia was able to successfully reach orbit and avoid an abort. After the successful deployment of Chandra and the safe return of the crew, in-vestigation revealed that the controller failure was due to a wire short in the pay-load bay. It was suspected that the Kapton insulation on the wire rubbed off against a burred screw head, the result of overtightening of the screw during a maintenance event 4 to 5 years prior to the STS-93 mission. Vibrations led the abraded wire to short during flight. The Space Shuttle Program was grounded for 4 months while a program-wide inspection and wire chafing mitigation effort of all orbiter wiring ensued.

Kristy S Yun↗

STS-1 Forward RCS Oxidizer Tank Subsystem Preliminary Failure Assessment

The launch of the Space Shuttle Columbia on STS-1 marked the beginning of a new era in American spaceflight. It was the only crewed first flight of a launch vehicle to date, and was also the first crewed system to use large solid rockets as primary propulsion. A potential disaster was narrowly averted at liftoff when an ignition overpressure pulse swept up the Shuttle stack. The frequency of this transient shock wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. Among the results of this unexpected loading was failure of an oxidizer tank support strut in the orbiter’s forward reaction control system module, which could have led to loss of the mission, crew, and vehicle. This particular incident is investigated in more detail using classical structural mechanics, and the results are discussed to provide additional insight.

Space Shuttle↗

STS-1 Forward RCS Oxidizer Tank Subsystem Structural Failure Assessment

The launch of the Space Shuttle Columbia on STS-1 marked the beginning of a new era in American spaceflight. It was the only crewed first flight of a launch vehicle to date, and was also the first crewed system to use large solid rockets as primary propulsion. A potential disaster was narrowly averted at liftoff when an ignition overpressure pulse swept up the Shuttle stack. The frequency of this transient shock wave exceeded pre-launch predictions, and resulted in high, alternating normal accelerations along the length of the vehicle. Among the results of this unexpected loading was failure of an oxidizer tank support strut in the orbiter’s forward reaction control system module, which could have led to loss of the mission, crew, and vehicle. This particular incident is investigated in more detail using classical structural mechanics and finite element analyses, and the results are discussed to provide additional insight.

space shuttle↗

Comparison of a space shuttle flight (STS-78) and bed rest on human muscle function

The purpose of this investigation was to assess muscle fiber size, composition, and in vivo contractile characteristics of the calf muscle of four male crew members during a 17-day spaceflight (SF; Life and Microgravity Sciences Spacelab Shuttle Transport System-78 mission) and eight men during a 17-day bed rest (BR). The protocols and timelines of these two investigations were identical, therefore allowing for direct comparisons between SF and the BR. The subjects' age, height, and weight were 43 +/- 2 yr, 183 +/- 4 cm, and 86 +/- 3 kg for SF and 43 +/- 2 yr, 182 +/- 3 cm, and 82 +/- 4 kg for BR, respectively. Calf muscle strength was examined before SF and BR; on days 2, 8, and 12 during SF and BR; and on days 2 and 8 of recovery. Muscle biopsies were obtained before and within 3 h after SF (gastrocnemius and soleus) and BR (soleus) before reloading. Maximal isometric calf strength and the force-velocity characteristics were unchanged with SF or BR. Additionally, neither SF nor BR had any effect on fiber composition or fiber size of the calf muscles studied. In summary, no changes in calf muscle strength and morphology were observed after the 17-day SF and BR. Because muscle strength is lost during unloading, both during spaceflight and on the ground, these data suggest that the testing sequence employed during the SF and BR may have served as a resistance training countermeasure to attenuate whole muscle strength loss.

Non-NASA Center↗

Microgravity in the STS-29 space shuttle discovery affected the vestibular system of chick embryos

Out of 32 embryos flown (16 @ E2 + 16 @ E9) for 5 days, 16 survived. All sixteen E2 were dead at landing. Eight were opened and eight were incubated at 1.0G. Autopsy showed that 4 E2 survived over 24 hours in space. Eight E14 hatched without anatomical malformations, and 8 E14 were fixed. The height of the macular epithelia was 31 mu m (mean) in control and 26 mu m in flight chicks. The cross-sectional area of macular nuclei of control was 17 mu m(2) for hair cells and 14 mu m(2) in supporting cells. In flight, cross-sectional area was 17 mu m(2) in hair cells and 15 mu m(2) in supporting cells (n=250). The shape factor of cartilage cells (1.0 = perfect circle) between control (mean = 0.70) and flight (mean = 0.72), and the area of cartilaginous cells between controls (mean = 9 mu m(2)) and flight (mean = 9 mu m(2)) did not differ (n=300). The nuclei of support cells were closer to the basement membrane in flight than in control chicks. The immunoreactivity of otoconia with anti keratan, fibronectin or chrondroitin sulfate was not different between flight and control ears. There were more afferent fibers inside the macular epithelia of flight (p<0.05) than control. Three of 8 flight animals had elevated vestibular thresholds (VT), with normal mean response amplitudes and latencies. Modified afferent innervation patterns requiring weeks to compensate are sufficient to elevate VT, and should be investigated further. Other reversible (sublethal) microgravity effects on sensory epithelia (vacuoles, swelling, etc) require quantification.

Flight Experiment↗

Advancing the STS Neutron Moderator Design with an Automated Optimization Workflow and Unstructured Mesh Modeling

With the Second Target Station approaching its final design phase, a detailed neutronics evaluation of its critical components is necessary. Optimizing the dimensions of the two cold-source moderators that are at the heart of this facility presents a multi-objective optimization problem for which an accurate geometric description is crucial. We have applied a fully automated optimization workflow in which a detailed unstructured mesh geometry is automatically generated with Attila4MC, starting from a parametrized CREO geometry followed by preprocessing with SpaceClaim. With this geometry, a MCNP run is performed to calculate the brightness metrics, which are subsequently provided to the optimization algorithm in DAKOTA that provides new parameters and drives the optimization loop until convergence. In this paper, we show the results of the analysis that are used for the final design of the cylindrical and tube moderator. The optimization simulations provide a refinement to and confirmation of the conclusions of the previous design iteration. Additional to the optimization, a sensitivity study is performed to study the effect of minor geometry changes, which is important for the final engineering design. In conclusion, with these studies, we demonstrate that the automated workflow and high-fidelity unstructured mesh modeling are efficient tools for a thorough design evaluation.

DAKOTA↗

Current ramp-up studies for NSTX-U in support of the development of non-inductive current ramp-up scenarios in STs

The Spherical Tokamak (ST) is a low-aspect-ratio tokamak projected to enable simultaneous operation at high normalized toroidal beta and high bootstrap current fraction. However, a compact ST reactor cannot be built with a full-sized solenoid. The remaining current required for sustained operation must be ramped up non-inductively. Sustained 100% non-inductive current drive at the MA level has not yet been demonstrated on an ST. Non-inductive current ramp-up is therefore a more challenging objective that the NSTX-U research program aims to address. In support of this development, free-boundary TRANSP simulations have been used to develop a current ramp-up scenario in which a significant fraction of the current is driven non-inductively by a combination of neutral-beam and bootstrap current drive. The resulting discharge has properties favorable for non-inductive current drive, such as a low normalized internal plasma inductance of approximately 0.45, a minimum safety factor exceeding 2, and a slightly reversed-shear q-profile. In these discharges, the plasma current ramps to 900 kA within 250 ms in an L-mode configuration, with varying electron density and density profiles. These discharges should be suitable for next-step NSTX-U experiments aimed at generating a robust L-mode fiducial scenario with low central solenoid flux consumption, which could be progressively improved as new NSTX-U experimental discharges are developed.

Raman, Roger [Univ. of Washington, Seattle, WA (Un↗