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National Aeronautics and Space Administration

2012 TECHNICAL UPDATE

NASA ENGINEERING & SAFETY CENTER
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3

The NESC Overview

Pages 2-6

(Above) The NESC supported multiple assessments for the 

International Space Station. 

(On the cover) Background: Measured velocity distribution 

in the wake of an 8%-scale model of the Orion crew module 

obtained in the ARC 11-Foot Transonic Wind Tunnel using 

particle imaging velocimetry. (Photos left to right) A CFD 

prediction of the HL-20 lifting body, an SLS model in the 

LaRC Unitary Plan Wind Tunnel, an Orion crew module in 

the ARC Unitary Plan Wind Tunnel.
4 5

Safety & Mission

Program Assurance at Centers 4%

Management 17%

NESC 24%

Engineering & Scientific Organizations 41% Anonymous 1% 

Other NASA Offices 2%

Aeronautics Research

2%

Science

17%

General (Across 

Multiple Mission 

Directorate)

15%

Office of Chief Engineer 2.5%

Center Management 2%

Office of Safety and

Mission Assurance 2.5%

External to Agency 4%

Sources of Accepted Requests: 495 Total

All statistics as of December 31, 2012

Exploration Systems

31%

Space

Operations

35%

Accepted Requests: 495 Total

ARC

21

58

155

9

GRC

47

MSFC

143

12

DFRC GSFC JPL JSC LaRC SSC

47

KSC

39

102

NASA Employees Supporting 

NESC Assessments

The NESC Assessment Team Structure

Approximately 700 Members

NESC Extended Team

18 Technical

Discipline Teams

• Aerosciences • Avionics

 • Electrical Power 

• Flight Mechanics

• Guidance, Navigation,

and Control • Human Factors

• Human Spaceflight Operations

 • Life Support/Active Thermal

• Loads and Dynamics

• Materials

• Mechanical Systems

• Nondestructive Evaluation

• Passive Thermal • Propulsion

• Robotic Spaceflight • Software

• Structures

• Systems Engineering

Member

Percentage

NESC Core Team 

Approximately 60 Members

NESC Principal Engineers

Assessment Team Leads

NESC Chief Engineers

NESC Points of Contact

at each Center

Management and Technical 

Support Office

Contracts, Budgets,

Partnerships

NASA Technical Fellows

Senior Technical Experts/TDT

Leadership

Systems Engineering Office

Technical Integration

Assessment

Team

NASA

71%

Industry

22%

Academia

5%

Other

Government

Agencies

2%

The NESC Model

The NESC Overview The NESC Overview

This concept began with the Resident Engineer Program, where 

junior NASA employees were invited to join the NESC for 1-year 

detail assignments. This has evolved into a broader effort, where 

young engineers support individual assessments on a case-bycase basis.

Another important feature of the NESC is the NESC Review Board 

(NRB). All decisions and items needing approval by the NESC are 

discussed by the NRB. The NRB members come from all areas of 

the NESC and represent all 10 NASA Centers and each of the TDT 

disciplines. The NRB is successful because 

people with different experience bases and 

technical backgrounds approach each issue 

from a different vantage point  resulting 

in a more complete understanding of the 

problem and a robust decisionmaking 

process.

As NASA moves forward, reaching for new 

heights and revealing the unknown, the 

NESC contributes by providing a structure 

that facilitates interaction between Centers 

and between programs and delivers the 

highest level of expertise to where it is 

needed. Though the Space Shuttle era has 

ended, NASA’s focus on human spaceflight 

remains strong, and the NESC continues 

to help build the foundation for the next 

generation of human exploration by performing assessments and 

contributing technical assistance to the NASA organizations and 

private companies developing new spacecraft.

The NESC is a resource available for anyone at NASA searching 

for an independent engineering assessment. NESC assessments 

have benefited all of the NASA mission directorates. For more 

information or to submit a request, contact your Center’s NESC 

Chief Engineer or visit nesc.nasa.gov.

The NESC is 

guided by the 

philosophy 

that robust 

engineering is 

as essential 

in promoting 

safety as it is 

for mission 

success.

The NASA Engineering and Safety Center (NESC) employs

the talent and diversity of NASA’s workforce to ensure safety and 

mission success for NASA’s high-risk programs. The NESC is 

guided by the philosophy that robust engineering is as essential 

in promoting safety as it is for mission success. Hundreds of 

scientists and engineers work on technical issues each year 

within the framework provided by the NESC. The NESC reports 

to the NASA Chief Engineer and is also closely affiliated with the 

Office of Safety and Mission Assurance. This arrangement allows 

independence, objectivity, and flexibility when working with other 

NASA organizations. 

The NESC promotes safety through engineering excellence. This 

is realized by assembling science and engineering experts from 

across the country into “assessment teams,” whose purpose is to 

address specific technical issues. The leadership and managerial 

support for each assessment are provided by the NESC Core 

Team. Core Team members work directly for the NESC. The 

NESC Extended Team is the collective engineering and scientific 

talent from 18 NESC Technical Discipline Teams (TDTs). Each 

TDT is centered around an engineering discipline, and most are 

led by a NASA Technical Fellow (the exceptions are the Robotic 

Spaceflight, Human Spaceflight Operations, and Systems 

Engineering TDTs, led by the NESC Chief Scientist, NESC Chief 

Astronaut, and the manager of the Systems Engineering Office 

respectively). TDT members come from all 10 NASA Centers as 

well as academia, industry, or other government agencies. When 

forming an assessment team, the assessment lead will draw the 

appropriate skill mix from the TDTs. 

Those NASA employees who contribute their skills to TDTs and 

assessments also gain from their experience with the NESC. 

They acquire a broad NASA-wide perspective, problem-solving 

experience, and technical contacts they can use when they 

return to their home Centers. The NESC is also striving to 

ensure a productive and prepared workforce for NASA’s future 

by integrating early-career engineers into NESC assessments. 

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012
NRB approves 

final report

Outbrief to 

Stakeholders

Conversion to 

NASA Technical

Memorandum

General

Distribution

Technical 

Bulletins

Lessons

Learned

NRB

NESC Chief Engineers

Make request

NASA Other federal agencies

Principal 

Engineer lead

Approve plan

Systems Engineering Office 

Accept request

Principal 

Engineer lead

NESC

Core Team

Extended 

Team

Assessment Team

NRB

NRB

Write final report

Formulate findings, observations, 

and recommendations

Form and lead 

assessment team

Develop plan

Process request

Conduct initial evaluation

Perform testing, modeling, 

analysis, data collection ...

The Systems Engineering Office

screens each new request and 

assigns it to one of the NESC

Chief Engineers for an initial 

evaluation. The NESC Review

Board (NRB) then decides

whether or not to proceed with the 

assessment.

A lead is assigned, usually from the 

Principal Engineers Office, to run 

the assessment. The team then 

develops the assessment plan,

which is presented to the NRB for 

comments and approval.

The team proceeds with the technical portion of the assessment. This

may entail testing, data analysis,

literature searches, interviews,

modeling—whatever has been 

specified in the plan and is necessary to meet the goals of the 

assessment. As the assessment

draws to a close, the team formulates findings, observations, and 

recommendations and publishes 

them in a peer-reviewed final 

report, which is presented to the 

NRB for approval.

6 7

The NESC Overview The NESC Overview

Discipline Lessons Learned

As the stewards of their respective disciplines, NASA 

Technical Fellows are responsible for identifying, 

capturing, and disseminating engineering lessons 

learned and best practices. In 2012, multiple 

lessons learned were documented in NESC 

Technical Bulletins and/or posted on the appropriate 

Community of Practice (CoP) website, covering a 

wide range of engineering issues, including:

· Pressure Testing and Venting of

 Enclosed Volumes

· Use of Titanium for Tribological Applications

· Setting Human Factors Requirements for

 Induced Environments

· Structural Analyses and Margins of Safety

· Flying Through Instabilities

· Tin Whisker Risks to Spacecraft Electronic

 Components 

Discipline CoP Workshops

NASA Technical Fellows organize and host CoP workshops 

and other technical interchange forums. In 2012, the following 

workshops/forums were held: 

· The 2nd NASA Spaceflight Fault Management Workshop

· The Structures, Loads and Dynamics, and

 Mechanical Systems (SLaM) Workshop

· The In-Space Nondestructive Inspection Workshop

· The High Voltage Design Workshop 

· Thermal and Fluids Analysis Workshop 

Technology Roadmap Development Teams

NASA Technical Fellows are supporting the 

renewed emphasis on NASA innovation 

and technology development. Recently the 

NASA Office of the Chief Technologist (OCT) 

developed 14 Space Technology Roadmaps 

(STRs), which describe the time sequencing 

and interdependencies of high-priority 

advanced space technology research and 

development over the next 5 to 30 years. The NASA Technical 

Fellows were instrumental in the development of these STRs, 

each of which focuses on a particular technology area, including 

Communication and Navigation Systems; Materials/Structures/

Mechanical Systems and Manufacturing; Thermal Management 

Systems; and Entry, Descent, and Landing Systems. The final 

versions of these roadmaps have been released to the public. 

NEN Engineering Discipline CoP Enhancements

Each NASA Technical Fellow maintains a discipline-focused online 

CoP within the NASA Engineering Network (NEN) framework. 

These CoP sites are intended to provide an online resource for the 

next generation of NASA engineers seeking specific engineering 

knowledge or aid in addressing challenging engineering questions. 

NASA Technical Fellows routinely update the content of their CoP 

sites with noteworthy discipline information, lessons learned, and 

technical reports.

External Professional Society and

Engineering Community Activities

Many members of the NESC team support professional societies 

and engineering communities outside of NASA as recognized 

experts in their disciplines. They have reviewed and edited over 

40 articles for engineering and scientific journals, including the 

International Journal for Numerical Methods in Engineering; the 

International Journal of Fracture; Engineering Fracture Mechanics; 

the International Journal for Structural Health Monitoring; the 

Journal of Acoustic Emission; and the Journal for Materials 

Evaluation.

In addition to helping programs and projects solve the Agency’s toughest technical problems, the NESC team also 

supports the NASA mission through participation in various activities that include discipline stewardship, technology 

evaluation, education, knowledge transfer, and outreach. Here are examples of NESC engagement in these areas.

Community of Practice page at nen.nesc.gov

Assessments form the structure and define the process the NESC uses to respond to requests and arrive at 

solutions to technical issues. The length of time an assessment takes and the size of the assessment team 

vary. The process outlined below can be tailored to accommodate requirements for a given assessment. 

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

The Process of Finding Solutions to Difficult Problems Additional NESC Contributions in Support of the NASA Mission
8

The NESC Overview

The NESC Academy Now Online

The NESC Academy has undergone a major 

upgrade and has greatly increased the number 

of discipline - specific videos and webcasts this 

year. Currently, there are 123 videos spanning 

13 technical disciplines available for viewing by 

various audiences. The NASA Technical Fellows 

and their Technical Discipline Team members are 

included among the contributors and continued 

an effort to effectively capture engineering 

knowledge through the revitalized NESC Academy. 

They conducted over 16 NASA - wide technical webcasts and recorded numerous 

discipline - specific video tutorials. For example, 

the NASA Technical Fellows for Structures, Loads 

and Dynamics, and Mechanical Systems hosted 

monthly technical webcasts addressing such topics

as “Large Space Vehicle Lift Off: Problems 

Definition and Assessment” and “Selection of 

Lubricants for Space Vehicles.”

The NASA Technical Fellow for Guidance, Navigation, 

and Control (GNC) holds bimonthly tutorial-type 

webcasts covering the fundamental aspects of the 

GNC discipline, such as “Fundamentals of Spacecraft 

Attitude Control.” All such webcasts are recorded 

and captured on the NESC Academy website for 

future viewing by NASA engineers. As an example 

of a video tutorial, the NASA Technical Fellow for Nondestructive 

Evaluation (NDE) created lessons on the “Probability of Detection 

for NDE” and on “Materials Durability,” while the NASA Technical 

Fellow for Passive Thermal developed a four-part lesson on the 

topic of “Form Factors, Grey Bodies and Radiation Conductances.”

All webcasts and lesson videos are available on the NESC 

Academy website. Another 88 videos are in work for release in 

the near future, so check out the NESC Academy regularly at 

nescacademy.nasa.gov.

The NESC staffed an exhibit at the Smithsonian Air & Space Museum during Hispanic Heritage Month

in October. On hand to represent the NESC was (from left) Oscar Gonzalez, NASA Technical Fellow for

Avionics; Terecita Mayorga, a technical representative from GSFC; and Michael Aguilar, NASA Technical

Fellow for Software. The NESC team was part of the Meet the Engineers – “Latinos in STEM” exhibit with this 

year’s theme of Hispanic Innovators in Air & Space. Engineers from the NESC Shell Buckling Knockdown 

Factor Assessment prepare for a destructive test of a 

lightweight fluted-core composite panel (center) in the 

LaRC Structures and Materials Laboratory.

NESC TECHNICAL UPDATE 2012

Technical Highlights

Pages 8-31
10 11

Technical Highlights

aggressive schedule ... they understood 

that we might only get one chance to make 

an impact on the SLS design.”

Collaboration

The SBKF Team entered into a Space Act 

Agreement with Dynetics Inc., Huntsville, 

AL, to help with the development of an 

advanced booster concept for the SLS 

Program. Ms. Flugstad stated, “Dynetics 

came to us because they wanted to work 

with cutting-edge design technology so 

that they may develop a robust and costeffective booster concept. They, like 

us, believe that the updated knockdown 

factors can help achieve this goal.”

The SBKF Team continues their successful 

collaboration with the Boeing Corporation 

on a lightweight fluted-core composite 

structural concept. Dr. Hilburger outlined 

the work stating, “We are currently 

preparing for the testing of a 13-footdiameter barrel that was manufactured 

by Boeing and was shipped to LaRC in 

August 2011.ˮ A partnership with the SLS 

Advanced Development Office (ADO) was 

established in the spring of 2012 and will 

provide the SBKF effort with a significant 

amount of funding in FY13 and FY14. SLS 

ADO is a technology development program 

for SLS that seeks to develop technologies 

that reduce cost and increase reliability 

in the areas of materials, propulsion, and 

spacecraft and vehicle systems. “ADO saw 

SBKF as a high-payoff activity that could 

provide near-term and long-term benefits 

to SLS cost, reliability, and performance,” 

stated Dr. Hilburger.

Knockdown Factor

Updates for SLS

The SBKF Team proposed a development and implementation strategy for the 

new knockdown factors for SLS. Boeing 

has implemented the preliminary knockdown factors in their core stage orthogrid 

designs and has reported several positive outcomes. “Boeing has indicated the 

potential for both mass and cost savings 

on the core stage liquid hydrogen tank by 

reducing material thickness requirements 

and a reduction in machining time ... this 

is a really good initial outcome. We expect 

more of this in the future as we develop 

and implement more knockdown factor 

updates,” stated Dr. Hilburger. A second 

knockdown factor update was released 

for review in September of 2012. “This 

update included new knockdown factors 

for orthogrid- and isogrid-stiffened cylinders with longitudinal weld lands. This 

update was an exciting step forward in that 

it would, for the first time, enable designers 

to explicitly account for the effects of the 

weld land feature in the preliminary design 

phase,” he added.

A final technical hurdle is being addressed 

on the side of manufacturing. Dr. Hilburger 

explained, “This was in response to SLS 

requirements that the assumed worstcase, as-built geometry used in cylinder 

buckling simulations and knockdown 

factor calculations, be shown to bound the 

actual as-built cylinder geometry produced 

using existing design and manufacturing 

standards of practice for friction stir welded 

cylinders.” To meet this requirement, a 

Manufacturing State-of-Practice assessment team, which is made up of 

manufacturing discipline experts from 

NASA and industry, was implemented. 

The team is studying state of practice 

for fabricating friction stir welded 

metallic cylinders for launch vehicles 

and are also obtaining full-scale launch 

vehicle barrel geometry measurements 

from several sources to establish a 

better understanding of the type of 

geometric variability to be expected in 

future SLS launch vehicle structures.

They are also conducting buckling 

analyses of selected preliminary SLS core 

stage barrel designs that include geometric

imperfections.

It has been recently observed that weld 

lands can reduce the predicted buckling 

load in orthogrid-stiffened cylinders by 

as much as 30% when included in highfidelity structural models. However, there 

were no guidelines available to account for 

this effect in the preliminary design phase in 

which such details are typically neglected. 

This reduced buckling load resulted in 

negative design margins and subsequent 

redesigns. “In the most recent update, a 

separate design knockdown factor has 

been derived for stiffened cylinders with 

weld lands that can be used in preliminary 

design cycles and should reduce the risk 

of developing unconservative designs. 

In addition, this factor can be adjusted 

or removed, as appropriate, when the 

structural models include the weld

land detail so that double bookkeeping

of design margin does not occur,” stated 

Dr. Hilburger.

Looking Ahead to FY13

Three areas of work are planned in FY13. 

The SBKF Team has already supported 

the SLS Program Preliminary Design 

Review by providing documentation that 

gave the technical justification for using 

the new knockdown factors. Another 

knockdown factor update will be released 

and is planned to include factors that can 

account for cylinders with circumferential 

weld lands, nonuniform loading that can 

come about due to fit-up mismatch, and 

cylinders subjected to combined bending 

and compression loads. The SBKF Team 

will also resume buckling tests to complete 

the validation of the new knockdown 

factors being developed. 

Introduction to

Knockdown Factors

Over the past 4 years, Dr. Mark Hilburger 

has led an NESC assessment team that 

is intent on reducing the overall weight 

of launch vehicles. During launch vehicle 

design, an empirical design factor often 

referred to as a “knockdown factor” is 

used to account for unknown variability in 

the buckling load of thin-walled cylinder 

structures such as cryogenic tanks or 

interstages. Dr. Hilburger described the 

team’s challenge: “Knockdown factors 

were developed during the Apollo era 

when results from buckling tests indicated 

loads much lower than those predicted by 

theory. Today our improved high-fidelity 

modeling and testing techniques are 

showing that historical knockdown factors 

may be too conservative for the design of 

modern aerospace-quality launch vehicle 

structures. Updating the knockdown 

factors could enable significant weight 

savings in launch vehicles and help 

mitigate some of their development and 

performance risks.”

The NESC Shell Buckling Knockdown 

Factor (SBKF) Assessment was established 

to develop and validate new knockdown 

factors for future metallic and composite 

launch vehicle structures. The NESC 

has supported the design and fabrication 

of large-scale test capabilities and test 

articles of five large-scale structural test 

articles. They also provide programmatic 

and technical support, peer reviews and 

advocacy.

Current Status

Deputy Assessment Manager, Courtney 

Flugstad, stated, “This was a year of 

transition for SBKF ... from testing efforts 

to a focus on the development and 

implementation of the first set of new 

knockdown factors for buckling-critical 

cylinders. We also transitioned from 

working knockdown factors for the Ares 

V vehicle to NASA’s new heavy lift Space 

Launch System (SLS).ˮ The team also 

completed the first update to the NASA 

Special Publication-8007 “Buckling of 

Thin-Walled Cylindersˮ, 1968, which gave 

design recommendation for buckling of 

thin-walled circular cylinders on the SLS 

core stage design. “Industry continues to 

follow the SBKF progress closely and is 

very interested in using these knockdown 

factor updates,” says Ms. Flugstad, 

adding, “We have had inquiries from 

several companies on when these factors 

will be available.”

The SBKF Team conducted a host of 

design trade studies soon after the 

preliminary SLS vehicle configuration

and loads were defined. The results 

of the trade studies were used to 

formulate a strategy for developing the 

new knockdown factors for high-payoff 

orthogrid- and isogrid-stiffened tanks

and dry structure. Dr. Hilburger explained, 

“The aggressive SLS development 

schedule meant that SBKF would have to 

transition quickly from the Ares V vehicle to 

the new SLS configuration, and the trade 

studies enable them to make informed 

changes to their development plan and 

schedule. You can’t hurry through the 

beginning stages of these development 

activities, you have to take time to fully 

understand the problem and engage the 

end user to understand their needs ...

detailed trade studies and planning are 

essential. The SBKF Team did a fantastic 

job switching gears and meeting the 

Launch Vehicle Shell Buckling

Knockdown Factor Development and Implementation

“ Historical knockdown factors 

may be too conservative 

for the design of modern 

aerospace-quality launch 

vehicle structures. Updating 

the knockdown factors could 

enable significant weight 

savings in launch vehicles.ˮ — Dr. Mark Hilburger

SKBF test day visitors 

(from left), Robert 

Lightfoot, NASA 

Associate Administrator; 

George Olden, MSFC; 

Courtney Flugstad, 

SBKF deputy, Clint 

Cragg, NESC Principal 

Engineer; Charles 

Bolden, NASA 

Administrator; Michael 

Roberts, MSFC; and

Dr. Mark Hilburger, SBKF 

assessment lead.

Mark Hilburger and Marc Schultz review a test plan 

in LaRC's Structures and Materials Laboratory.

A section of space shuttle external tank covered in photogrammetry targets being mounted in the shell buckling test fixture at MSFC.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights

FEATURED ASSESSMENTS FEATURED ASSESSMENTS
12 13

impact modeling being performed by 

NASA and the Orion CM development 

contractor. The PACER system drove 

the trajectory and attitude measurement 

uncertainty well below a point to where it 

was not of concern to the analysts as it 

was an order of magnitude more accurate 

than the model outputs.

According to Mr. Daniel Yuchnovicz of the 

NESC, “The result was a precise trajectory 

characterization of the CM that served 

as the baseline or ground truth for all 

other trajectory measurements.” Object 

velocities, accelerations, gravity direction, 

and maximum plunge depth were derived 

from the photogrammetry results. These 

solutions also made it possible to augment 

the original high-speed videos to clearly 

visualize vehicle shape and motion even 

when the CM was otherwise obscured by 

significant water dynamics. 

Mr. T. K. Mattingly, former Apollo and 

Shuttle astronaut, was a consultant on 

the NESC CMWLMA Team. Referring to 

the augmented videos made possible by 

photogrammetry, he indicated, “The drop 

video was helpful but the photogrammetric 

overlays made it magic. Now we can 

visualize what’s really happening and 

correlate our digits with reality. I can’t 

imagine doing without such a tool on 

future dynamic data collection projects. 

This has the potential to be an engineering 

analyst's best friend.”

Mr. Severance pointed out, “Lessons 

learned from using PACER during the 

CMWLMA have been applied to subscale and full-scale water entry tests of 

the Orion CM. In addition, the flexibility 

of PACER to scale from using a single 

camera up to multiple camera rigs was 

particularly useful in recent measurements 

of the take-off and landing trajectory of 

the V-22 tilt-rotor on an aircraft carrier.” 

Mr. Thomas Jones, also at LaRC, led the 

CMWLMA photogrammetry hardware setup and also led the V-22 photogrammetry 

study. Mr. Jones said, “Compared to 

conventional methods, PACER allowed 

us to greatly simplify our camera network 

configuration, allowing us to capture data 

and deliver results much more effectively 

than previously possible.”

A NASA-sponsored patent application for 

the PACER system has been submitted. 

A company specializing in augmented 

reality has licensed the technology, and 

discussions are continuing with other 

companies. Dr. Miller demonstrated in 

his doctoral research how to extend the 

capabilities of PACER to low-cost nanosatellite applications, including star-based 

orientation, close-proximity docking, and 

full-sky imaging.

New Photogrammetry Technique is Accurate and Adaptable

A new photogrammetry system has been 

developed to measure the position and 

orientation of two rigid bodies relative to 

one another. Mr. Kurt Severance, of the 

Flight Software System Branch at LaRC, 

was the principal developer of the new 

technique. Mr. Severance, along with

Dr. Samuel Miller, formerly of LaRC, refined 

and implemented this technique for two 

significant NESC assessments. The 

system was first designed for the NESC’s 

Max Launch Abort System (MLAS). MLAS 

included a full-scale Orion crew module 

(CM) outfitted with four inexpensive highspeed cameras designed to record the 

separation from its protective forward 

fairing. The four cameras employed 

low-cost, wide-angle lenses to capture 

nonoverlapping views of the protective 

fairing that contained numerous circular 

photogrammetric targets. Because 

conventional photogrammetry requires 

low-distortion lenses and overlapping 

camera views of the object of interest, a 

new algorithm was needed. 

Mr. Severance summarized the technique 

as follows: “If all the targets are constrained 

to a single rigid body, then the constraint of 

overlapping camera views can be removed, 

and a representative set of equations 

can be developed. The solution to the 

equations is the one unique 6-degree-offreedom orientation of the rigid object that 

produces the target patterns observed 

in all the cameras. Modern camera 

calibration techniques were employed, 

and a robust target-tracking algorithm was 

implemented to follow targets from frame 

to frame, even in the midst of significant 

flying debris. All these technologies 

were combined and implemented into 

a common platform using commercially 

available software development tools 

and runs on a workstation laptop, which 

could be used on site immediately after an 

experiment.”

The new photogrammetry system is 

called pose from an arbitrary camera rig 

(PACER). It provides maximum flexibility 

in choosing the number of cameras, the 

types of lenses, and the placement of 

those cameras in accessible locations for 

a flight experiment or ground test facility. 

Mr. Severance pointed out that “PACER 

was successfully used to determine the 

relative positions between the MLAS CM 

and fairing to within 1/2 of an inch even 

after 16 feet of separation. This capability 

was extended and applied to the NESC’s 

Crew Module Water Landing Modeling 

Assessment (CMWLMA) tests in Phase 

I and Phase II. Displacements with 

millimeter accuracy and attitude within 

hundredths of a degree were obtained for 

the water entry tests.” In this two-phase 

test, a full-size Orion CM was repeatedly 

dropped in the water at nominal and

off-nominal splashdown velocities to 

collect trajectory, attitude, and other data 

that were then used to validate water 

“ The drop video was helpful but the photogrammetric overlays made it magic ... I can’t 

imagine doing without such a tool on future dynamic data collection projects. This has the 

potential to be an engineering analyst's best friend.” 

— T. K. Mattingly, former Apollo and Shuttle astronaut, and engineering consultant

FEATURED ASSESSMENTS FEATURED ASSESSMENTS

(Above) Photogrammetry was used to directly measure the CM trajectory and 

attitude during water impact tests at the Aberdeen Test Center, Maryland.

(Left) Photogrammetry supported the critical separation event during the MLAS 

flight test by looking for recontact between the CM and the MLAS I fairing. 

Photogrammetry targets are visible on the fairing's interior.

Thomas Jones, Head of the Advanced Sensing and 

Optical Measurement Branch at LaRC, developed 

the network of high-speed cameras used during CM 

water drop testing.

This image from a high-speed video shows how a crew module wireframe model was mathematically aligned to the known positions 

of the photogrammetry targets (white dots) at the proper scale. The water surface and orientation was modeled using the free-fall 

trajectory and attitude measured by photogrammetry at the instant of water contact.

Kurt Severance is the principal developer of the 

PACER photogrammetry system.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights
14 15

The NESC, in partnership with the JSC 

Human Exploration Science Office, is 

working to improve micrometeoroid and 

orbital debris (MMOD) damage predictions 

and risk assessments for the International 

Space Station, the Orion Multi-Purpose 

Crew Vehicle, and other spacecraft. 

Working with university partners, the 

team is developing hydrocode impact 

simulations to model damage from MMOD 

particles with higher densities than what 

has previously been considered. The 

team will also be performing hypervelocity 

(up to 5.6 miles/second) and ultra-high 

velocity (up to 6.2 miles/second) impact 

testing to test higher density projectiles 

and evaluate new materials that exhibit 

both radiation protection as well as 

MMOD shielding capabilities. 

Exploration Flight Test-1 (EFT-1) will be the first flight test of 

NASA’s Orion Multi-Purpose Crew Vehicle (MPCV) crew module 

exposing the vehicle to Earth entry from beyond Low Earth 

Orbit (LEO). Beyond LEO entry involves higher aerodynamic 

heating and spacecraft thermal protection systems that have 

not been used since Apollo. The NESC is employing remote 

infrared imaging of EFT-1 to provide global temperature 

measurements that will enhance and corroborate onboard 

thermocouple instrumentation. The remote imaging also serves 

as risk mitigation in the event onboard instrumentation should 

experience a failure. The remote imaging technology used in this 

test was developed and refined through imagery of the NASA 

Space Shuttle orbiters during reentry and landing.

Micrometeoroid and Orbital Debris Design and Analysis Improvements

Remote Imaging of the EFT-1 Entry for Aerothermal Flight Data Risk Reduction

Aerodynamic Testing

of Alternate Spacecraft

on Space Launch System 

The Space Launch System (SLS) will be human 

rated to carry the Multi-Purpose Crew Vehicle. 

Commercial crew providers have proposed a 

number of spacecraft shapes to service the 

International Space Station. These shapes 

range from a winged spacecraft to capsules and 

lifting bodies. The NESC is testing five generic 

shapes, representative of proposed spacecraft 

concepts, on an SLS wind tunnel model to

determine their aerodynamic performance during 

ascent. These tests will provide preliminary 

aerodynamic data should alternate spacecraft 

be proposed for launch using the SLS.

During a nominal Orion crew module (CM) 

reentry descent, the spacecraft’s reaction 

control system (RCS) will maintain CM 

attitude control until its capsule parachute 

assembly system (CPAS) drogue 

parachutes deploy at 25,000 feet. The 

CPAS drogues will deploy early if the 

CM’s guidance, navigation, and control 

(GNC) system senses the onset of windinduced aerodynamic instability within 

the contingency altitude range of 35,000 

to 25,000 feet. While a contingency 

deployment is not anticipated with a 

fully functioning RCS, the possibility 

increases if one string of the dual-string 

RCS were to fail. The CPAS development 

and certification effort included CM test 

article air drops from aircraft at altitudes 

up to 25,000 feet. High-altitude drops 

were planned in the contingency range 

using a new balloon airdrop system, 

but were removed after Monte Carlo 

simulations showed the probability of CM 

aerodynamic instability within this range 

was very low, even when descending on 

one string of the RCS. It was anticipated 

that qualification of the contingency 

drogue deployment could be based 

on analytical predictions using CPAS 

modeling and simulation (M&S) tools 

validated with drop test data collected 

below 25,000 feet. 

The NESC was asked to independently 

assess the CM aerodynamic instability 

M&S results and the CPAS M&S tools’ 

drogue parachute high-altitude loads 

and inflation predictions. Aerodynamics, 

GNC, and M&S experts reviewed the 

RCS capability, atmospheric wind model, 

and pitch damping derivative model 

used in the CM stability simulation, while 

parachute design and test, M&S, and 

statistics experts reviewed the CPAS 

M&S tools capabilities, methods, and 

development history. 

The NESC team found the project’s 

CM stability tool could produce correct 

simulated motion and statistics for 

a descending CM. RCS and wind 

models were correctly modeled but the 

aerodynamic damping derivative (Cmq) 

model had issues, which led to incorrect 

stability predictions. Using the Apollo 

Program CM Cmq model, the team 

showed the probability of instability loss 

was several times greater than had been 

predicted. The team also found the CPAS 

M&S tool was well anchored with test data 

within the nominal drogue deployment 

envelope. However, contingency altitude 

opening load prediction using the tool 

have unknown levels of uncertainty 

in part because, like all other current 

parachute M&S tools, the CPAS tool uses 

a mix of empirical and physics-based 

models. Empirical models are usually 

not employed beyond regions anchored 

with data. The NESC recommended 

collecting high altitude air drop data 

using any capable airdrop asset to qualify 

drogue parachute deployment within the 

contingency deployment range. 

The NESC assessed the importance of 

differences in thermal protection system 

(TPS) material arc jet testing results from 

multiple facilities and their effect on TPS 

sizing. The team investigated the level 

of risk accepted by depending on a 

single facility for TPS certification. The 

assessment included a historical review 

of Apollo TPS certification data and other 

relevant programs to gain insight regarding 

the importance of multiple arc jet test 

facilities. The team performed data mining 

and engineering analysis to penetrate 

and understand facility differences. The 

team also defined a framework for newly 

commissioned tests and surveyed other 

arc jet facilities for future use.

Qualif﻿ication of Parachute Systems for High Altitude Deployment

Artist's

rendering of 

the Orion crew 

module thermal 

measurements 

from a U.S. Navy 

P-3 observation 

aircraft.

High-speed images from the front (left) and side (right) taken approximately 0.01 seconds after impact of 

a 0.11-inch diameter aluminum projectile traveling at 4.31 miles/second into a proposed MMOD shield 

configuration.

Test section of 

LaRC Unitary 

Wind Tunnel

with the

HL-20

lifting body 

spacecraft on

an SLS model.

JSC's Atmospheric Reentry Materials and Structures Evaluation Facility Arc Jet Test Position-2.

Orion boilerplate drop test article and pallet being extracted from C-17.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS HUMAN EXPLORATION AND OPERATIONS

Review of Apollo Thermal 

Protection Test Data
16 17

Regions of 

interest for 

interference

Parachute 

Models

Mass

Properties

Aerodynamics &

Aerothermodynamics

SLS

Earth 

Atmosphere 

Models

Thermal Protection

Systems

Propulsion

Planet Model

(gravity & topographic)

SLS Booster Interface

Loads Analysis

The Space Launch System (SLS) uses 

solid rocket boosters to overcome high 

aerodynamic and inertial forces during 

launch and initial ascent. The booster 

aerodynamic forces can produce large 

loads where they attach to the SLS 

core stage. The NESC is optimizing 

the booster shape to minimize the 

aerodynamic loads applied to the core 

stage. State-of-the-art computational 

aerodynamics design tools are used to 

design the booster shape and minimize 

the interface loads. Wind tunnel tests 

of candidate shapes showing the best 

potential for load reduction will be 

conducted to verify the computational 

design.

CPAS Wake Deficit Wind Tunn

Testing for MPCV-Class Spacecraft

The capsule parachute assembly system 

(CPAS) is used to decelerate the Orion 

Multi-Purpose Crew Vehicle (MPCV) crew 

module (CM) for landing during reentry. 

The subsonic/transonic wake of the CM 

during heatshield forward descent interacts with the CPAS and is a critical factor 

that must be accounted for in the CPAS 

design. The aerodynamic character of 

the CM wake has a significant impact on 

the deployment and performance of the 

parachutes. Computational fluid dynamics (CFD) simulations play a key role in 

predicting the aerodynamic behavior of 

the wake because wind tunnel testing 

of CPAS concepts and configurations is 

costly and limited. However, below

Mach 1, CFD prediction of the MPCV 

wake flow is questionable,

leading to conservative design 

decisions. As a result, CPAS 

component designs may

be oversized to account

for uncertainty in the

CFD-derived wake

aerodynamics.

The NESC team 

sponsored wind 

tunnel testing at 

the ARC Unitary 

Plan Wind

Tunnel to 

acquire detailed wake flow measurements 

behind a capsule model. The test used 

particle image velocimetry (PIV) in concert 

with more conventional test techniques 

to acquire high fidelity unsteady flowfield 

data in the capsule wake. These data 

will be used to characterize the flowfield 

behind MPCV-class vehicles, and as 

validation data for CFD simulations used 

in the CPAS design. Multiple NASA Centers teamed to complete test formulation, 

model design and fabrication, and data 

acquisition and analysis.

Wind tunnel testing of the capsule is 

complete and data analysis is in process. 

PIV test data are high quality and unique 

for this type of geometry operating at 

transonic speeds. These data, along with 

pressure sensitive paint (PSP), unsteady 

pressure transducer, boundary layer 

rake, and thermal imaging measurements provide the most 

comprehensive quantification ever acquired for 

the wake flow on 

this type of 

vehicle. 

The NESC is developing an analytical tool 

that can be used to accurately predict the 

maximum expected flight environment 

(MEFE) for pyroshock events induced 

in composite material. Pyroshock tests 

will capture shock wave acceleration 

time history as it transverses across the 

composite panel at various locations 

(nearfield, midfield, and farfield). These data 

will provide the necessary information for 

the generation of attenuation curves for 

the composite materials being examined 

(solid and honeycomb core) resulting in an 

empirical analytical model for shock MEFE 

predictions.

Pyroshock Characterization of Composite Materials

Independent Modeling and Simulation for Exploration Systems

NASA flight programs have benefited from independent system 

models and integrated simulations to identify and resolve highlycoupled system failure modes and technical risks, particularly 

those that occur at or near complex hardware, software, or 

discipline interfaces. These failure modes may only manifest 

themselves when components are operated as an integrated 

system; they do not necessarily occur when evaluating, testing, or 

operating single components or elements. 

The NESC is assembling a multi-Center team to develop 

independent models, and perform independent simulations to 

mitigate risks that may result from the Human Exploration Office’s 

Programs: Space Launch System (SLS), Orion Multi-Purpose 

Crew Vehicle, Ground Systems Development and Operations, 

and Commercial Crew Program partners. The effort will employ 

low, moderate, and high fidelity multiple degrees-of-freedom 

(DOF) flight simulations and physics or empirically based models

to integrate, analytically evaluate critical element and subsystem 

models, and define and understand the boundaries of operational 

environments for which each system must perform. 

The purpose of these efforts are two-fold: (1) enable the team to 

have an independent set of subject matter experts to provide 

early identification of unforeseen analysis issues or design 

interface and integration issues that occur within the highly 

integrated nature of these new systems and (2) proactively 

develop mature, verified, and validated independent models and 

integrated simulations to enable the NESC to be ready to provide 

independent assessments and technical analysis throughout the 

program life cycle as issues arise.

A 3 -DOF simulation of the SLS Block I nominal ascent from 

launch to core stage engine cut-off using independent tools was 

completed in October 2012. A 6 -DOF simulation for the same 

phase of flight is scheduled for completion by the end of

January 2013.

The accuracy of current combustion stability tools is limited by 

the level of empiricism, i.e., not fully physics-based, embedded 

in the models. The limited accuracy can lead to significant 

uncertainties in stability assessments, resulting in increased 

engine development costs. The Space Launch System (SLS) 

advanced liquid booster design is particularly in need of improved 

accuracy in this regard. The NESC will leverage recent testing and 

physics-based modeling advancements made under NASA and 

U.S. Air Force support to improve the combustion stability models 

used in the design process. 

Integrated Combustion Stability Analysis

F-1 engine testing 

in the 1960s had to 

overcome a serious 

combustion stability 

problem. SLS is 

considering engines 

in the same thrust 

class as the F-1.

Visualization of PSP data acquired from the 

CPAS wake deficit wind tunnel model in the ARC 

Unitary Plan Wind Tunnel at Mach 0.7.

Design

techniques 

employing 

computational 

aerodynamics

will be used to 

develop booster 

geometries that 

minimize SLS 

booster-to-core 

stage interface 

loads.

Suspended pathfinder solid laminate composite 

panel (3 by 6 foot) with photogrammetry speckle 

pattern and accelerometer attach points.

New and existing models of SLS 

systems and environments will be 

incorporated into an independent 

simulation of SLS operations.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS HUMAN EXPLORATION AND OPERATIONS
18 19

One of the conclusions from the 

NESC’s Composite Crew Module 

(CCM) Assessment was that the 

ability of a composite pressure 

shell to contain consumable gases was not well understood and, 

therefore, posed a significant 

technical risk relative to a metallic 

alternative. CCM and subsequent 

programs demonstrated that the 

permeability is sufficiently low 

even under reasonable design 

limit strains. However, several 

outstanding risks remain. They 

include permeability/leakage after impact, permeability of bolted 

joints, permeability of potted 

inserts, permeability after life cycling, and permeability of an outof-autoclave splice, among others. With these risks in mind, the 

NESC carried out a CCM leak characterization evaluation to quantify some of these 

risks on the full-scale structure. In addition 

to examining bolted penetrations, the effort 

quantified permeability from coupons with 

and without impacts, which demonstrated 

that a simple liner solution could mitigate 

the impact problem. Following that demonstration, the liner solution was partially 

installed on the CCM to examine feasibility 

of full-scale implementation.

Leak testing demonstrated that low leak 

rates are achievable in the sandwich 

composite material system. The tests also 

demonstrated that at a coupon level, a 

polymeric liner (appliqué film) is capable 

of mitigating the concern of the leakage 

after impact. This mitigation scheme would 

allow for many low velocity impacts to go 

undetected, without compromising the leak 

performance that is required. Despite some 

difficulty in installation, the film was effective at reducing the leak rate associated 

with the through-thickness inserts. The 

film also appeared to reduce the leak rate 

associated with the out-of-autoclave cured 

splice. The leak rate associated with critical 

features, such as bolted penetrations, was 

quantified and demonstrated that very low 

leak rates are achievable. 

The composite crew module full-scale pressure vessel test 

article being readied for a vacuum test at MSFC.

Composite Crew Module Leak Characterization

The NESC sponsored the Assessment of Gravitational Loads and 

Environments (AGILE) that informed and helped initiate a series 

of human-in-the-loop vibration studies to address specific thrust 

oscillation concerns that arose during the former Constellation 

Program (CxP). The resulting design-point assessments funded 

by the Human Research Program (HRP) and CxP established 

quantitative CxP requirements for maximum allowable vibration 

due to thrust oscillation. Subsequent HRP investigations 

demonstrated an innovative strobing countermeasure 

that restores display readability to nonvibrated levels, and 

consequently provided relief for future NASA

vehicle designs.

Fundamental research questions identified during the AGILE 

study are being addressed in a more general investigation of 

vibration-relevant, trade-space parameters. The knowledge 

garnered from AGILE aided development of the human vibration 

chapter in NASA's Human Integration Design Handbook (SP2010-3407). Furthermore, this knowledge allowed AGILE team 

members to help the Agency by addressing the Multi-Purpose 

Crew Vehicle Program and Space Launch System Program 

design questions.

The Orion Multi-Purpose Crew Vehicle 

(MPCV) crew module (CM) thermal 

protection system (TPS) requires targeted 

consideration and/or reduction of 

individual material property uncertainties, 

model and flight regime-specific margin 

application, and credible reliability 

calculations to ensure an optimum design. 

A joint NESC/Orion MPCV Program 

assessment to formulate a heatshield 

reliability estimate based on bondline 

temperature margin was completed in 

2011. High-value, follow-on work was 

identified and led to an assessment to 

formulate a heatshield reliability estimate 

based on bondline temperature margin. 

The joint NESC/ Orion MPCV Program 

assessment team is leveraging the 

expertise of MPCV TPS and materials 

subject matter expertise with NESC 

technical and statistics expertise 

to formulate a reliability model, 

employ efficient experiment design 

methodologies, and apply Bayesian 

network methodology. 

Activities will continue through September 

2013, where the joint team will mature the 

Avcoat bondline-temperature reliability 

assessment process by selecting 

heatshield failure criteria, incorporating 

new arc jet test and material property 

data, and adopting improvements to 

the Avcoat thermal response analytical 

ablation model. Using the refined 

reliability assessment process, an 

updated reliability estimate will be 

established with the critical influencing 

parameters identified. Recommendations 

for updating the existing Avcoat sizing 

process using the TPS margin policy will 

be provided.

The updated reliability model will be used

to investigate the amount and type of 

testing and analysis required to improve 

reliability. The team will develop and 

demonstrate a new statistically and 

probabilistically based means to define 

heatshield thickness for a target reliability.

A prototype resource allocation process to 

further reduce uncertainties and improve 

the reliability estimate will be developed 

using Bayesian network techniques.

Assessment of Gravitational Loads and Environments

Orion CM Thermal Protection System Margin

The NESC is conducting a feasibility 

study for spin forming a complex-shaped, 

single-piece aluminum lithium (Al-Li) Orion 

Multi-Purpose Crew Vehicle (MPCV) crew 

module (CM)-like forward pressure vessel 

bulkhead. Spin forming the bulkhead 

can eliminate multipiece fabrication and 

assembly methods currently used to 

construct the MPCV CM bulkhead, cone, 

and barrel regions. The design trade and 

materials/process studies being conducted 

at JSC, LaRC, and MSFC will identify the 

benefits and limitations associated with 

the one-piece Al-Li bulkhead design. 

Preliminary results suggest bulkhead spin 

forming could simplify fabrication, reduce 

processing cost, and lower system weight, 

while maintaining or increasing reliability 

and safety.

Spin Forming of a Crew Module Metallic Forward Pressure Vessel Bulkhead

The NESC was requested to conduct a 

peer review of the Orion Multi-Purpose 

Crew Vehicle (MPCV) Exploration Flight 

Test-1 (EFT-1) landing and recovery 

planning in support of the Landing and 

Recovery Office within the Ground

Systems Development and Operations 

(GSDO) Program. The NESC is reviewing 

the concept of operations, plans, and 

procedures for two tests that the GSDO 

Program will conduct with the Orion MPCV 

Program and the U.S. Navy. Ultimately, 

these plans and procedures will be used to 

recover the Orion crew module (CM) as part 

of EFT-1 recovery 600 miles south of San 

Diego and deliver the CM to Sea Launch 

Astrotech in Long Beach, CA. 

Orion EFT-1 Landing and 

Recovery Planning Peer 

Review

An aluminum alloy 2219 

spin-formed MPCV CM-like 

bulkhead containing a single 

friction stir weld (FSW) region.

Bulkhead Barrel

Cone

FSW

Vibration chair occupant in the ARC Human Vibration Laboratory responding 

via touch-screen input. Eye and head movement are recorded.

Artist’s rendering of the Orion MPCV CM during reentry.

Orion MPCV recovery test article being stabilized 

during initial testing conducted in 2009.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS HUMAN EXPLORATION AND OPERATIONS
20 21

Model-Based Systems Engineering of the Exploration Systems Interfaces

An NESC team is modeling the interfaces between Space 

Launch System (SLS), Orion Multi-Purpose Crew Vehicle (MPCV), 

and Ground Systems Development and Operations (GSDO) 

components using model-based systems engineering techniques. 

Using the numerous documents and data sources describing 

these interfaces, the team is building a single model of the 

interface. Analyses to be performed using this model include 

the distribution of flight, health, and safety information between 

GSDO, MPCV, and SLS, and how SLS internally processes 

the data; the commands from GSDO/MPCV to SLS, and how 

those commands are processed by SLS, including distribution 

of command responses; and abort behavior initiation and SLS 

response, including how Eastern Range data are processed 

by SLS for the flight termination system. This work will help 

determine what interfaces are required and the expected 

behaviors that need to be engineered and documented.

Orion Crew Module and Service Module Umbilical Strut Vibration Testing

Commodities are transferred between 

the Orion Multi-Purpose Crew Vehicle 

(MPCV) crew module (CM) and service 

module via an external umbilical that is 

driven from the CM by dual-spring struts. 

No development umbilical strut vibration 

testing was scoped in the Orion MPCV 

Program plan. To reduce program risk, 

the NESC, working with Lockheed Martin, 

performed qualification-level vibration 

and performance tests on a springstrut development unit, which ultimately 

uncovered issues that would not have 

been identified until strut qualification 

testing. Based on the test results and a 

follow-on failure investigation, corrective 

actions are being implemented by the 

Orion MPCV Program for the upcoming 

Exploration Flight Test-1.

Carbon-Carbon Silicon 

Carbide Material

Characterization

Work continues on the NESC assessment 

to characterize carbon-carbon silicon 

carbide (C/C-SiC) material used in the 

Multi-Purpose Crew Vehicle (MPCV) 

launch abort system attitude control 

motor (ACM). Testing at room and 

elevated temperature (up to 3000°F) 

is being conducted to understand 

material behavior under predicted 

operational environments. Test data will 

be used for the ACM component design 

database, to assess the capability of the 

analytical materials model, and identify 

C/C-SiC damage modes. Advanced 

characterization methods, including x-ray 

computed tomography, acoustic emission, 

and 3-dimensional surface strain imaging 

are being used to quantify the behavior of 

this complex ceramic composite.

Orion Docking Mechanism Jettison System Linear Shape Charge End Gap Testing

The Orion Multi-Purpose Crew Vehicle (MPCV) docking 

mechanism jettison system design uses a circumferential 

linear shape charge for separation. There is a concern the 

gap between the shape charge ends could prevent complete 

separation of the docking tunnel. The NESC was asked to 

assess options and perform concept demonstration tests to 

evaluate methods to achieve complete tunnel separation. 

Tests performed at the JSC Energy Systems Test Area 

demonstrated effective configurations, including an overlapped 

shape charge end arrangement that provided complete 

separation of the docking tunnel.

(From left) Maureen 

Dutton, Rick Dean, 

Nick Kidd of the JSC 

Energy Systems Test 

Branch examine a 

simulated docking 

mechanism jettison 

system tunnel section 

separation test

firing setup.

Conceptual SLS/MPCV/GSDO interface model.

Stewart Walker of the LaRC Advanced Materials and Processing Branch is shown conducting a 3-point 

strength test on a ceramic C/C-SiC composition material. The specimen is highly instrumented to understand performance.

NESC and

Lockheed Martin 

personnel

examine the 

spring strut prior 

to random

vibration testing.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS HUMAN EXPLORATION AND OPERATIONS
22 23

Nitrous Oxide Fuel Blend Experiment 

(NOFBX) is an oxidizer/fuel blend 

monopropellant developed by Firestar 

Technologies, LLC. NOFBX is less 

toxic than the most commonly used 

monopropellant, hydrazine, and offers 

substantial increase in specific impulse. 

Flight testing of an NOFBX propulsion 

module is planned on the International 

Space Station (ISS). The ISS Engineering 

Directorate Safety Lead requested an 

independent consultation from the NESC 

in regards to the hazard mitigation and 

avoidance plan for the flight experiment. 

The NESC conducted a thorough review of 

available NOFBX data and provided the ISS 

Program with a list of recommendations for 

reducing the risk of conducting the

flight test.

Progress 44 Anomaly 

Investigation

A Soyuz-U booster prematurely shutdown 

during flight causing the loss of Progress 

44. The NESC participated in the NASA 

Anomaly Investigation Team, which was 

independent of a Russian team chartered 

to determine and correct the cause of 

the failure. NASA’s technical analysis 

and understanding of a proposed engine 

fuel deprivation scenario showed it was 

feasible and consistent with the Russian 

team’s findings. NASA concurred with the 

corrective actions and recurrence control 

proposed by the Russian team.

A successful launch of Progress 45 

showed no booster performance issues.

ISS ORU Wet Storage Risk Assessment

The NESC is assessing the risk of storing spare components for the International 

Space Station (ISS) water recovery and oxygen generation systems that have been 

filled with deionized water. A concern is that these orbital replaceable units (ORUs) 

may be at risk for corrosion and/or biological growth (biofouling) during extended 

storage. Since there are no procedures to flush spare ORUs on the ISS, the NESC is 

evaluating the wet storage risk by sampling water from ground spares and reviewing 

the materials used in ORU construction.

At a workstation in the ISS Harmony node, astronaut Dan Burbank replaces a catalytic reactor in the 

water recovery system.

Nitrous Oxide Fuel Blend Experiment

An NESC assessment of the 

Commercial Crew Programʼs (CCP) 

use of commercial off-the-shelf (COTS) 

electronic components for space 

environment in safety-critical manned 

spacecraft avionics systems was 

requested by the International Space 

Station (ISS) Program. CCP providers 

were encouraged to develop new, lowercost methods of avionics design and 

verification with the only constraint being 

that they demonstrate no hazard will be 

presented to the ISS. At least one CCP 

provider developed a process that relies 

heavily on COTS parts combined with 

assembled component qualification and 

acceptance testing to verify system safety 

and reliability. Alternative approaches to 

verification of systems with COTS parts, 

such as those used in industry and other 

government agencies, including the 

Federal Aviation Administration, are being 

suggested by CCP providers for review 

and assessment.

An NESC assessment team is evaluating 

whether these alternative approaches 

would be suitable for the use of COTS 

parts in safety-critical manned spacecraft 

avionics systems. Planned for completion 

in 2013, the NESC team will document 

guidelines necessary for CCP spacecraft. 

The guidelines will be based on the 

review of existing COTS parts application 

documents used by the aerospace and 

automotive industries, NASA, and other 

government agencies, and comparison 

and evaluation of their approaches with 

respect to electrical, electronic, and 

electromechanical parts-level, avionics 

system-level, and mission-level reliability, 

and system safety risk.

Members of the Avionics Technical 

Discipline Team performed a study to 

respond to specific questions from the 

Commercial Crew Program (CCP) to help 

frame the technical, cost, and schedule 

risk trades associated with the desire of 

some CCP partners to employ electrical, 

electronic, and electromechanical (EEE) 

parts of a lower grade than traditionally 

used in most NASA safety-critical 

applications. The fundamental question 

posed was whether commercial off-theshelf (COTS) EEE parts, with architectural 

similar redundancy and limited screening 

only through box or system-level 

testing, can be used in safety-critical 

flight hardware systems. NASA has 

successfully used COTS EEE parts in 

spacecraft for specific and sometimes 

mission-critical applications throughout 

the Agency’s history by employing careful 

selection, qualification, and screening. 

The level of screening required for COTS 

EEE parts to ensure they will work 

successfully is highly dependent on 

the mission, their application, and part 

technology, and is well characterized in 

existing NASA parts documents such as 

EEE-INST-002. 

Qualitative analysis by the NESC team 

indicated significant differences in 

reliability and safety can result between 

screened military-grade parts and 

unscreened COTS EEE parts. Differences 

are influenced by mission duration and 

system architecture, including the use 

of like or diverse backup systems. The 

team found that the term “COTS” is 

broadly defined and not consistently 

applied. Some industries employ supply 

chain controls to ensure the quality and 

reliability of COTS EEE parts used in their 

products, while others use COTS parts 

from commercial catalogs without any 

testing other than functionality. 

The NESC team concluded that an 

alternative approach for the use of COTS 

EEE parts in critical applications, other 

than those which have proved successful, 

requires a firm basis for substantiation.

To reduce the likelihood that COTS EEE 

parts failures result in unacceptable 

mission risk, the NESC recommended the 

CCP require vehicle providers to develop 

and implement a top-down mission

assurance program to address EEE parts 

derating, qualification, traceability, and 

counterfeit control; demonstrate how 

it mitigates the risks associated with 

EEE parts applications; and provide 

data supporting the effectiveness of the 

proposed screening approach ensuring 

part failure rates are adequately bounded. 

NASA conducted significant research on 

the HL-20 winged reusable spacecraft 

in the 1980s. The HL-20 is similar in 

concept to some Commercial Crew 

Program vehicles proposed for access 

to the International Space Station (ISS). 

The concept was developed before 

computational fluid dynamics (CFD) 

and desktop flight simulation tools 

were broadly applied. This assessment 

employs modern CFD to enhance and 

extend the HL-20 aerodynamic database 

and develop desktop simulations for the 

vehicle. The simulation capability may 

be used by NASA engineers evaluating 

the flight performance of similar concepts 

during a return from the ISS or in the event 

of an ascent abort.

Smart Buyer Assessment for

Winged Reusable Spacecraft

NOFBX flight experiment solid model rendering.

The Progress spacecraft heads to the International 

Space Station from the Baikonur Cosmodrome in 

Kazakhstan.

CFD prediction 

of the HL-20 

lifting body.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS HUMAN EXPLORATION AND OPERATIONS

Use of Commercial EEE Parts in Commercial Crewed Spacecraft

Use of Commercial Electronic Parts in Commercial Crewed Spacecraft
24 25

NESC Alternate Orion CM Heatshield Carrier Design

The NESC was requested 

to develop alternate 

designs to the Orion crew 

module (CM) heatshield 

carrier structure with 

a goal of reducing the 

overall mass by 25% 

or approximately 800 

pounds. The NESC 

formed a team of 

engineers from LaRC, 

DFRC, JSC, and industry 

to develop and trade alternative concepts 

that could be implemented for the 

Exploration Mission-1 test flight.

The NESC design is a load-sharing 

approach that allows the heatshield carrier 

structure to bear against the aft dome of 

the crew module pressure vessel, through 

an “H”-like interface structure that mirrors 

the backbone shape within the crew 

module pressure vessel. This allows the 

mass of the hardware, fixed to the crew 

module backbone, to pass its inertial load 

directly to the heatshield carrier structure 

during reentry and water landing. 

This makes for a more 

direct load path and a 

more efficient structure, 

saving approximately 400 

pounds. 

The NESC team is also 

looking at analytical 

techniques that consider 

buckling via dynamic 

analysis rather than static 

analysis. Dynamic analysis 

is required to properly 

analyze the impulsive, highly dynamic 

water landing event, which is a driving 

load case. This technique has the potential 

to save an additional 400 pounds. Lastly, 

the NESC is looking at a switch in material 

systems from the current composite skin 

to a metallic skin such as stainless steel or 

titanium orthogrid. This material change 

has the potential to save 200 to 500 

additional pounds. All of these options are 

being considered for possible downselect 

in 2013 and if selected, will lead to 

detailed design as future work.

The Office of the Chief Technologist’s 

(OCT) Small Spacecraft Technology 

Program (SSTP) seeks to advance and 

validate the utility of small spacecraft to 

execute space missions. To accomplish 

its goals, SSTP needs efficient and costeffective access to space. Currently SSTP 

relies on a rideshare strategy but prefers a 

dedicated, affordable nano-launcher. The 

NESC is providing propulsion expertise 

to an OCT study team formed to examine 

the existence, maturity, and feasibility of 

dedicated SSTP nano-launcher systems.

Threaded Fastening Systems

Design, Verification, and Installati

A shear/tension fixture was designed 

at MSFC for NESC use in support 

of NASA-STD-5020 “Requirements 

for Threaded Fastening Systems in 

Spaceflight Hardware” development. 

Dr. Sayed Nassar, founding Director of 

the Fastening and Joining Research 

Institute (FAJRI) at Oakland University 

in Rochester, Michigan, and member 

of the NASA-STD-5020 development 

team, requested use of this fixture 

in research of multiaxial fatigue in 

threaded fasteners. The NESC loaned 

the fixture for use by students until 

FAJRI fabricated a duplicate fixture. 

According to Dr. Nassar, the fixture was 

instrumental in aiding undergraduate 

and graduate students in their research.

Pictured are Amir Kazemi, Ph.D. student (left) and Maurizio Joe Bentivegna (right) senior exchange

student from Mannheim University, Germany, using the fastener shear tension fixture.

The NESC received a request from the Chief of the GSFC 

Electrical Engineering Division to perform an independent 

assessment of the Maxwell single board computer (SBC) 

printed circuit board (PCB) panels. This assessment 

was designed to identify if the earlier PCB manufacturing 

problems had been resolved and identify any other problems 

early in the manufacturing process of the PCB, giving NASA 

greater insight about the reliability of the SBC PCB. In this 

ongoing assessment, the NESC team has been preparing 

and evaluating coupon microsections from current SBC 

panels to review the interconnect stress test data. 

Assessment of Maxwell SBC Panels

The International Space Station (ISS) 

Program requested the NESC participate 

in an independent reliability assessment 

of the Low Impact Docking System 

(LIDS) that is to be integrated onto ISS 

and review other proposed simplified 

docking systems. The team conducted 

technical interchange meetings with the 

LIDS engineers and with contractors 

proposing simplified docking system 

alternatives. Reviews of analyses, trade 

studies, and hardware test data provided 

the support for the NESC position that 

was presented to the ISS Program.

As commercial crew provider designs 

near the preliminary design review level, 

several providers are identifying processes 

for requalifying multiuse electrical and 

mechanical components for use in various 

shock environments that include pyrotechnics, mortar firings, and water impacts. To 

assist the commercial providers with their 

processes, the NESC formed a team of 

NASA experts to share experiences with 

qualifying hardware in shock environments 

for the Space Shuttle Program (SSP) and 

other NASA programs and projects. The 

team developed a report that is available to 

the commercial crew providers through the 

Commercial Crew Program Office.

SSP Shock Test Experience for Reusable Flight Hardware

● Nose cap

● Pilot & drogue parachutes

● 3 aft attach struts

● Thrust vector control 

system

● External tank attach ring

● Electrical cables

● System tunnel

● Linear shaped charge

● Forward booster

separation motor

Many parts of the solid rocket booster were subjected to pyroshock environments. 

Testing of low-cost engines for nano-launcher

upper stage.

Partial coupon 

microsection 

illustrates 

measurement of 

internal annular ring 

and solid copper 

microvia structures at 

upper right edge.

Engineering model of the LIDS being tested in 

the JSC 6 degrees-of-freedom test stand.

Existing heatshield design.

Existing Orion CM pressure vessel.

Proposed heatshield design 

with “Hˮ interface structure.

Lower portion of pressure 

vessel and backbone with 

“H" heatshield carrier.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

HUMAN EXPLORATION AND OPERATIONS GENERAL

Dedicated Nano-launcher 

for Small Spacecraft

ISS Simplified Dockin

System
26 27

Fault Management (FM) is an evolving 

field that includes fault tolerance, fault 

mitigation, fault protection, and system 

health management. It is most often 

affiliated with systems engineering 

and/or software engineering. FM plays 

a critical role in ensuring safe and 

reliable spaceflight, for both robotic 

and crewed missions. FM systems 

prevent or detect, isolate, diagnose, 

and respond to anomalous and failed 

conditions interfering with nominal 

mission operations. NASA engineers 

have established varied techniques and 

approaches for designing, implementing, 

and testing FM systems for spacecraft, 

launch vehicle, aeronautical vehicle, and 

ground system applications. Although 

NASA’s FM systems have performed 

successfully, their implementation has, 

in some cases, adversely stressed 

programmatic and engineering resources. 

Flight projects have suffered from 

unexpected cost growth and schedule 

slips during final FM system integration 

and test. NASA needs reliable and 

affordable FM systems that are developed 

with the engineering rigor of other safety 

critical processes. Vetted recommended 

best practices and engineering guidelines 

are needed to establish an Agency-wide 

systematic engineering process for the 

design and development of NASA’s FM 

systems.

Recognizing that FM systems increase 

safety, reliability, availability, and 

performance in NASA’s systems, the 

NESC, in collaboration with JPL, has 

developed a NASA Fault Management 

Handbook, NASA-HDBK-1002, to provide 

overarching conceptual engineering 

guidelines and recommended best 

practices.

The handbook is in the NASA Standards 

Program Office System, and has 

completed a comprehensive Agency-level 

review process. The insights and concepts 

captured in this handbook provide a basis 

for moving the discipline toward a formal 

and consistent methodology. Application 

on future programs may help to avoid 

program cost overruns, schedule slips, 

in-flight failures traceable to a lack of 

established approaches, and disciplined 

and systematic FM development 

techniques.

The Black Brant motor has experienced combustion stability 

events during flight. To understand the cause of instability and 

ensure that the appropriate mitigation steps are taken, the motor 

combustion stability model needs to be updated. An NESC 

assessment team will use combustion response data generated 

by the Sounding Rocket Project Office to update the combustion 

response characteristics of the baseline and modified motor 

propellant. Analysis with this updated characteristic will increase 

understanding of the current motor configuration and insight into 

its stability characteristics.

Development of a NASA Fault Management Handbook

Current ground data acquisition systems 

offer high dynamic range and sample 

rates for multiple measurement channels. In contrast, flight data acquisition 

systems do not generally offer the same 

level of measurement fidelity due to the 

low technology readiness level associated 

with higher performing electronics. Specifically, current generation 24-bit analogto-digital electronics have not been 

packaged and tested to expected launch 

vehicle/spacecraft environments. Limited 

flight data acquisition options increases 

the risk for flight test and launch programs 

to provide adequate data quantity and 

quality to meet users’ needs for vehicle 

performance characterization. 

To address the identified deficiency, the 

NESC created the multi-Center High Fidelity Data Acquisition System (HiDAQ) Project Team. The primary objective was to 

develop a prototype data acquisition unit 

capable of operating within specified flight 

environments, while delivering high fidelity 

data acquisition needs. The team baselined a set of performance, functional, and 

operational requirements for the HiDAQ 

demonstration unit. These requirements 

were used in multiple design and analysis 

cycles to define a configuration capable 

of meeting a broad range of data acquisition and avionics needs. The prototype 

unit design and supporting analyses were 

evaluated by multiple NESC Technical Discipline Team members during the HiDAQ 

design review. 

The team has moved into the fabrication 

and development testing phase. The aluminum housing has been fabricated, and 

the high-quality analog-to-digital boards, 

capable of recording up to 102,400 

samples per second with over 18 effective 

bits dynamic range, have been delivered 

for performance testing. The prototype 

will be capable of measuring 48 channels, 

with prescribed sensor power options for 

a variety of dynamic sensor types. Unit 

integration and environmental testing is 

scheduled to occur in 2013.

High Fidelity Data Acquisition System Development

Development of Verification Data for Flight Simulatio

Flight simulations are increasingly relied upon to aid in 

design optimization, reduce risk and development costs, 

and provide overall flight prediction of aerospace vehicle 

designs. Independently developed tools are typically used to 

perform these simulations, and this independence provides 

valuable cross-checking between the analyses conducted 

by project partners. However, the fundamental aspects of 

the simulation frameworks are implemented differently, which 

can lead to disagreement in predictions. In this ongoing 

NESC assessment, the team will provide test cases, which 

will verify that the underlying equations of motion (force and 

moment summation, moment transfer, acceleration and 

velocity integration, state propagation) and the basic models 

(gravity, geodesy, atmosphere) of a simulation framework 

are implemented properly. These test cases will serve as a 

benchmark for simulation frameworks used by NASA and 

others, and are expected to result in higher productivity and 

confidence in flight simulation predictions.

FM systems play a prominent role within NASA’s aeronautics, human, and robotic spaceflight missions.

T-burner test rig used for obtaining combustion response data.

HiDAQ team members with fabricated rapid prototype unit.

Comparisons between five simulations for an early Ares I-X concept.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

GENERAL

Assessment of Combustion

Instability in Black Brant Motors

GENERAL
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Science

General

Human Exploration and Operations
30 31

ASRG Heater Head

Critical Flaw Analysis

The NESC performed a technical 

assessment of the Advanced Stirling 

Radioisotope Generator (ASRG) heater 

head component to evaluate flight 

hardware acceptance criteria. Metallic 

oxides found in the heater head material 

act as embedded flaws, presenting a risk 

of fatigue failure during dynamic stress 

environments. The NESC determined that 

the use of traditional analytical methods 

to predict the maximum allowable flaw 

size was not appropriate due to the thin 

heater head wall thickness. The NESC 

also provided technical expertise to 

develop test methods for evaluating the 

critical flaw size and acceptance criteria.

Chandra X-Ray Observatory COPV Risk Assessment

JWST NIRSpec Microshutter Subsystem Investigation

The Chandra X-Ray Observatory 

(CXO) Project requested evaluation of 

the integral propulsion system (IPS) 

composite overwrapped pressure vessel 

(COPV) hydrazine propellant tank to 

elevated temperatures. The investigation 

focused on concerns of composite 

overwrap stress rupture and metallic liner/

hydrazine compatibility. Comparison of 

overwrap stress levels to current stress 

rupture assessment guidelines determined 

the IPS tank has a relatively low failure 

risk. The absence of long-term hydrazine/

liner compatibility data identified the 

potential for increased risk for surface 

corrosion, stress corrosion cracking, and/

or environmentally assisted crack growth. 

The NESC recommended the CXO Project 

obtain the necessary hydrazine exposure 

information to estimate any change in 

relative risk.

A. Rollers after 588 cycles. B. Rollers after 

77,357 cycles. Rollers have a 1.5 degree

misalignment.

A. B.

(Above) Vacuum Roller Traction 

Contract Rig used to characterize 

vacuum wear marks and debris.

The NESC provided an independent 

assessment of the James Webb 

Space Telescope (JWST) Near Infrared 

Spectography (NIRSpec) Microshutter 

Subsystem life test results. Although the 

mechanisms’ performance met the two 

time design life requirement, debris noted 

during post-test inspection is a concern 

for instrument operation. The NESC team 

evaluated the effect of contamination 

on the instrument’s performance and 

conducted a series of tests to determine 

when debris generation begins. Results 

of the engineering tests led to an NESC 

recommendation for a design modification 

to reduce the contamination potential. 

A follow-on assessment was initiated to 

evaluate alternate materials with results 

expected by February 2013.

JPL requested the NESC provide 

technical expertise after several close 

calls were experienced during the Mars 

Science Laboratory (MSL) ground test 

and checkout activities. The NESC effort 

consisted of two primary tasks: reviewing 

procedures for critical ground processing 

operations, specifically flight hardware 

lifts and hoists, for potential human 

factors engineering and other technical 

issues; and reviewing the data, findings, 

and corrective actions from the incident 

documentation to identify potential gaps 

and/or recurring factors.

A lift/hoist procedure review resulted 

in several recommendations, which 

were implemented by the MSL Ground 

Processing Team. This review resulted in 

follow-on consultations regarding critical 

LaRC and GSFC lift/hoist operations. 

The close-call recurring cause analysis 

identified the top four proactive risk 

reduction opportunities, which the NESC 

made recommendations to address as 

they have the potential to adversely affect 

future missions. 

Hubble Space Telescope Attitude Observer Anomaly

The Hubble Space Telescope (HST) experienced occasional 

losses of lock during fine guidance sensor guide star acquisitions, 

threatening a potential loss of science. These acquisition losses 

were associated with an increasing disparity between the fine 

guidance sensor-derived estimates of gyroscope bias calculated 

in orbit day and those calculated in orbit night. The attitude

observer anomaly was the result of corrosion of the multiple flex 

leads, each the diameter of a human hair, which serve as the 

internal electrical connection to the gyroscope float. The NESC is 

supporting the HST Project by updating gyroscope life predictions 

and developing a new multidisciplinary model of the gyroscope 

flex lead degradation physics. 

Mars Science Laboratory Ground Test and Checkout

Micrograph of 

buckled nickelsilver motor flex 

lead found on 

a gyroscope 

returned from HST. 

Corrosion was due 

to submersion of 

lead in gyroscope 

fluid.

Fitting of the aeroshell to the Mars Science Laboratory rover and sky crane.

The advanced Stirling heater head is shown on 

the left side of the subassembly.

Illustration of Chandra X-Ray Observatory.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

SCIENCE SCIENCE
32 33

Development of an Autonomous Aerobraking Capability

NASA uses aerobraking to reduce the 

propellant required to deliver a spacecraft 

into its desired final orbit around a 

target planet or moon with a significant 

atmosphere. While aerobraking reduces 

the propellant required to reach the final 

orbit, this reduction comes at the expense 

of added orbital insertion time (typically 

3 to 6 months), continuous Deep Space 

Network (DSN) coverage, and ground staff 

to continuously monitor the spacecraft 

during the aerobreaking maneuvers. The 

requirements for ground monitoring and 

trajectory updates introduces potential 

error due to the communication lag 

between Earth and the spacecraft, 

including a reduced ability to correct 

aerobraking maneuvers in the final orbital 

insertion stages. 

An NESC team is developing the 

capability to move the iterative 

ground-based process to an onboard 

autonomous aerobraking maneuver 

process. Autonomous aerobraking 

allows onboard flight corridor evaluation 

and apoapsis maneuver calculations, 

offering mission cost avoidance by 

reducing ground operations staff and 

DSN coverage demands. These onboard 

processes include a state (orbital 

position) propagator, atmospheric density 

modeling, critical spacecraft element 

thermal modeling, and maneuver strategy 

logic. This model and algorithm suite is 

known as the Autonomous Aerobraking 

Development Software (AADS). 

Phase 2 of this NESC study focused 

on AADS model updates and increased 

fidelity, Program to Optimize Simulated 

Trajectories II (POST2) simulation 

environment enhancements, and 

preparation for testing on a flight-like 

hardware-in-the-loop testbed. A new 

state propagator was developed with 

an architecture tailored for onboard 

spacecraft applications. This onboard 

tool improves the state determination 

and estimation, reducing position and 

timing errors in the prediction of the 

next periapsis state, which is critical 

in improving the performance of the 

atmosphere estimator. Concurrently, the 

auto-navigation tool will be incorporated 

as a separate option for state propagation. 

The atmosphere estimator development 

provided uncertainty estimates associated 

with the atmospheric density predictions, 

which are critical in understanding the 

predicted density confidence level of the 

next periapsis. The maneuver estimator 

was developed using these density 

uncertainties to bias the calculated 

maneuver. The estimates of the previous 

atmospheric passes’ density (in addition 

to density prediction) allow the maneuver 

estimator to keep the spacecraft within a 

safe aerobraking corridor. The simulation 

environment improvements integrated 

the AADS with the latest POST2 version. 

Spacecraft models are being incorporated 

to allow for 6 degrees-of-freedom 

simulation analyses. AADS's accuracy 

performance was improved from Phase 

1. Ultimately, AADS will be targeted for 

inclusion on a future spacecraft mission 

for flight evaluation in a “shadow mode,” 

where onboard autonomous aerobraking 

commands would be compared to 

ground-based aerobraking commands. 

Once shadow mode flight validation is 

successfully completed, autonomous 

aerobraking could be used as the prime 

aerobraking operations strategy for 

subsequent missions.

SCIENCE

JWST Fine Guidance

Sensor Motor Anomaly

The James Webb Space Telescope (JWST) Project has 

experienced a lingering problem with a failed fine guidance sensor 

dual wheel mechanism. Technical expertise to the Material 

Review Board was requested to help determine the root cause 

and to provide corrective actions. The NESC provided support in 

reviewing the design and recommending modifications that would 

result in meeting mechanism life requirements. Design change 

implementation is expected by early 2013.

JWST fine guidance sensor 

filter wheel mechanism.

NPP Solar Array Deployment

Torque Margin Assessment

The NESC provided technical expertise for the National Polarorbiting Operational Environmental Satellite System (NPOESS) 

Preparatory Project (NPP) solar array low torque margin 

investigation. The NASA Technical Fellow for Mechanical 

Systems provided an independent review of the contractor 

deployment margin analyses and tests. The torque margins 

were identified as not meeting project requirements during 

spacecraft final integration and test. At the recommendation 

of the NASA Technical Fellow, several tests were conducted, 

the analyses were updated, and hardware modifications 

were made, resulting in a more accurate (less uncertainty) 

margin determination. Final results were presented to the NPP 

and the Director of the National Oceanic and Atmospheric 

Administration. The NPP solar arrays were successfully 

deployed after launch.

Cassini Spacecraft Electrical Anomaly

The NESC provided technical expertise 

for the Cassini spacecraft short circuit 

anomaly investigation. This anomaly was 

initially believed to have been caused by 

a capacitor short circuit in the Cassini 

Plasma Spectrometer (CAPS) instrument 

low voltage power supply. After thoroughly 

reviewing the available telemetry, and 

locating comparable vintage components, 

the NESC team determined that tin 

whiskers emanating from tin plate inductor 

covers were the most likely source for the 

short circuits experienced. The primary 

conclusions found that there was low risk 

associated with resuming CAPS operation, 

provided sufficient power margin was 

available from the radioisotope thermal 

generator.

NASA’s Sounding Rocket Program 

(SRP) in the Science Mission Directorate 

(SMD) provides low-cost opportunities to 

conduct leading edge research. The SRP 

workhorse motor, used alone or as part 

of a multistage rocket, is a 1960s design 

manufactured in Canada. After years of 

reliable performance, recent flights have 

experienced various performance issues. 

A NASA internal design initiative takes 

advantage of modern design tools and 

production practices needed to ensure 

reliability of future sounding rocket 

missions. 

The NESC formed a multi-Center team 

and developed a conceptual design of 

a new sounding rocket motor that met 

SRP performance and cost requirements. 

Propellant characterization and scale-up 

testing were completed in partnership 

with the U.S. Army. Various motor 

development options were studied and 

presented to the SRP Office. 

The NESC-led team advanced the 

motor design to the preliminary design 

review level. The SMD approved design 

development plan includes one ground 

hotfire test and three development flights. 

The next development phase will be 

completed under SMD sponsorship with 

additional support provided by the Office 

of the Chief Engineer and the Human 

Exploration and Operations Mission 

Directorate.

SCIENCE

Design Concept for New Sounding Rocket Sustainer Motor

Aerobraking is used to reduce the propellant required to deliver a spacecraft into its desired final orbit 

around a target planet or moon that has an atmosphere.

(Above) NPP Satellite Solar Array Deployment Test. (Inset) NPOESS satellite.

The Black Brant sounding rocket motor 

(black upper stage), operational since the 

1960s, is the workhorse of NASA’s SRP.

CAPS low 

voltage power 

supply circuit 

board. 

Southwest Research Institute

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Technical Highlights Technical Highlights

Periapsis

Circular Science Orbit
35

Center Focus

The Ames Research Center (ARC) has a 

diverse set of capabilities and specialized 

engineering expertise, including aeronautics; 

arc jet facilities; life sciences; human factors; 

astronomy; astrophysics; entry, descent, 

and landing; thermal protection systems; 

and computational fluid dynamics (CFD) 

supporting a variety of Agency programs and NESC activities. This 

past year, these capabilities and expertise supported more than 

10 NESC assessments and 11 NASA Technical Fellow Technical 

Discipline Teams (TDTs). The NASA Technical Fellow for Human 

Factors is resident at ARC.

In support of aerodynamics assessments, ARC has unique 

infrastructure such as multiple wind tunnels, including the world’s 

largest, and one of the world’s most powerful computers running 

state-of-the-art CFD simulations/analyses. In this area, ARC led a 

major NESC assessment related to the Orion crew module Capsule 

Parachute Assembly System (CPAS) wake deficit investigations. 

CPAS Wake Deficit Wind Tunnel Test

Dr. James Ross has spent the last several years coordinating ARC 

wind tunnel testing that has helped define the aerodynamic and 

loads databases for the Orion Multi-Purpose Crew Vehicle (MPCV) 

Program while also supporting multiple NESC assessments

and Aerosciences TDT-related activities. As part of these support 

activities, he and the Orion MPCV Aerosciences Team noticed the 

analysis methods used with the test data to build the aerodynamic 

database showed poor accuracy in some flight regimes, particularly 

for subsonic/transonic flight. To address these shortcomings,

Dr. Ross proposed a plan to measure the flow field around a generic 

reentry crew module. Recently completed, this NESC-sponsored 

test, led by Dr. Ross, obtained a data set that includes pressure 

distributions from pressure sensitive paint, skin friction, and 

boundary layer surveys on the heatshield; infrared thermography 

to visualize transition to turbulent flow and flow separation; and 

off-body particle image velocimetry (PIV) flow measurements. The 

PIV measurements are of particular interest to the Orion MPCV 

Program to validate estimates of the wake velocities used for the 

parachute system design. Dr. Ross stated, “The investment that 

the NESC made in funding this work has provided unique data 

for the validation of computational aerodynamics tools and has 

enhanced our ability to obtain measurements that have already 

benefited other NASA programs.”

CPAS Wake Deficit Wind Tunnel

Test PIV Measurements

Mr. J. T. Heineck and Dr. Gloria Yamauchi obtained their PIV expertise 

along different paths. Mr. Heineck began scientific photography 

as an extension of his work as an ARC staff photographer. This 

interest led him to work at the ARC Fluid Mechanics Laboratory 

advancing a variety of novel flow measurement and visualization 

techniques. Dr. Yamauchi, of the ARC Aeromechanics Branch, 

has performed research in rotorcraft aerodynamics for most of her 

ARC career, and adopted PIV to obtain detailed flow field velocity 

measurements around a full-scale rotor in the National Full-Scale 

Aerodynamic Complex. While Mr. Heineck and Dr. Yamauchi have 

collaborated for many years, the NESC CPAS wake deficit test 

required the best from them to obtain the necessary measurements 

the Orion crew module parachute designers needed to verify key 

design assumptions. After completing the test, Dr. Yamauchi 

stated, “Keeping two independent PIV systems operational in the 

11-foot by 11-foot transonic test section of the Unitary Plan Wind 

Tunnel was definitely a challenge.” In spite of the test difficulty, 

Mr. Heineck appreciated the challenge and the opportunity and 

stated, “Our ability to measure the flow in a production wind tunnel 

has definitely benefited from the investment the NESC made in 

this test.” Gloria Yamauchi and J. T. Heineck inspect the model of the Orion crew

module prior to a laser profilimeter test at ARC.

Dr. James Ross prepares a model of the Orion crew module, coated with pres

-

sure sensitive paint, in the ARC Unitary Plan Wind Tunnel.

Dr. Timothy Krantz (left) and Richard 

Manco at the GRC vacuum roller rig.

NESC TECHNICAL UPDATE 2012

Nans Kunz

Center Focus

Pages 33-42
36 37

Center Focus Center Focus

The Glenn Research Center (GRC) provided 

a broad spectrum of technical expertise in 

support of NESC assessments and NESC 

Technical Discipline Teams. Using expertise 

in composite pressure vessel mechanics 

and modeling capabilities, GRC personnel 

supported an in-depth study and thermomechanical analysis of the Chandra X-Ray Observatory propellant 

tanks, alleviating concerns of stress rupture failure. In support 

of the Crew Module Water Landing Modeling Assessment, 

GRC experts used acceleration, pressure, and strain data from 

water drop tests to validate models, and improve modeling and 

simulation strategies. Results have led to higher fidelity water 

landing structural response predictions to support improved vehicle 

designs. GRC provides expertise in tribology and mechanical 

components to numerous NESC assessments, including producing 

a corrosion-immune shockproof bearing. This proof-of-concept 

hardware, made from an emerging nickel-titanium superelastic 

alloy, could replace conventional bearing alloys in applications 

such as the International Space Station (ISS) urine processor. GRC 

provided power system expertise to identify and evaluate failure 

mechanisms causing short circuits within the Cassini spacecraft, resulting in technical guidance necessary to resume safe 

operation of the plasma spectrometer.

Expertise in Nuclear Systems

Benefits Cassini Investigation

Mr. Lee Mason is Chief of the GRC Thermal Energy Conversion 

Branch.  His 25-year NASA career has focused on space power 

and propulsion technology development, with an emphasis 

on nuclear systems. His expertise has been crucial in aiding 

the Advanced Stirling Radioisotope Generator (ASRG) Flight 

Project. According to Mr. Mason, “My primary role is to oversee 

the transition for the high efficiency Stirling engine technology 

from laboratory test devices to highly reliable flight units.” The 

ASRG will reduce the plutonium fuel requirements by more 

than a factor of four compared to radioisotope thermoelectric 

generators (RTGs). Mr. Mason provided assistance in evaluating 

the inspection and structural analysis of ASRG heater head oxide 

inclusions. His background was utilized for the NESC assessment 

of Cassini RTG electrical power shorts. Mr. Mason led the RTG root 

cause investigation, which included support from JPL and Orbital 

Sciences Corporation experts.  Mr. Mason indicated, “We had to 

dig through test reports that were written many years before the 

1997 launch.  Fortunately, the engineers kept good records and we 

were able to pinpoint the likely causes for the apparent current 

leakage that was observed with the faulty RTG.” 

Expertise in Mechanical

Components and Tribology

In support of the James Webb Space Telescope Near-Infrared 

Spectrograph Microshutter Subsystem Assessment, Dr.  Timothy 

Krantz, assisted by engineering technician, Mr. Richard Manco, 

performed wear tests using GRC’s vacuum roller rig to quantify 

interface wear and develop recommendations regarding debris 

generation. Dr. Krantz was first employed by the Army Research 

Laboratory and since then has performed research at GRC for 25 

years. His work has centered on improved gearboxes and drive 

systems for rotorcraft. This skill set and tools have proven invaluable 

to spacecraft mechanical system concerns. Dr. Krantz stated, 

“Research for rotorcraft drive systems has required me to obtain 

experience and skills in many aspects of mechanical systems. I’ve 

had to explore system-level effects on loads and motions, material 

strength and integrity, dynamics, efficiency, manufacture of precise 

geometry, wear, lubrication, reliability, and qualification testing. My 

coworkers and I have quickly adapted analysis codes and test 

rigs created for rotorcraft research to the  NESC’s assessments 

for spacecraft.”  Dr.  Krantz has contributed to NESC efforts for 

Space Shuttle orbiter rudder speed brake gear margins, body flap 

actuator and rudder speed brake bearings, rudder speed brake 

gear chipping, and ISS Solar Alpha Rotary Joint Anomaly for which 

he received the NESC Engineering Excellence Award.

Lee Mason with the ASRG engineering unit.

The Dryden Flight Research Center (DFRC) 

provided technical expertise to the NESC for 

numerous activities, including the Alternative 

Fuel Effects on Contrails and Cruise Emissions 

Probing Aircraft Flight Test Hazard Mitigation 

Assessment; flight simulations to support 

the development of verification data for flight 

simulation; use of commercial off-the-shelf avionics safety-critical 

avionics systems for commercially crewed spacecraft; and arc jet 

testing as part of a review of Apollo thermal protection system test 

data to support the Orion Multi-Purpose Crew Vehicle development. 

DFRC engineers are members of NESC Technical Discipline Teams 

(TDTs) and have supported numerous TDT 

investigations. 

Contributing Programmable 

Logic Devise Expertise

Mr. Mike Delaney is a DFRC instrumentation 

engineer and a member of the NESC 

Avionics TDT, where he is the chair of 

the Programmable Logic Devices (PLD) 

subcommunity of Practice (CoP). The PLD 

CoP website is on the NASA Engineering 

Network and has been used to inform 

the technical community of issues found 

in devices from two manufacturers. Mr. 

Delaney presented the PLD state-of-thediscipline briefing at the Avionics TDT 

annual meeting. Mr. Delaney stated, “It 

has been a great experience and I gained 

more knowledge on how the space side 

of NASA does avionics. In particular, what 

I’ve learned about device reliability and 

screening will be very useful on upcoming 

designs. I also got the opportunity to 

explain how the Dryden aircraft could be 

used for space research and technology 

risk reduction efforts.” 

U.S. Air Force F-22 Life

Support System Investigation 

Dr. Gregg Bendrick, DFRC Chief Medical Officer, was a member 

of the NESC assessment formed to assist the U.S. Air Force in 

addressing hypoxia problems in the F-22 fighter aircraft. “It 

was a lot like being on a special ops team,” said Dr. Bendrick in 

describing his experience with the NESC. “By taking a dozen or 

so highly qualified individuals with different areas of expertise, we 

were able to provide some cross-cutting analysis for the Air Force 

that was helpful in finding the root cause, or rather the root causes, 

of this very complex issue.” Moreover, the experience gave

Dr. Bendrick new insights on NASA’s capabilities. “By working with 

the other team members at the NESC, not 

only did I learn a lot about other peoples’ 

work disciplines, but I realized that NASA 

has a tremendous resource here in the 

NESC that can be used to address all sorts 

of complex technical issues in the future.”

Aircraft Flight Control TDT

Training Development

Mr. John Burken is a DFRC engineer with 

over 36 years experience in control law 

design and a member of the Guidance, 

Navigation, and Control TDT. Mr. Burken 

developed a Fundamentals of Aircraft 

Flight Control Tutorial. This tutorial 

explores formal academic control theory 

and design implementation. This may help 

control designers to be more efficient and 

reduce the design cycle time. Mr. Burken 

stated, “All my work experience has been 

with atmospheric vehicles. Due to my 

interaction with the NESC, I have found it 

refreshing to work outside my ʻatmosphere’

and recognize the interesting challenges of 

spacecraft controls.” 

Dr. Timothy Krantz (left) and Richard Manco at the vacuum roller rig.

Dr. Gregg Bendrick, member of the NESC F-22

Assessment Team.

Mike Delaney, Chair of the PLD subcommunity of practice. John Burken reviewing his NESC Flight Control Tutorial.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Dr. James F. Stewart Dawn C. Emerson
38 39

Center Focus Center Focus

The Jet Propulsion Laboratory (JPL) 

participated in numerous NESC assessments 

and contributed to NASA Technical Fellows 

Technical Discipline Team (TDT) investigations. 

JPL engineers led the NESC’s Orion Crew 

Module Water Landing Modeling Assessment, 

with data and analyses being provided to the 

Orion Multi-Purpose Crew Vehicle Program and to the Commercial 

Crew Program providers to aid in their capsule recovery 

environment and modeling tools. The NESC Composite Pressure 

Vessel Working Group developed a test plan for stress rupture, 

based on needs identified in previous NESC assessments. JPL 

provided critical support to a number of NESC assessments, 

including software tools, battery usage in operational missions, 

and pyrovalve reliability. Technical assessments were completed 

for the Cassini Plasma Spectrometer instrument and for the Mars 

Science Laboratory aero/reaction control system interaction 

model validation and evaluation of hardware handling near misses. 

JPL is developing thermal protection system thermal performance 

and entry, descent, and landing (EDL) databases to gather and 

secure at-risk historical data. The JPL-led 

Robotics Operations TDT is working several 

tasks to advance robotic exploration and 

to look across disciplines and missions to 

understand and influence the current state 

of the discipline. 

Supporting the International 

Space Station

Mr. H. Q. Pham is the thermal team lead for 

the ISS Solar Array Wing Mast (Fast Mast) 

Shadowing Characterization Assessment. 

The goal of the test was to empirically assess 

the mast structural capability when exposed 

to expected nonuniform solar exposure, and 

to understand whether the ISS operational envelope can be safely 

expanded. 

The NESC team delivered the mast test article to JPL, set up the 

test article prior to thermal vacuum (TVAC) testing, conducted 

the TVAC test, and performed the post-thermal/structural test 

correlation to map test article temperatures to the structural 

model. Since the TVAC test, a thermal model correlation has been 

successfully completed. Mr. Pham indicated, “NESC provided 

me with a unique opportunity to support an inter-Agency project 

with colleagues from various NASA Centers and industries. This 

experience helped me to develop new skills that I can apply to 

future projects that involve diverse, multi-Center multidisciplinary 

teams working in fast-paced environments.”

Developing the EDL Repository

Ms. Elmain Martinez has been a JPL systems engineer and 

software developer for over 20 years. When the opportunity 

to work with the NESC as a team lead for an EDL repository 

project came available, she jumped at it. The team consisted of 

EDL experts, software developers, and information specialists to 

develop a NASA engineering archive for EDL 

data, models, diagrams, video/images, and 

other technical information. In parallel with 

the software effort, Ms. Martinez worked 

with the EDL experts to locate material from 

older missions. She worked with members 

of the EDL community, engineers, and 

records/library staff at a number of NASA 

Centers. In reflecting on her experience, 

Ms. Martinez stated, “Working with people 

from all over NASA has been an unmatched 

experience. In addition to learning about 

EDL and improving my leadership skills, the 

greatest reward was the team synergy and 

dedication. I would do it again.” 

The Goddard Space Flight Center (GSFC), 

including the Wallops Flight Facility, 

participated in a wide range of NESC activities. 

The NASA Technical Fellows for Avionics; 

Electrical Power; Guidance, Navigation, 

and Control (GNC); Mechanical Systems; 

and Software are resident at GSFC. GSFC 

personnel participated on Agency-wide teams to perform 

independent technical assessments and reviews and contributed 

technical expertise to programs, including the James Webb 

Space Telescope (JWST) Near-Infrared Spectrograph Microshutter; the JWST fine guider sensor motor; the Geostationary 

Operational Environmental Satellite – (GOES-R) series reaction 

wheels; the Hubble Space Telescope (HST) attitude observer; 

and the Cassini Plasma Spectrometer (CAPS) short investigation. 

NESC discipline activities that benefited GSFC projects included 

single-board computer producibility improvements; guidelines 

for the use of commercial off-the-shelf electrical, electronic, and 

electromechanical parts; green propellant research; and best 

practices for updating acoustics environments using flight data. 

PSpice Circuit Analysis for

CAPS Power System Short Circuits

Ms. Amri Hernandez-Pellerano, a power system electronics 

designer in the GSFC Power Systems Branch, is involved in the 

design and implementation of power system 

electronics for scientific spacecraft. When 

the CAPS instrument encountered multiple 

short circuits on the power system causing 

operations to be temporarily halted, the 

NESC was requested to provide technical 

expertise to determine root cause and the 

risk of returning the CAPS to service. Ms. 

Hernandez-Pellerano generated detailed 

PSpice circuit simulations of the CAPS lowvoltage power supply front-end interface to 

the radioisotope thermoelectric generatorbased power bus. The simulations aided in 

characterizing the short circuit conditions, 

which allowed the NESC team to identify tin whiskers as the 

proximate cause of the shorts. CAPS was reactivated to support 

the Enceladus flyby. Ms. Hernandez-Pellerano stated, “The NESC 

has provided me the opportunity to participate in investigation 

teams where there is an interaction of experts from other NASA 

Centers, industry, and academia.   It has been a tremendous 

experience to be part of and contribute in several investigations 

and assessments where there is an exchange of new perspectives, 

technical information, analysis methods, and opinions.  It has been 

an honor to collaborate with team members external to GSFC and 

expand interaction with in-house personnel.”

Analysis for Hubble Space Telescope

Gyro Attitude Observer Anomaly

Mr. David Mangus is a GSFC aerospace engineer with over 30 

years of experience in GNC systems and has been a member 

of the NESC GNC Technical Discipline Team since its inception. 

Mr. Mangus served on the NESC team 

that supported the HST Attitude Observer 

Anomaly (AOA) Review Board, where his 

knowledge of the HST attitude determination 

and control system provided indispensable 

technical insights into the origins and 

impacts of the HST AOA problem.

Mr. Mangus developed concepts for 

analyzing the HST gyro telemetry data to 

update the existing gyro reliability models 

and to provide guidance to the HST Flight 

Operations Team to best manage gyro 

resources. The HST team followed the

NESC recommendation to add open-loop anomaly compensation in the on-board flight software and is operating in

this mode using three of six gyros. The other three gyros are 

maintained in a standby mode to conserve their remaining life. 

The NESC continues to support the HST Program by updating 

gyroscope life predictions and by developing a multidisciplinary 

model of the gyroscope flex lead degradation physics.

Mr. Mangus stated, “Working with the NESC has been a major 

highlight of my career. Interacting with other Center engineers 

and teams on challenging assessments, and understanding

their methodology and capabilities, has greatly expanded my 

resources for future collaboration.” 

Elmain Martinez led the EDL repository 

development.

(Left to right) E. Sunada, D. Klein, and H. Pham 

reviewing ISS Fast Mast temperature predictions.

The NESC Fast Mast Test Team at JPL.

David

Mangus

Amri

HernandezPellerano

Illustration of Cassini spacecraft near Saturn.

Hubble Space Telescope on orbit.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Timothy G. Trenkle R. Lloyd Keith
40 41

Center Focus Center Focus

The NESC is involved in multiple activities 

and projects at the Kennedy Space Center 

(KSC). KSC continues to provide support 

and expertise to a wide variety of NESC 

assessments and testing. KSC engineers 

provided expertise on 12 NESC Technical 

Discipline Teams, including Electrical Power, 

Flight Mechanics, and Loads and Dynamics. The KSC expertise 

plays a role in resolving many of the Agency’s difficult problems, 

including SSC E-1 test stand blast effects and mitigation; 

Commercial Crew Program commercial off-the-shelf avionics parts 

usability, requirements, and verification development, certification 

framework, and landing gear consultation; Space Launch System 

Program shock testing; Orion crew module (CM) drogue parachute 

damping and CM landing and recovery support; NESC composite 

CM leak testing; Ground Systems Development and Operations 

Program system requirements review; Mars Science Laboratory 

ground processing; KSC’s Rocket U course development support; 

and KSC Visitor's Center Space Shuttle Program Atlantis orbiter 

static display structural assessment. 

Improving Safety of Human Spaceflight Programs

The NESC recognizes great value in mentoring junior-level 

engineers through direct involvement in complex, multidisciplinary 

issues within the Agency. Ms. Kelly Currin, formerly an aerospace 

engineer with the KSC Engineering Propulsion and Cryogenics 

Branch, was the lead test site engineer for the advanced 

exploration systems ground operations unit to demonstrate 

advanced liquid hydrogen loading and transfer concepts. With the 

NESC, she evaluated the Orion CM drogue parachute damping 

effects utilizing the Apollo legacy damping model, resulting in a 

technical paper presented at the American Institute of Aeronautics 

and Astronautics Applied Aerodynamics Conference. Ms. Currin 

performed tolerance analysis for the translation stage mechanism 

on the James Webb Space Telescope Near-Infrared Spectrograph 

Microshutter Subsystem. She was a member on the launch blast 

environments assessment, where she developed a database 

containing available launch vehicle accident and test program 

overpressure, impulse, fragmentation, and deflagration data. 

“The opportunity to participate in multiple assessment teams as 

a resident engineer with the NESC was the highlight of my career 

thus far with NASA. Specifically, the launch blast environments 

assessment has been incredibly rewarding in that I feel I am 

contributing to improving the safety of future human spaceflight 

programs.” Ms. Currin recently left NASA and is now employed by 

the Sierra Nevada Corporation.

Developing Advanced Flight Instrumentation

Mr. Peter Johnson is approaching 25 years since he was hired as 

part of KSC’s post-Challenger Space Shuttle Program return-toflight effort, working as the Flight Instrumentation Section lead. In 

support of the NESC, Mr. Johnson is the avionics lead for the Max 

Launch Abort System II (MLAS II) Project, balancing subsystem 

needs and performance requirements, and developing an avionics 

suite that meets these requirements. The prototype MLAS data 

acquisition avionics will be tested at the KSC electromagnetic 

interface and environmental labs. Mr. Johnson stated, “Honestly, 

I am always humbled by my experiences working with the NESC. 

The Smart Buyer Team, my first experience with the NESC, brought 

some of the finest, most creative NASA minds together. That team 

introduced me to the in-depth, technically based, rapid response 

approach that the NESC has become known for. Being able to 

draw from the industry, academia, and government triumvirate, 

working with the NESC gives me access to the most current 

technology, skills, processes, and, without a doubt, the finest 

minds in the country.”

Peter Johnson 

compares a 

proposed avionics 

box manufactured 

by Quad Tron for the 

MLAS II flight test 

vehicle (foreground) 

with the same three 

shuttle-era boxes it 

functionally replaces.

Kelly Currin was the structures lead on the Maraia Project at KSC.

The Johnson Space Center (JSC) and the 

White Sands Test Facility (WSTF) provided engineering analysis, design, and test expertise 

to a wide range of NESC activities in support 

of the International Space Station (ISS), development of the Orion Multi-Purpose Crew Vehicle (MPCV), and consultation for Commercial 

Crew Program vehicle developers. The NESC Deputy Director for 

Safety; a Principal Engineer; and the NASA Technical Fellows for 

Life Support/Active Thermal, Loads and Dynamics, and Passive 

Thermal are resident at JSC. JSC personnel provided expertise 

and leadership to numerous internal and external assessments 

such as an investigation into the U.S. Air Force’s F-22 fighter aircraft life support system. The JSC NASA Technical Fellows joined 

with other Agency discipline leaders to strengthen technical community connections through joint sponsorship and participation 

in activities such as the Thermal and Fluids Analysis Workshop; 

the Thermal and Environmental Control and Life Support Systems 

Steering Committee; and the Structures, Loads, and Mechanisms 

Steering Committee, including a Young Professionals Symposium. Finally, NESC personnel at JSC engaged in Standing Review Boards for the ISS Program, the ISS Stratospheric Aerosol 

and Gas Experiment III, the Materials on ISS Experiment–X, and 

the Human Research Program, and chaired 

Program Integration Reviews for the Earth 

System Science Pathfinder and Space Technology Programs.

WSTF Testing Support

Mr. Jon Haas has supported a number of 

NESC assessments during his 16-year WSTF 

career. Most recently, Mr. Haas is leading an 

ongoing project assessing stress rupture 

of composite overwrapped pressure vessels. He also participated in assessing the 

Air Force’s F-22 life support system where 

he contributed his experiences testing oxygen and life support system components for 

NASA spacecraft to the team studying the 

complex interactions inherent in the humanmachine interfaces of this advanced fighter 

jet. According to Mr. Haas, “Working alongside NASA Technical Fellows, Principal Engineers, and subject matter experts has been 

one of the great rewarding experiences of my career ... The diversity of perspective in approaching the most technically challenging 

problems NASA faces has given me a host of new tools to use 

every day.”

Orion MPCV Docking Mechanism

Jettison System Testing 

Mr. Scott Hacker is the pyrotechnics test group lead engineer 

in JSC’s Propulsion and Power Division’s Energy Systems Test 

Area, where he has worked for 20 years. This expertise led to his 

selection as the NESC technical lead pursuing design options and 

concept demonstration testing for pyrotechnic separation of the 

docking mechanism and the Orion crew module docking tunnel. 

According to Mr. Hacker, “The multi-Center project team brought 

a great wealth of experience ... It’s also exciting knowing that our 

conceptual design efforts may influence a part of the final Orion 

configuration.” Additionally, he “really enjoyed being part of a 

diverse, competent team and accomplishing such great, practical 

results. The seasoned engineers with decades of experience were 

invaluable, yet it was one of the least experienced members of 

our team that first suggested our final recommended solution. It’s 

always rewarding to see the different team member contributions 

combine into a final successful outcome.” 

ISS Life Support Systems 

Dr. Nigel Packham is the NESC Discipline 

Deputy for Life Support. Dr. Packham’s 

background in life support systems 

engineering for the NASA Space Shuttle, 

Space Shuttle-Mir, and the ISS Programs, 

coupled with his expertise in closedenvironment air and water life support 

systems, brings considerable experience 

to the NESC. Dr. Packham participated in 

two recent NESC assessments for the ISS:

a comparison of air quality monitoring 

systems to determine relative risk to the 

crew for potential trace contaminant 

exposure, and crew and system impacts 

due to potential corrosion and biological 

contaminant growth internal to prewetted 

environmental control and life support 

system replacement components stored on 

the ISS. 

Scott Hacker (foreground) reviews a successful 

test with MPCV Program Manager Mark Geyer 

(left) and two technicians (background, Rick Dean 

left, Nick Kidd right).

Dr. Nigel 

Packham 

examines a 

water sample 

returned from 

the ISS.

Jon Haas in the WSTF Carbon Overwrapped Pressure Vessel Pressurized Life Test Cell.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

T. Scott West Stephen A. Minute
42 43

Center Focus Center Focus

The Marshall Space Flight Center (MSFC) 

provided subject matter expertise from 

engineers, scientists, and technicians to over 

40 NESC assessments and investigations, 

and to 15 of the NESC Technical Discipline 

Teams. NESC studies involved areas of 

exploration systems, space operations, 

science, and crosscutting discipline activities. Some of

the more significant investigations included shell buckling 

knockdown factor testing, sounding rocket sustainer motor design 

and development, composite crew module permeability testing, 

shock-proof bearing development, spin forming of complex 

structures, composite pyroshock characterization, and engine 

combustion stability analysis. The NASA Technical Fellow for 

Propulsion is resident at MSFC. 

Increasing NASA Flight Measurement Capabilities

Dr. Jeremy Kenny, propulsion system fluid dynamics analyst, led 

the development of a prototype high-speed flight data acquisition 

avionics unit. Through the High Fidelity Data Acquisition (HiDAQ) 

Project, Dr. Kenny obtained invaluable experience through the 

coordination of engineering multi-Center support from MSFC, 

LaRC, and KSC in project requirements, design, and analysis 

maturation. Leading an applied development project provided 

the opportunity to increase project and engineering management skills, which are not typically exercised during fluid

dynamics analyses. “The NESC has given me a great opportunity 

to develop a data acquisition unit capable of supporting many 

different flight programs. Being the project lead has exposed me 

to the multiple aspects of flight hardware design, development, 

testing, and evaluation, as well as learning from an excellent

engineering team.” 

HiDAQ Project Thermal Design,

Analysis, and Testing

Ms. Callie McKelvey has been an aerospace engineer with 

the Thermal Analysis and Control Branch for the last 5 years.

Ms. McKelvey is participating in the HiDAQ Project through 

the design, analysis, and testing of its thermal control system. 

Ms. McKelvey generated a thermal model, including the 

chassis, boards, chips, heat spreaders, and aluminum chassis 

encapsulating epoxy. This model determined which components 

would benefit from a copper heat spreader and predicted internal 

box temperatures to the chip/component level. The model will 

be correlated to thermal cycle and thermal vacuum test results. 

Concerning her experience with the NESC, Ms. McKelvey stated, 

“The HiDAQ Project has allowed me the opportunity to work on a 

multi-Center project team, explore new modeling techniques and 

test flight hardware, and gain experience with data acquisition 

systems.  It has been an educational and rewarding experience for 

a young engineer. In addition to HiDAQ, I have had the pleasure 

of participating in several other NESC-sponsored opportunities, 

such as the Thermal and Fluids Analysis Workshop and the NASA 

Engineering Network. I hope to continue working with the NESC 

in the future.” 

Electromagnetic Environmental Effects Testing

Mr. Jonathan Mack, an electrical engineer, has been with NASA 

for 5 years.  Currently, he is supporting the NESC on the HiDAQ 

Project. Mr. Mack provided electromagnetic environmental effects 

requirements, design guidance for grounding, electrical bonding, 

and electromagnetic interference (EMI) testing.   He generated 

the test plan for the EMI portion of component environmental 

testing.  Mr. Mack stated, “Working with the NESC was a great 

experience.   I made several professional contacts both within 

MSFC and around the Agency.   Developmental projects like 

HiDAQ are always fun to work on. They give you an opportunity to 

think outside the box and innovate in the way you approach your 

requirements and design.” 

The Langley Research Center (LaRC) continues 

to support the NESC mission to address the 

Agency’s high-risk programs and projects. 

LaRC personnel have contributed technical 

expertise in the areas of structures; materials; 

nondestructive evaluation; flight sciences; 

fabrication technology; loads and dynamics; 

computational fluid dynamics; mechanisms; guidance, navigation, 

and control; flight mechanics; and avionics. Several of the NESC 

assessment activities at LaRC included material characterization 

of the Orion crew module (CM) launch abort system (LAS) attitude 

control motor (ACM) carbon-carbon silicon carbide (C/C-SiC) 

pintle design; autonomous aerobraking capability development; 

exploration systems independent modeling and simulation; 

and shell buckling knockdown factor development for largescale testing. LaRC is the host Center for the NESC Director's, 

Principal Engineers, Systems Engineering, and the Management 

and Technical Support Offices. The NASA Technical Fellows 

for Aerosciences, Flight Mechanics, Materials, Nondestructive 

Evaluation, and Structures are resident at LaRC. 

Orion CM LAS ACM C/C-SiC

Materials Characterization

Mr. Craig Ohlhorst and Dr. Wallace Vaughn are members of the 

NESC’s C/C-SiC Materials Characterization Team for the Orion CM 

LAS ACM pintle design. The overall investigation goal was to deliver 

mechanical properties test data to the modeling team to validate 

their material models. Special test specimens were fabricated to 

simulate the ACM pintle and the pintle guide features. To help 

characterize the material failure using x-ray computed tomography 

(CT), acoustic emission, and Vic-3D (digital image correlation), 

measurements were made before, during, and after mechanical 

testing. Dr. Vaughn was responsible for developing the combined 

CT and cantilever beam test fixture, which allowed the three-point 

bend test coupon to be under load during the CT scan. This should 

allow for improved C/C-SiC crack imaging. Mr. Ohlhorst indicated, 

“Working in coordination with the nondestructive evaluation and 

modeling teams has been a great experience.” 

Exploration Systems Independent

Modeling and Simulation

Mr. Brett Starr, Mr. Frank Vause, Dr. James Beaty, and Mr. Paul 

Tartabini, members of NESC’s Independent Modeling and 

Simulation Team, are developing trajectory-based loads models for 

the Space Launch System (SLS) as part of an NESC independent 

verification assessment. This systems approach to predicting 

flight loads couples structural analysis and trajectory modeling 

to provide load estimates that will be more comprehensive and 

accurate than conventional load indicators like q-alpha (product 

of dynamic pressure and angle of attack). Linking the trajectory 

simulation to the structural analysis process makes it possible for 

the distributed vehicle aerodynamic, inertial, and propulsion forces 

at each time point along the trajectory to be fed into the structural 

force and moment solver. The multidisciplinary process can be 

readily implemented in SLS ascent trajectory Monte Carlo analyses 

to establish expected vehicle load limits. “Trajectory-based loads 

models were used successfully throughout the Ares I-X Project,” 

explained Mr. Starr, “it makes sense to apply them to SLS.” 

Orion CM High Altitude Parachute

System Deployment Analysis

Mr. Jeremy Shidner, an aerospace engineer in the LaRC Atmospheric 

Flight and Entry Systems Branch, is a member of the NESC team 

analyzing the likelihood of high altitude instability of the Orion 

CM resulting in the need for a contingency 

parachute deployment. Mr. Shidner 

advised the NESC on the complexities of 

parachute simulation in dynamic unknown 

environments by modeling the expected 

wind environments. Results from the 

evaluation helped identify greater instability 

rates leading to CM tumbling than were 

initially predicted by the Orion Multi-Purpose 

Crew Vehicle Program. “The experience of 

working with the best parachute experts in 

the world to answer the questions raised 

here has been awesome. It really opened my eyes to the reality 

of the demand we place on parachute systems, and the amazing 

engineering NASA uses to meet that demand.” 

(From left) Frank Vause, Brett Starr, Paul Tartabini, and Dr. James Beaty.

Dr. Wallace Vaughn (left) and Craig Ohlhorst. 

 Dr. Jeremy Kenny examines a ruggedized sensor for the HiDAQ.

Callie McKelvey developed the HiDAQ thermal model. Jonathan Mack developed EMI design guidance for the HiDAQ.

Jeremy Shidner

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Walter C. Engelund Steven J. Gentz
44

Center Focus

The Stennis Space Center (SSC) provided 

expert technical support to the NESC, 

including the E-1 Test Facility Blast/Acoustic 

Effect Mitigation Tools Assessment and the 

Cryogenic Propellant Storage and Transfer 

(CPST) Project Mission Concept Review (MCR) 

Board. SSC has members on several NESC 

Technical Discipline Teams. The NESC provided computational 

fluid dynamics (CFD) and blast mitigation expertise for the E-1 

facility. The NESC was requested to develop analytical/empirical 

tools and techniques to characterize potential blast/acoustic 

environments from a test article in one cell, and determine 

mitigation designs/techniques to reduce or control those effects on 

a test article in an adjacent cell. The E-1 was conceived as a threecell multiuser test facility for rocket components. Over time, E-1 

evolved to testing large thrust chambers, engine systems, and large 

engines, which negated many of the original design protections 

for blast/fragmentation. SSC’s ability to accommodate multiple 

simultaneous E-1 tenants is critical to the Agency’s multifaceted 

approach to space access, with concurrent development of 

commercial and Space Launch System engine systems. NESC 

activities utilized the capabilities of SSC’s Engineering and Test 

Directorate personnel and its unique facilities.

E-1 Test Facility Analysis

Dr. Danny Allgood, an SSC CFD expert, developed E-1 blast 

and overpressure predictions. His assignment to the NESC 

assessment has been invaluable. Dr. Allgood stated, “Although I 

had a background in modeling propellant detonations, this project 

has allowed me the unique experience of modeling blast waves 

from solid explosives on a very large scale. In working with the 

NESC, SSC had the opportunity to gain valuable exposure to the 

complexity of modeling and mitigating the overpressure issues 

at the E-1 stand.   Before this project was brought to light, the 

Agency as a whole did not have the documented knowledge of 

how to model the overpressure hazards that existed during test 

or launch.  By the NESC pulling together the necessary technical 

expertise,  a validated capability in modeling was demonstrated. 

As a result, safety in NASA’s rocket testing and launch programs 

will be improved for the future.”

Mr. Tom Meredith, E-1 Chief Engineer, focused on blast mitigation 

tools/techniques. His participation was critical with potential 

mitigation materials and coordinating facility blast testing.

Mr. Meredith stated, “This study should prove to be beneficial to 

the Agency in keeping E-1 a multicell, multicustomer test facility

for government or privately funded rocket test customers,” and 

“the NESC will benefit from this project from the setting up of a real 

field experiment that will provide data with different overpressure 

sources throughout the facility to map out the reflective waves of 

E-1 and to show how those waves may affect other test articles in 

the facility. This project will provide a real-world situation to gather 

data to compare the real world data with model data.” 

Cryogenic Propellant Storage

and Transfer Review

The NESC was requested to provide a CPST Project Technology 

Demonstration MCR representative. Mr. David Coote was selected 

due to his experience and expertise. Mr. Coote stated, “SSC has 

a fairly comprehensive range of competencies and experience in 

analysis, design, and operations of cryogenic propellant storage 

and transfer systems that we regularly exercise on seven distinct 

and active test areas supporting NASA, DoD, and commercial 

propulsion systems development and test programs. Working 

with the NESC, SSC had an opportunity to share our technical 

competencies and experience to an area that extends beyond our 

mission of propulsion system testing. The Agency benefits by 

having a focal point for projects to solicit specific expertise they 

either don’t have readily available or need more of, and works to 

optimize use of Agency resources.” 

Tom Meredith (left) and Dr. Danny Allgood examine blast mitigation materials at 

the E-1 Test Facility.

David Coote reviewing cryogenic propellant storage and transfer concepts.

The composite crew module full-scale 

pressure vessel test article being

readied for a vacuum test at MSFC.

NESC TECHNICAL UPDATE 2012

Biographies

Pages 44-47

Alumni

Page 48

Awards & Recognition

Page 49

Publications

Pages 50-51

Michael D. Smiles
46 47

Biographies Biographies

Clinton H. Cragg 

NESC Principal Engineer 

Mr. Clinton H. Cragg is a Principal Engineer with the NESC 

at Langley Research Center. Mr. Cragg came to the NESC 

after retiring from the U.S. Navy. Mr. Cragg served as the 

Commanding Officer of the U.S.S. Ohio and later as the Chief of 

Current Operations, U.S. European Command. Mr. Cragg has over 34 years of 

experience in supervision, command, and ship-borne nuclear safety.

Dr. Nancy J. Currie

NESC Principal Engineer

Dr. Nancy J. Currie is a Principal Engineer with the NESC and 

is resident at Johnson Space Center (JSC). Dr. Currie was 

formerly the NESC Chief Engineer at JSC. Dr. Currie came to 

the NESC from, where she served as the Deputy Director of the 

Engineering Directorate. Dr. Currie has over 23 years of experience in robotics 

and human factors engineering. Selected as an astronaut in 1990, Dr. Currie is 

a veteran of four space shuttle missions and has accrued 1000 hours in space.

Dr. Michael G. Gilbert

NESC Principal Engineer

Dr. Michael G. Gilbert is a Principal Engineer with the NESC at 

Langley Research Center (LaRC). Dr. Gilbert was formerly the 

NESC Chief Engineer at LaRC. Before joining the NESC, he 

was Head of the LaRC Systems Management Office. Dr. Gilbert 

has over 34 years of engineering, research, and management experience with 

aircraft, missile, spacecraft, Space Shuttle, and International Space Station 

Programs.

Michael T. Kirsch

NESC Principal Engineer

Mr. Michael T. Kirsch is a Principal Engineer with the NESC 

at Langley Research Center. Mr. Kirsch joined the NESC 

from NASA’s White Sands Test Facility, where he served as 

the Deputy Manager responsible for planning and directing 

developmental and operational tests of spacecraft propulsion systems and 

related subsystems. Mr. Kirsch has over 23 years of experience in managing 

projects and test facilities.

NESC Chief Engineers

Dawn C. Emerson

NESC Chief Engineer

Ms. Dawn C. Emerson is the NESC’s Chief Engineer at Glenn 

Research Center (GRC). Ms. Emerson came to the NESC from 

GRC, where she most recently served as the Deputy Project 

Manager during formulation of the Solar Electric Propulsion 

Flight Demonstration Project. Ms. Emerson has over 27 years of management 

and technical experience with NASA and private industry.

Walter C. Engelund

NESC Chief Engineer 

Mr. Walter C. Engelund is the NESC’s Chief Engineer at Langley 

Research Center (LaRC). Mr. Engelund came to the NESC from 

LaRC, where he served as the Head of the Atmospheric Flight 

and Entry Systems Branch. Mr. Engelund has over 23 years of 

experience as a recognized expert in launch and entry vehicle aerodynamics, 

atmospheric flight dynamics, and hypersonic flight systems.

Steven J. Gentz

NESC Chief Engineer

Mr. Steven J. Gentz is the NESC’s Chief Engineer at Marshall 

Space Flight Center. Mr. Gentz was formerly a Principal 

Engineer with the NESC at Langley Research Center.

Mr. Gentz has over 29 years of experience involving numerous 

NASA, Department of Defense, and industry failure analyses and incident

investigations, including Challenger, Columbia, Tethered Satellite System, and 

the TWA 800 Accident Investigations.

R. Lloyd Keith

NESC Chief Engineer 

Mr. R. Lloyd Keith is the NESC’s Chief Engineer, as well as 

support and backup for the Center Chief Engineer, at the Jet 

Propulsion Laboratory. Mr. Keith has over 35 years of experience 

working in both technical and managerial positions. Mr. Keith 

has supported a number of flight projects, including the Mars Pathfinder 

Project, SeaWinds, Stardust, Mars ’98, New Millennium Deep Space 1, and the 

Flight Hardware Logistics Program. 

Nans Kunz

NESC Chief Engineer 

Mr. Nans Kunz is the NESC’s Chief Engineer at Ames Research 

Center (ARC). Mr. Kunz came to the NESC from the Systems 

Engineering Division at ARC. Mr. Kunz has over 34 years of 

engineering experience leading and managing NASA programs 

and projects, including serving as the Chief Engineer of the Stratospheric

Observatory For Infrared Astronomy (SOFIA) Project.

Stephen A. Minute 

NESC Chief Engineer

Mr. Stephen A. Minute is the NESC’s Chief Engineer at 

Kennedy Space Center (KSC). Mr. Minute came to the NESC 

from KSC, where he served as the Chief of the Space Shuttle 

Safety, Quality, and Mission Assurance Division. Mr. Minute 

has over 28 years of engineering and management experience in the Space 

Shuttle and International Space Station Programs.

Michael D. Smiles

NESC Chief Engineer

Mr. Michael D. Smiles is the NESC’s Chief Engineer at Stennis 

Space Center (SSC). Mr. Smiles joined the NESC from SSC, 

where he served as the Safety and Mission Assurance (S&MA) 

Manager. Mr. Smiles has over 27 years of management and 

technical experience with NASA at SSC and Marshall Space Flight Center. 

Dr. James F. Stewart

NESC Chief Engineer

Dr. James F. Stewart is the NESC’s Chief Engineer at 

Dryden Flight Research Center (DFRC). Dr. Stewart joined 

the NESC from DFRC, where he served as the Dryden

Exploration Mission Director. Dr. Stewart has over 46 years 

of management and technical experience leading missile and aircraft

programs.

Ralph R. Roe, Jr.

NESC Director

Mr. Ralph R. Roe, Jr. is the NESC’s Director at Langley Research 

Center. Mr. Roe has over 29 years of experience in human 

spaceflight program management, technical management, and 

test engineering. Mr. Roe previously held several key positions 

in the Space Shuttle Program, including Vehicle Engineering Manager, Launch 

Director, and Kennedy Space Center Engineering Director.

Timmy R. Wilson

NESC Deputy Director

Mr. Timmy R. Wilson is the NESC’s Deputy Director at

Langley Research Center. Mr. Wilson was formerly the

NESC’s Chief Engineer at Kennedy Space Center (KSC). Prior 

to joining the NESC, Mr. Wilson served as Deputy Chief Engineer 

for Space Shuttle Processing at KSC. Mr. Wilson has over 31 years of engineering and management experience supporting the Space Shuttle Program.

Michael P. Blythe

NESC Deputy Director for Safety

Mr. Michael P. Blythe is the NESC’s Deputy Director for Safety 

and is resident at Johnson Space Center. Prior to joining the 

NESC, Mr. Blythe served as the Acting Assistant Associate 

Administrator in the Office of the Administrator at NASA 

Headquarters. Mr. Blythe came to the Office of the Administrator from the Office 

of Chief Engineer, where he served as the Director for the Engineering and 

Program/Project Management Division. In this capacity, he was responsible 

for establishing and implementing Agency engineering and program/project 

management policy, procedures, and processes to improve the efficiency and 

success of NASA’s investments.

Dawn M. Schaible

Manager, Systems Engineering Office

Ms. Dawn M. Schaible is Manager of the NESC’s Systems

Engineering Office at Langley Research Center. Prior to 

joining the NESC, Ms. Schaible worked in the International 

Space Station/Payload Processing Directorate at Kennedy 

Space Center. Ms. Schaible has over 25 years of experience in systems

engineering, integration, and ground processing for the Space Shuttle and 

International Space Station Programs.

Daniel J. Tenney

Manager, Management and

Technical Support Office 

Mr. Daniel J. Tenney is Manager of the NESC’s Management and 

Technical Support Office at Langley Research Center (LaRC). 

Prior to joining the NESC, Mr. Tenney served as the Deputy Chief 

Financial Officer for Systems at LaRC, where he managed over 30 information 

systems. Mr. Tenney has 23 years of professional financial, accounting, and 

systems experience at NASA.

Patrick G. Forrester

NESC Chief Astronaut

Mr. Patrick G. Forrester is the NESC’s Chief Astronaut and 

is resident at Johnson Space Center. Mr. Forrester began 

his NASA career in 1993 after serving in the U.S. Army.

As a Master Army Aviator, he logged over 4800 hours in over 50 

different aircraft. He was selected as an astronaut candidate in 1996 and flew 

on STS-105 (2001), STS-117 (2007), and STS-128 (2009). He has logged over 

950 hours in space, including four spacewalks totaling 25 hours and 22 minutes 

of extra vehicular activity time. 

Dr. Daniel Winterhalter 

Chief Scientist

Dr. Daniel Winterhalter is the NESC’s Chief Scientist and is 

resident at Jet Propulsion Laboratory (JPL). Dr. Winterhalter 

has over 34 years of experience as a research scientist at JPL. 

His research interests include the spatial evolution of the solar 

wind into the outer reaches of the heliosphere, as well as its interaction with 

and influence on planetary environments. In addition, as a member of several 

flight teams, he has been intimately involved with the planning, launching, and 

operation of complex spacecraft and space science missions. 

Wayne R. Frazier 

NASA Headquarters Senior

SMA Integration Manager 

Mr. Wayne R. Frazier currently serves as Senior Safety and 

Mission Assurance Manager in the Office of Safety and Mission 

Assurance (OSMA), where he is assigned as the Liaison Officer 

to the NESC, the Office of the Chief Engineer, the Software Independent 

Verification and Validation Facility in West Virginia, and other remote activities 

of OSMA. He was formerly Manager of System Safety in the OSMA at NASA 

Headquarters and has over 37 years of experience in system safety, propulsion 

and explosive safety, mishap investigation, range safety, pressure systems, 

crane safety, and orbital debris mitigation.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Continued next page

Core Leadership Team NESC Principal Engineers

NASA Headquarters Liaison
48 49

Biographies Biographies

Dr. William H. Prosser

NASA Technical Fellow

Dr. William H. Prosser is the NASA Technical Fellow for 

Nondestructive Evaluation and is resident at Langley 

Research Center (LaRC). Dr. Prosser joined the NESC from 

the Nondestructive Evaluation Sciences Branch at LaRC.

Dr. Prosser has over 25 years of experience in the field of ultrasonic and 

acoustic emission sensing techniques.

Dr. Ivatury S. Raju

NASA Technical Fellow

Dr. Ivatury S. Raju is the NASA Technical Fellow for Structures 

and is resident at Langley Research Center (LaRC). Dr. Raju 

was the Senior Technologist in the LaRC Structures and 

Materials Competency prior to joining the NESC. Dr. Raju 

has over 37 years of experience in structures, structural mechanics, and

structural integrity.

Steven L. Rickman

NASA Technical Fellow

Mr. Steven L. Rickman is the NASA Technical Fellow for Passive 

Thermal and is resident at Johnson Space Center (JSC).

Mr. Rickman joined the NESC from JSC’s Thermal Design 

Branch, where he served as the Chief. Mr. Rickman has over 

27 years of management and technical experience in passive thermal control.

Henry A. Rotter

NASA Technical Fellow

Mr. Henry (Hank) A. Rotter is the NASA Technical Fellow for 

Life Support/Active Thermal and is resident at Johnson Space 

Center (JSC). Mr. Rotter joined the NESC from the JSC Crew 

and Thermal Systems Division and the Space Launch Initiative 

Program, where he was Engineering Manager and the Orbital Space Plane

Team Leader for life support and active thermal control teams. Mr. Rotter has 

over 45 years of life support and active thermal control systems experience 

during the Apollo, Space Shuttle, and Orbital Space Plane Programs.

Dr. David M. Schuster

NASA Technical Fellow

Dr. David M. Schuster is the NASA Technical Fellow for 

Aerosciences and is resident at Langley Research Center. 

Prior to joining the NESC, Dr. Schuster was the Branch 

Head for the Structural and Thermal Systems Branch

in the Systems Engineering Directorate. Dr. Schuster has over 34 years of 

experience in the aerospace industry with expertise in aeroelasticity and 

integrated aerodynamic analysis.

Denney Keys, NASA Technical Fellow 

for Electrical Power, passed away

in December 2012.

Our friend and colleague will be greatly 

missed and he will be remembered for 

his significant contributions to the

Goddard Space Flight Center,

the NESC, and NASA.

NASA Technical Fellows

Michael L. Aguilar

NASA Technical Fellow

Mr. Michael L. Aguilar is the NASA Technical Fellow for Software and is resident at Goddard Space Flight Center (GSFC). 

Mr. Aguilar joined the NESC from GSFC, where he served

as the James Webb Space Telescope (JWST) Instrument

Software Manager. Mr. Aguilar has over 36 years of experience on embedded 

software development.

Cornelius J. Dennehy

NASA Technical Fellow

Mr. Cornelius J. Dennehy is the NASA Technical Fellow for 

Guidance, Navigation, and Control (GNC) and is resident at 

Goddard Space Flight Center (GSFC). Mr. Dennehy came to 

the NESC from the Mission Engineering and Systems Analysis Division at GSFC, where he served as the Division’s Assistant Chief for 

Technology. Mr. Dennehy has over 32 years of experience in the architecture, 

design, development, integration, and operation of GNC systems, and space 

platforms for communications, defense, remote sensing, and scientific mission 

applications.

Roberto Garcia

NASA Technical Fellow

Mr. Roberto Garcia is the NASA Technical Fellow for

Propulsion and is resident at Marshall Space Flight Center.

Mr. Garcia came to the NESC from the Solid Propulsion

Systems Division, where he served as Division Chief.

Mr. Garcia has over 21 years of experience in performing aerodynamic, hydrodynamic, and engine system design and analysis of rocket propulsion.

Oscar Gonzalez

NASA Technical Fellow

Mr. Oscar Gonzalez is the NASA Technical Fellow for Avionics and is resident at Goddard Space Flight Center (GSFC).

Mr. Gonzalez came to the NESC from GSFC, where he served 

as the International Space Station/Express Logistic Carrier 

Avionics Systems Manager. Mr. Gonzalez has over 34 years of NASA and

private industry experience where he has held a variety of critical leadership roles in power electronics, electrical systems, instrument systems, and

avionics systems. 

Denney J. Keys

NASA Technical Fellow

Mr. Denney J. Keys is the NASA Technical Fellow for

Electrical Power and is resident at Goddard Space Flight

Center (GSFC). Mr. Keys served as the Lead Power Systems

Engineer in the Power Systems Branch at GSFC before

joining the NESC. Mr. Keys has over 32 years of private industry and NASA 

experience with electrical power systems.

Dr. Curtis E. Larsen

NASA Technical Fellow

Dr. Curtis E. Larsen is the NASA Technical Fellow for Loads 

and Dynamics and is resident at Johnson Space Center.

Prior to joining the NESC, Dr. Larsen was the Technical

Discipline Manager for Cargo Integration Structures in the

Space Shuttle Program’s Flight Operations and Integration Office.

Dr. Larsen has over 32 years of engineering experience with expertise in

stochastic structural dynamics, structural safety, and probabilistic

engineering applications.

Daniel G. Murri

NASA Technical Fellow

Mr. Daniel G. Murri is the NASA Technical Fellow for Flight

Mechanics and is resident at Langley Research Center (LaRC). 

Mr. Murri served as Head of the Flight Dynamics Branch 

at LaRC before joining the NESC. He has over 31 years of

engineering experience conducting numerous wind-tunnel, simulation,

light-test, and theoretical studies in the exploration of new technology

concepts and in support of aircraft development programs.

Dr. Cynthia H. Null

NASA Technical Fellow

Dr. Cynthia H. Null is the NASA Technical Fellow for Human 

Factors and is resident at Ames Research Center. Before joining the NESC, Dr. Null was a scientist in the Human Factors 

Division and Deputy Program Manager of the Space Human 

Factors Engineering Project. Dr. Null has 26 years of experience lecturing on 

Human Factors, and another 20 years of experience in Human Factors applied 

to NASA programs.

Joseph W. Pellicciotti

NASA Technical Fellow

Mr. Joseph W. Pellicciotti is the NASA Technical Fellow for 

Mechanical Systems and is resident at Goddard Space Flight 

Center (GSFC). Mr. Pellicciotti served as the Chief Engineer 

for the GSFC Mechanical Systems Division before joining 

the NESC. Mr. Pellicciotti has over 24 years of combined private industry 

and NASA experience designing structure and mechanisms for commercial, 

military, and civil spacecraft.

Dr. Robert S. Piascik

NASA Technical Fellow

Dr. Robert S. Piascik is the NASA Technical Fellow for

Materials and is resident at Langley Research Center (LaRC). 

Dr. Piascik joined the NESC from the LaRC Mechanics of 

Materials Branch and the Metals and Thermal Structures 

Branch, where he served as a Senior Materials Scientist. Dr. Piascik has over 

28 years experience in the commercial nuclear power industry and over 

19 years of experience in basic and applied materials research for several

NASA programs.

Timothy G. Trenkle

NESC Chief Engineer

Mr. Timothy G. Trenkle is the NESC’s Chief Engineer at

Goddard Space Flight Center (GSFC). Mr. Trenkle joined

the NESC from GSFC, where he has over 20 years of

technical experience serving as the technical lead for a

number of flight programs and technical assignments, including serving

as the Chief Engineer for the National Polar-orbiting Operational Environmental Satellite System (NPOESS) Preparatory Project (NPP).

T. Scott West

NESC Chief Engineer

Mr. T. Scott West is the NESC’s Chief Engineer at Johnson 

Space Center (JSC). Mr. West came to the NESC from the 

Loads and Structural Dynamics Branch at JSC where he served 

as the Branch Chief. Mr. West has over 21 years of technical 

and management experience with Space Shuttle, International Space Station, 

Multi-Purpose Crew Vehicle and Exploration projects with NASA and private 

industry.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

NESC Chief Engineers Continued NASA Technical Fellows Continued

Continued next page
50 51

Alumni Awards & Recognition

NESC Leadership Award

Honors individuals who have had a pronounced 

effect upon the technical activities of the NESC

Scott P. Cryan In recognition of outstanding technical leadership and rendezvous sensor

expertise in the performance of the LIDAR Relative Navigation Rendezvous Sensor Detailed Test 

Objective Performance Evaluation Assessment

Elmain M. Martinez In recognition of outstanding leadership and technical competence in

designing and building the first NASA-wide Entry, 

Descent, and Landing database

Peter A. Parker In recognition of outstanding technical leadership and project execution in 

the performance of the LIDAR Relative Navigation Rendezvous Sensor Detailed Test Objective

Performance Evaluation Assessment

Jill L. Prince In recognition of outstanding technical leadership of the successful autonomous 

aerobraking feasibility study 

NESC Engineering

Excellence Award

Honors individual accomplishments of NESC jobrelated tasks of such magnitude and merit as to 

deserve special recognition

John C. Anderson In recognition of engineering excellence in support of the NESC Pyrovalve

Reliability Expendable Launch Vehicle Payloads 

Assessment

James M. Blackwood In recognition of engineering excellence in researching, evaluating,

analyzing, and disseminating near-pad historical launch vehicle accident blast environments to

improve safety system design and crew

survivability for NASA Human Space Flight

Programs

Robert R. Graber In recognition of engineering excellence and leadership in the application 

of a logical framework for assessing risk for the 

Pyrovalve Reliability Expendable Launch Vehicle

Payloads Assessment

Karen M. McNamara In recognition of engineering excellence in support of the NESC International Standards Organization Technology 

Readiness Level Standard Assessment

Jay L. Perry In recognition of engineering

excellence in support of the NESC International Space Station Air Quality Monitoring

System Assessment

Russell A. Wincheski In recognition of

engineering excellence in the examination

of manufacturing defects and stress corrosion 

cracking associated with the Antares II vehicle 

Aerojet AJ-26 engines

Robert J. Wingate In recognition of engineering excellence for outstanding contributions to 

the NESC Structures and Mechanical Systems 

Technical Discipline Teams in the development of 

the NASA Requirements for Threaded Fastening

Systems in Spaceflight Hardware Standard

James M. Womack In recognition of engineering excellence in developing test plans and 

providing test data analyses for evaluating and

optimizing a fine water mist portable fire

extinguisher for the International Space Station and 

other crewed spacecraft

NESC Administrative 

Excellence Award

Honors individual accomplishments or contributions that contributed substantially to support 

NESC’s mission

Sherry Y. Erskine In recognition of exemplary 

performance and sustained, dedicated support 

to the NASA Engineering and Safety Center as the 

Business Point of Contact for the Marshall Space 

Flight Center

Erin Moran In recognition of sustained and 

exemplary technical writing and leadership support 

through disciplined attention to organizational 

processes and methodical organizational skills in 

the documentation of NESC products

NESC Group Achievement Award

Honors a group of employees comprised of 

government and non-government personnel 

for outstanding accomplishment through the 

coordination of individual efforts that have 

contributed substantially to the accomplishment 

of the NESC’s mission

Commercial Crew Electrical, Electronic and 

Electromechanical Parts Study Team

In recognition of outstanding support to the 

NESC in establishing technical guidelines for safe, 

reliable, and cost-effective electrical, electronic, 

and electromechanical parts management activities 

for the Commercial Crew Program

NASA Engineering and Safety

Center Academy Team

In recognition of outstanding support of NESC 

knowledge capture and transfer through 

implementation of the NESC Academy online 

learning system

NASA Engineering and Safety Center Entry, 

Descent, and Landing Repository Team

In recognition of outstanding contributions to design 

and build the first NASA-wide Entry, Descent, and 

Landing database

F-22 Life Support System

Independent Analysis Team

In recognition of outstanding contributions in

support of the F-22 Life Support System 

independent analysis activity

NESC Honor Award Recipients for 2012 

Frank H. Bauer

NESC Discipline Expert for Guidance, Navigation, and Control 

(2003 – 04) Left the NESC to 

become the Exploration Systems 

Mission Directorate Chief Engineer 

at NASA HQ and has since retired

Dr. Charles J. Camarda

NESC Deputy Director for Advanced Projects (2006 – 09) Left the 

NESC to become Senior Advisor 

for Innovation in the Office of the 

Chief Engineer at NASA

Headquarters

Kenneth D. Cameron

NESC Deputy Director for Safety 

(2005 – 08) Left the NESC to accept 

a position with Northrop Grumman

Steven F. Cash

NESC Chief Engineer at Marshall Space Flight Center (MSFC) 

(2005) Left the NESC to become 

the Manager, Shuttle Propulsion 

Office at MSFC

Derrick J. Cheston

NESC Chief Engineer at 

Glenn Research Center (GRC) 

(2003 – 07) Left the NESC to 

participate in the Senior Executive 

Service Candidate Development 

Program and then returned to GRC 

as the Chief of the Mechanical and 

Fluid Systems Division

J. Larry Crawford

NESC Deputy Director for 

Safety (2003 – 04) Left the NESC 

to become Director of Safety and 

Mission Assurance at the Kennedy 

Space Center and has since retired

Mitchell L. Davis

NASA Technical Fellow for Avionics (2007 – 09) Left the NESC to become the Chief Avionics Systems 

Engineer in the Electrical Engineering Division at Goddard Space 

Flight Center

Dennis B. Dillman

NESC Chief Engineer at NASA 

Headquarters (HQ) (2005 – 08) Left 

the NESC to join the Science Mission Directorate at NASA HQ

Freddie Douglas, III

NESC Chief Engineer at Stennis 

Space Center (SSC) (2007 – 08) Left 

the NESC to become Manager, 

Office of Safety and Mission Assurance at SSC

Patricia L. Dunnington

Manager, Management and Technical Support Office (2006 – 08) 

Retired

Dr. Michael S. Freeman

NESC Chief Engineer at Ames Research Center (2003 – 04) Retired

T. Randy Galloway

NESC Chief Engineer at

Stennis Space Center (SSC) 

(2003 – 04) Currently the Director

of the Engineering and Test

Directorate at SSC

Dr. Edward R. Generazio

NESC Discipline Expert for Nondestructive Evaluation (2003 – 05) 

Left the NESC to become a Senior 

Research Engineer, Research 

Directorate, Langley Research 

Center

Dr. Richard J. Gilbrech

NESC Deputy Director 

(2003 – 05) Currently the Center 

Director at Stennis Space Center

Michael Hagopian

NESC Chief Engineer at Goddard Space Flight Center (GSFC) 

(2003 – 07) Left the NESC to 

become the Chief Engineer in the 

Engineering Directorate at GSFC 

and has since left NASA to accept a position with Sigma Space 

Corporation

David A. Hamilton

NESC Chief Engineer at Johnson 

Space Center (2003 – 07) Retired

Dr. Charles E. Harris

NESC Principal Engineer 

(2003 – 06) Currently the Director, 

Research Directorate, Langley 

Research Center

Dr. Steven A. Hawley

NESC Chief Astronaut (2003 – 04) 

Left the NESC to become the 

Director of Astromaterials Research and Exploration Science

at Johnson Space Center

and has since retired

Marc S. Hollander

Manager, Management and Technical Support Office (2005 – 06) Left 

the NESC to accept a position as 

the Associate Director for Management, National Institutes of Health

George D. Hopson

NASA Technical Fellow for

Propulsion (2003 – 07) Retired

Keith L. Hudkins

NASA Headquarters Office of the 

Chief Engineer Representative 

(2003 – 07) Retired

Danny D. Johnston

NESC Chief Engineer at Marshall Space Flight Center (MSFC) 

(2003 – 04) Left the NESC to work 

a detailed assignment at MSFC in 

the NASA Chief Engineer’s Office 

and has since retired

Michael W. Kehoe

NESC Chief Engineer at Dryden 

Flight Research Center (DFRC) 

(2003 – 05) Left the NESC to 

become the DFRC Liaison in the 

Crew Exploration Vehicle Flight 

Test Office at Johnson Space 

Center and has since retired

Robert A. Kichak

NESC Discipline Expert for Power 

and Avionics (2003 – 07) Retired

Dr. Dean A. Kontinos

NESC Chief Engineer at Ames 

Research Center (ARC) (2006 – 07) 

Left the NESC to work a detailed 

assignment as the Technical 

Integration Manager of the Fundamental Aeronautics Program in 

the Aeronautics Research Mission 

Directorate at NASA HQ and has 

since returned to ARC in the Office 

of the Chief Engineer

Julie A. Kramer White

NESC Discipline Expert for

Mechanical Analysis (2003 – 06)

Currently the Chief Engineer,

Multi-Purpose Crew Vehicle Program at Johnson Space Center

Steven G. Labbe

NESC Discipline Expert for Flight 

Sciences (2003 – 06) Currently 

the Chief, Aeroscience and Flight 

Mechanics Division at Johnson 

Space Center

Matthew R. Landano

NESC Chief Engineer at Jet 

Propulsion Laboratory (JPL) 

(2003 – 04)  Returned to his

assignment at JPL as the Director 

of Office of Safety and Mission 

Success

David S. Leckrone

NESC Chief Scientist (2003 – 06) 

Left the NESC to become the 

Senior Project Scientist for the 

Hubble Space Telescope at

Goddard Space Flight Center

and has since retired

Richard T. Manella

NESC Chief Engineer at Glenn 

Research Center (GRC) (2009 – 10) 

Left the NESC to become the GRC 

Chief Engineer

John P. McManamen

NASA Technical Fellow for

Mechanical Systems (2003 – 07) 

Currently the Deputy Chief

Engineer, Commercial Crew

Program at Johnson Space Center

Brian K. Muirhead

NESC Chief Engineer at Jet Propulsion Laboratory (JPL) (2005 – 07) 

Returned to his assignment as the 

JPL Chief Engineer 

Dr. Paul M. Munafo

NESC Deputy Director (2003 – 04) 

Left the NESC to become the

Assistant Director for Safety and 

Engineering at Marshall Space 

Flight Center and has since retired

Stan C. Newberry

Manager of the NESC’s Management and Technical Support Office 

(2003 – 04) Left the NESC to

become the Deputy Center Director at Ames Research Center and 

has since left NASA to accept a 

position at DoD

Dr. Tina L. Panontin

NESC Chief Engineer at 

Ames Research Center (ARC) 

(2008 – 09) Returned to her assignment as the ARC Chief Engineer

Dr. Shamim A. Rahman

NESC Chief Engineer at Stennis 

Space Center (SSC) (2005 – 06) Left 

the NESC to become the Deputy 

Director of the Engineering and 

Test Directorate at SSC

Jerry L. Ross

NESC Chief Astronaut 

(2004 – 06)  Returned to his assignment as Chief of the Vehicle 

Integration Test Office at Johnson 

Space Center and has since retired

Dr. Charles F. Schafer

NESC Chief Engineer at Marshall 

Space Flight Center (2006 – 10) 

Retired

Steven S. Scott

NESC Chief Engineer at

Goddard Space Flight Center 

(GSFC) (2008 – 09) NESC Discipline 

Expert for Software (2003 – 05) 

Returned to his assignment as the 

GSFC Chief Engineer

Bryan K. Smith

NESC Chief Engineer at Glenn 

Research Center (GRC) (2008 – 10) 

Left the NESC to serve as Chief of 

the Systems Engineering and

Systems Analysis Division at GRC

John E. Tinsley

NASA Headquarters Senior Safety 

and Mission Assurance Manager 

for NESC (2003 – 04) Left the NESC 

to become the Director of the 

Mission Support Division at NASA 

Headquarters and has since left 

NASA to accept a position with 

Northrop Grumman

Clayton P. Turner

NESC Chief Engineer at

Langley Research Center (LaRC) 

(2008 – 09) Returned to his

assignment as the LaRC

Chief Engineer

Left to right: Dawn Schaible, SEO Manager/presenter; Erin Moran, Analytical Mechanics Associates, Inc.; Lloyd Keith, JPL; Peter Parker, LaRC; David Alexander, 

JSC; Russell Wincheski, LaRC; Robert Kichak, MEI Technologies, Inc.; Scott Cryan, JSC; James Womack, The Aerospace Corporation; Jay Perry, MSFC; Hope 

Venus, NESC; James Blackwood, Bangham Engineering, Inc.; Robert Graber, Science Applications International Corporation; Robert Wingate, MSFC; Karen 

McNamara, JSC; Pat Forrester, NESC Chief Astronaut/presenter; Sherry Erskine, MSFC; Jill Prince, LaRC; Ralph Roe, Jr., NESC Director/presenter.

Not pictured: John Anderson, Jacobs Technology, Inc., and Elmain Martinez, JPL.

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012
52 53

Publications Publications

41. Cassini Spacecraft Short Anomaly .............................................................................................................................................................. NASA/TM-2012-217756

42. James Webb Space Telescope’s (JWST) Near-Infrared Spectrograph (NIRSpec) Micro Shutter Subsystem (MSS) .................. NASA/TM-2012-217757/Volume I

43. James Webb Space Telescope’s (JWST) Near-Infrared Spectrograph (NIRSpec) Micro Shutter Subsystem

(MSS) Appendices ....................................................................................................................................................................... NASA/TM-2012-217757/Volume II 

44. Space Transportation System (STS)-133 External Tank (ET)-137 Intertank (IT) Foam Crack and Repair Assessment:

Elastic-Plastic, Thermo-Mechanical Nonlinear Structural Analyses ................................................................................................................NASA/TP-2012-217773

45. Icing Research Tunnel (IRT) Force Measurement System (FMS) ....................................................................................................................NASA/TP- 2012-217784

1. Null, C. H.: How one Functional Human-Factors Requirement Influenced a Rocket. Presented at NASA Project Management Challenge, February 22-23,

2012, Orlando, Florida. 

2. White, Jr., K.; and Johnson, K. L.: Empirical Tests of Acceptance Sampling Plans. Presented at 10th International Conference on Operations Research,

March 6-9, 2012, Havana, Cuba. 

3. Carr, G.; Ging, A.; and Keys, D. J.: Cassini Mission Short Circuit Anomalies Investigation. Presented at 30th Annual Space Power Workshop, April 16-19,

2012, Manhattan Beach, California. 

4. Sammons, M.; Powell, C.; Pellicciotti, J. W.; Buehrle, R. D.; and Johnson, K.: Passive Thrust Oscillation Mitigation for the CEV Crew Pallet System.

Presented at 41st Aerospace Mechanisms Symposium, May 16-18, 2012, Pasadena, California. 

5. Woolaway, S.; Kubitschek, M.; Berdanier, B.; Newell, D.; Dayton, C.; and Pellicciotti, J. W.: GMI Spin Mechanism Assembly Design, Development, and Test

Results. Presented at 41st Aerospace Mechanisms Symposium, May 16-18, 2012, Pasadena, California. 

6. Schuster, D. M.; Chwalowski, P.; Heeg, J.; and Wieseman, C. D.: A Summary of Data and Findings From the First Aeroelastic Prediction Workshop.

Presented at International Conference on Computational Fluid Dynamics, July 9-13, 2012, Kohala Coast, Hawaii. 

7. Raju, I. S.: What is VCCT and Why Does It Work?. Presented at The Symposium for Ed Rybicki: Celebrating 45 Years of Progress in Understanding Fracture, 

Residual Stress, and Erosion-Corrosion, July 11-12, 2012, Tulsa, Oklahoma. 

8. Rickman, S. L.: Form Factors, Grey Bodies and Radiation Conductances (Radks). Presented at Thermal and Fluids Analysis Workshop 2012, August 13-17, 

2012, Pasadena, California.

9. Garcia, R.: Readiness for Flight Review Process: A Propulsion Perspective. Presented at JANNAF 45th Combustion / 33rd Airbreathing Propulsion / 33rd

Exhaust Plume and Signatures / 27th Propulsion Systems Hazards Joint Subcommittee Meeting, December 3-7, 2012, Monterey, California. 

 1. Composite Structures Damage Tolerance Analysis Methodologies ........................................................................................................... NASA/CR-2012-217347

 2. Orion - Super Koropon Torque/Tension Report ........................................................................................................................................... NASA/CR-2012-217587

 3. Process Sensitivity, Performance, and Direct Verification Testing of Adhesive Locking Features .............................................................. NASA/CR-2012-217760

 4. Structural Assessment of the International Space Station (ISS) European-Manufactured Modules Appendices ...................... NASA/TM-2011-217172/Volume II

 5. Orion Flight Test-1 (OFT-1) Radiometer Feasibility Study (Phase I) ............................................................................................................. NASA/TM-2011-217180

 6. Comparison of the Booster Interface Temperature in Stainless Steel (SS) V-Channel Versus the

Aluminum (Al) Y-Channel Primer Chamber Assemblies (PCAs) ................................................................................................... NASA/TM-2011-217182/Volume I

 7. Comparison of the Booster Interface Temperature in Stainless Steel (SS) V-Channel Versus the

Aluminum (Al) Y-Channel Primer Chamber Assemblies (PCAs) Appendices .............................................................................. NASA/TM-2011-217182/Volume II

 8. Independent Review of the Constellation Program (CxP) Ares-I Launch Vehicle Control Sensitivity

to Orion Service Module (SM) Tank Slosh Dynamics - Version 2.0 ............................................................................................................. NASA/TM-2011-217183

 9. Composite Crew Module: Primary Structure ............................................................................................................................................... NASA/TM-2011-217185

10. Composite Crew Module: Design ............................................................................................................................................................... NASA/TM-2011-217186

11. Composite Crew Module: Materials and Processes ................................................................................................................................... NASA/TM-2011-217187

12. Composite Crew Module: Analysis ............................................................................................................................................................. NASA/TM-2011-217188

13. Composite Crew Module: Manufacturing ................................................................................................................................................... NASA/TM-2011-217189

14. Composite Crew Module: Test .................................................................................................................................................................... NASA/TM-2011-217190

15. Composite Crew Module: Nondestructive Evaluation ................................................................................................................................ NASA/TM-2011-217191

16. Orion Thermal Protection System (TPS) Margin Study Assessment ........................................................................................................... NASA/TM-2011-217299

17. Space Transportation System (STS)-133/External Tank (ET)-137 ET Foam Crack and Repair Assessment Thermal Analysis Report ...... NASA/TM-2011-217306

18. Likely Mechanism and Contributors to the Root Cause for Orbiter Wing-Leading-Edge Joggle RCC SiC Coating Spallation ................. NASA/TM-2011-217312

19. Progressive Failure Analysis of a RCC Slip-Side Joggle Region ................................................................................................................ NASA/TM-2011-217313

20. Space Transportation System (STS)-133/External Tank (ET)-137 Intertank (IT) Stringer Cracking Issue 

and Repair Assessment: Proximate Cause Determination and Material Characterization Study ............................................................... NASA/TM-2011-217318

21. Doppler Radar Profiler for Launch Winds at the Kennedy Space Center (Phase 1a) ................................................................................. NASA/TM-2011-217321

22. Development of Autonomous Aerobraking (Phase 1) ................................................................................................................................. NASA/TM-2012-217328

23. Orion Launch Abort System Carbon/Carbon Silicon Carbide Material Behavior: Phase I: Review of Existing

Data and Recommended Phase II ............................................................................................................................................................... NASA/TM-2012-217333

24. Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement - Variables Acceptance

Sampling Calculators: Derivations and Verification of Plans ........................................................................................................ NASA/TM-2012-217335/Volume I

25. Probabilistic Requirements (Partial) Verification Methods Best Practices Improvement - Variables Acceptance

Sampling Calculators: Empirical Testing ..................................................................................................................................... NASA/TM-2012-217335/Volume II

26. Space Transportation System (STS)-133/External Tank (ET)-137 Intertank (IT) Foam Crack and Repair Assessment - Overview ............ NASA/TM-2012-217338

27. Evaluation of GenCorp Incorporated Aerojet AJ26 Engine 4 (E4) Engine Investigation for Use on Orbital Science

Corporation (OSC) Antares Launch Vehicle ................................................................................................................................................ NASA/TM-2012-217339

28. Orion Crew Module (CM) Crew Seat Attenuation ........................................................................................................................................ NASA/TM-2012-217345

29. International Space Station (ISS) Heat Rejection Subsystem (HRS) Radiator Face Sheet Damage .......................................................... NASA/TM-2012-217348

30. Use of Commercial Electrical, Electronic and Electromechanical (EEE) Parts in NASA’s Commercial

Crew and Cargo Program (CCP) ................................................................................................................................................................. NASA/TM-2012-217558

31. Assessment of Microphone Phased Array for Measuring Launch Vehicle Lift-off Acoustics ..................................................................... NASA/TM-2012-217563

32. Composite Pressure Vessel Working Group (CPVWG) Task 3: Stress Rupture Test Approach .................................................................. NASA/TM-2012-217564

33. International Space Station Air Quality Monitoring System Assessment .................................................................................................... NASA/TM-2012-217572

34. Flight Data Entry, Descent, and Landing (EDL) Repository ......................................................................................................................... NASA/TM-2012-217574

35. Reacting Multi-Species Gas Capability for USM3D Flow Solver ................................................................................................................ NASA/TM-2012-217575

36. Linguistic Preprocessing and Tagging for Problem Report Trend Analysis ................................................................................................. NASA/TM-2012-217576

37. Max Launch Abort System (MLAS) Parachute System ............................................................................................................................... NASA/TM-2012-217579

38. Best Practices for Updating Acoustic Environments With Measured Flight Data ....................................................................................... NASA/TM-2012-217594

39. Independent Technical Assessment of James Webb Space Telescope (JWST) Cryocooler Disturbance

(Random and Pulsating) Model ................................................................................................................................................................... NASA/TM-2012-217596

40. Space Shuttle Program (SSP) Shock Test and Specification Experience for Reusable Flight Hardware Equipment ................................. NASA/TM-2012-217599

NESC TECHNICAL UPDATE 2012 NESC TECHNICAL UPDATE 2012

Presentation Papers

NESC/NASA Published Technical Memoranda 
54

Article Index

The NESC Overview ............................................................. 2-6

Featured Assessments

▪ Launch Vehicle Shell Buckling Knockdown Factor

 Development and Implementation .................................8-9

▪ New Photogrammetry Technique is Accurate

 and Adaptable ...........................................................10-11

Technical Highlights

▪ Qualif﻿ication of Parachute Systems for H

 Altitude Deployment ....................................................... 12

▪ Review of Apollo Thermal Protection Test Data .............. 12

▪ Micrometeoroid and Orbital Debris Design and

 Analysis Improvements ................................................... 13

▪ Remote Imaging of the EFT-1 Entry for Aerothermal

 Flight Data Risk Reduction ............................................. 13

▪ Aerodynamic Testing of Alternate

 Spacecraft on Space Launch System ............................. 13

▪ Independent Modeling and Simulation for

 Exploration Systems ....................................................... 14

▪ Integrated Combustion Stability Analysis ....................... 14

▪ Pyroshock Characterization of Composite Materials...... 15

▪ CPAS Wake Deficit Wind Tunnel Testing

 for MPCV-Class Spacecraft ............................................ 15

▪ SLS Booster Interface Loads Analysis ........................... 15

▪ Orion EFT-1 Landing and Recovery

 Planning Peer Review .................................................... 16

▪ Composite Crew Module Leak Characterization............ 16

▪ Spin Forming of a Crew Module Metallic Forward

 Pressure Vessel Bulkhead .............................................. 16

▪ Assessment of Gravitational Loads

 and Environments .......................................................... 17

▪ Orion CM Thermal Protection System Margin .............. 17

▪ Orion Crew Module and Service Module

 Umbilical Strut Vibration Testing .................................... 18

▪ Carbon-Carbon Silicon Carbide Material

 Characterization ............................................................. 18

▪ Model-Based Systems Engineering of the 

 Exploration Systems Interfaces ..................................... 19

▪ Orion Docking Mechanism Jettison System Linear

 Shape Charge End Gap Testing ..................................... 19

▪ Use of Commercial Electronic Parts in Commercial

 Crewed Spacecraft ......................................................... 20

▪ Use of Commercial EEE Parts in Commercial

 Crewed Spacecraft ....................................................... 20

▪ Smart Buyer Assessment for Winged Reusable

 Spacecraft ..................................................................... 20

▪ Nitrous Oxide Fuel Blend Experiment ........................... 21

▪ Progress 44 Anomaly Investigation............................... 21

▪ ISS ORU Wet Storage Risk Assessment ...................... 21

▪ NESC Alternate Orion Crew Module

 Heatshield Carrier Design............................................... 22

▪ International Space Station Simplified

 Docking System............................................................. 22

▪ SSP Shock Test Experience for Reusable

 Flight Hardware.............................................................. 22

▪ Dedicated Nano-launcher for Small Spacecraft............ 23

▪ Threaded Fastening Systems Design, 

 Verification, and Installation........................................... 23

▪ Assessment of Maxwell SBC Panels............................. 23

▪ High Fidelity Data Acquisition System Development.... 24

▪ Development of Verification

 Data for Flight Simulations ............................................ 24

▪ Development of a NASA Fault

 Management Handbook................................................ 25

▪ Assessment of Combustion

 Instability in Black Brant Motors ................................... 25

▪ Mars Science Laboratory Ground Test and Checkout.... 28

▪ Hubble Space Telescope Attitude Observer Anomaly .... 28

▪ Chandra X-Ray Observatory COPV Risk Assessment.... 29

▪ JWST NIRSpec Microshutter Subsystem Investigation .. 29

▪ ASRG Heater Head Critical Flaw Analysis ...................... 29

▪ NPP Solar Array Deployment Torque

 Margin Assessment ...................................................... 30

▪ Cassini Spacecraft Electrical Anomaly .......................... 30

▪ Design Concept for New Sounding

 Rocket Sustainer Motor................................................. 30

▪ Development of an Autonomous

 Aerobraking Capability ................................................... 31

▪ JWST Fine Guidance Sensor Motor Anomaly ................ 31

 Center Focus

▪ Ames Research Center ................................................. 33

▪ Dryden Flight Research Center .................................... 34

▪ Glenn Research Center ................................................. 35

▪ Goddard Space Flight Center ....................................... 36

▪ Jet Propulsion Laboratory ............................................. 37

▪ Johnson Space Center.................................................. 38

▪ Kennedy Space Center ................................................. 39

▪ Langley Research Center .............................................. 40

▪ Marshall Space Flight Center........................................ 41

▪ Stennis Space Center.................................................... 42

NESC Biographies .......................................................... 44-47

NESC Alumni ........................................................................ 48

Awards and Recognition .................................................... 49

NESC Publications ......................................................... 50-51

NESC TECHNICAL UPDATE 2012
NASA Engineering and Safety Center

Langley Research Center

National Aeronautics and Space Administration

Langley Research Center

Hampton, VA 23681

www.nasa.gov

 NP-2013-01-450-LaRC