Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates

OSIRIS-REx Touch-and-Go (TAG) Mission Design for Asteroid Sample Collection

The Origins Spectral Interpretation Resource Identification Security Regolith Explorer (OSIRIS-REx) mission is a NASA New Frontiers mission launching in September 2016 to rendezvous with the near-Earth asteroid Bennu in October 2018. After several months of proximity operations to characterize the asteroid, OSIRIS-REx flies a Touch-And-Go (TAG) trajectory to the asteroid's surface to collect at least 60 g of pristine regolith sample for Earth return. This paper provides mission and flight system overviews, with more details on the TAG mission design and key events that occur to safely and successfully collect the sample. An overview of the navigation performed relative to a chosen sample site, along with the maneuvers to reach the desired site is described. Safety monitoring during descent is performed with onboard sensors providing an option to abort, troubleshoot, and try again if necessary. Sample collection occurs using a collection device at the end of an articulating robotic arm during a brief five second contact period, while a constant force spring mechanism in the arm assists to rebound the spacecraft away from the surface. Finally, the sample is measured quantitatively utilizing the law of conservation of angular momentum, along with qualitative data from imagery of the sampling device. Upon sample mass verification, the arm places the sample into the Stardust-heritage Sample Return Capsule (SRC) for return to Earth in September 2023

OSIRIS-REx Touch-And-Go (TAG) Mission Design and Analysis

The Origins Spectral Interpretation Resource Identification Security Regolith Explorer (OSIRIS-REx) mission is a NASA New Frontiers mission launching in 2016 to rendezvous with the near-Earth asteroid (101955) 1999 RQ36 in late 2018. After several months in formation with and orbit about the asteroid, OSIRIS-REx will fly a Touch-And-Go (TAG) trajectory to the asteroid s surface to obtain a regolith sample. This paper describes the mission design of the TAG sequence and the propulsive maneuvers required to achieve the trajectory. This paper also shows preliminary results of orbit covariance analysis and Monte-Carlo analysis that demonstrate the ability to arrive at a targeted location on the surface of RQ36 within a 25 meter radius with 98.3% confidence

Elevated Temperature, Residual Compressive Strength of Impact-Damaged Sandwich Structure Manufactured Out-of-Autoclave

Several 1/16th-scale curved sandwich composite panel sections of a 10 m diameter barrel were fabricated to demonstrate the manufacturability of large-scale curved sections using minimum gauge, [+60/-60/0]s, toughened epoxy composite facesheets co-cured with low density (50 kilograms per cubic meters) aluminum honeycomb core. One of these panels was fabricated out of autoclave (OoA) by the vacuum bag oven (VBO) process using Cycom(Registered Trademark) T40-800b/5320-1 prepreg system while another panel with the same lay-up and dimensions was fabricated using the autoclave-cure, toughened epoxy prepreg system Cycom(Registered Trademark) IM7/977-3. The resulting 2.44 m x 2 m curved panels were investigated by non-destructive evaluation (NDE) at NASA Langley Research Center (NASA LaRC) to determine initial fabrication quality and then cut into smaller coupons for elevated temperature wet (ETW) mechanical property characterization. Mechanical property characterization of the sandwich coupons was conducted including edge-wise compression (EWC), and compression-after-impact (CAI) at conditions ranging from 25 C/dry to 150 C/wet. The details and results of this characterization effort are presented in this paper

Lucy: Navigating a Jupiter Trojan Tour

In January 2017, NASA selected the Lucy mission to explore six Jupiter Trojan asteroids. These six bodies, remnants of the primordial material that formed the outer planets, were captured in the Sun-Jupiter L4 and L5 Lagrangian regions early in the solar system formation. These particular bodies were chosen because of their diverse spectral properties and the chance to observe up close for the first time two orbiting approximately equal mass binaries, Patroclus and Menoetius. KinetX, Inc. is the primary navigation supplier for the Lucy mission. This paper describes preliminary navigation analyses of the approach phase for each Trojan encounter

NESC Independent Review of the Mars Reconnaissance Orbiter (MRO) Contamination Thermal/Vacuum (T/V) Anomaly Technical Consultation Report

The NESC eras requested by the NASA Jet Propulsion Laboratory (JPL) to conduct an independent review of the Mars Reconnaissance Orbiter (MRO) Thermal/Vacuum (T/V) Anomaly Assessment. Because the anomaly resulted in the surface contamination of the MRO, selected members of the Materials Super Problem Resolution Team (SPRT) and the NASA technical community having technical expertise relative to contamination issues were chosen for the independent review. The consultation consisted of a review of the MRO Project's reported response to the assessment findings, a detailed review of JPL technical assessment final report, and detailed discussions with the JPL assessment team relative to their findings

Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics

Stress Free Temperature Testing and Calculations on Out-of-Autoclave Composites

Future launch vehicles will require the incorporation of large composite parts that will make up primary and secondary components of the vehicle. NASA has explored the feasibility of manufacturing these large components using Out-of-Autoclave impregnated carbon fiber composite systems through many composites development projects. Most recently, the Composites for Exploration Project has been looking at the development of a 10 meter diameter fairing structure, similar in size to what will be required for a heavy launch vehicle. The development of new material systems requires the investigation of the material properties and the stress in the parts. Residual stress is an important factor to incorporate when modeling the stresses that a part is undergoing. Testing was performed to verify the stress free temperature with two-ply asymmetric panels. A comparison was done between three newly developed out of autoclave IM7/Bismaleimide (BMI) systems. This paper presents the testing results and the analysis performed to determine the stress free temperature of the material

Refining Lucy Mission Delta-V During Spacecraft Design Using Trajectory Optimization Within High-Fidelity Monte Carlo Maneuver Analysis

Recent advances linking medium-fidelity trajectory optimization and high-fidelity trajectory propagation/maneuver design software with Monte Carlo maneuver analysis and parallel processing enabled realistic statistical delta-V estimation well before launch. Completing this high-confidence, refined statistical maneuver analysis early enabled release of excess delta-V margin for increased dry mass margin for the Lucy Jupiter Trojan flyby mission. By 3.3 years before launch, 16 of 34 TCMs had 1000 re-optimized trajectory design samples, yielding tens of m/s lower 99%-probability delta-V versus targeting maneuvers to one optimal trajectory. One year later, 1000 re-optimized samples of all deterministic maneuvers and subsequent flybys further lowered estimated delta-V