Professional Documents
Culture Documents
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
NESC Overview
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
NESC Overview
• In 2003, the NASA Engineering & Safety Center (NESC) was formed as a
response to a Columbia Accident Investigation Board observation
• The NESC mission is to provide the Agency’s Programs and Projects with
rigorous independent technical perspectives on their most critical
technical issues
Five years later – The NESC remains independent:
• Centrally managed and funded through the Office of Chief Engineer
• Small staff of senior leaders and technical experts to lead broad based
engineering teams in “tiger team” fashion
• Unaffiliated with and unbiased by any specific NASA Program or Center
• Has an independent engineering chain of command to assure an avenue for
consideration of all points of view
• Facilitating hands-on design and development experience
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
NESC Background
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
NESC Composite Crew Module
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
January 2007 NASA Administrator
chartered the NESC to form an
agency team to…
• design and build a composite crew module,
• gain hands-on design, build, and test
experience,
• in anticipation that future exploration
system may be made of composite
materials.
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Composite Crew Module Overview
Splice Joint
Pressure Module = Upper Pressure Shell + Splice Joint + Lower Pressure Shell
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
System Dimensions
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Project Attributes
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Project Management
Project Manager Mike Kirsch LARC
Deputy Project Mgr--Technical Integration Jeff Stewart GSFC
Deputy Project Mgr--Technology Dev. Paul Roberts LARC
Administrative Assistant Terri Derby ATK (Swales)
Support Advisors
Resource Analyst Pamela Throckmorton LARC Advisor Damodar Ambur LARC
Pro-E & IT Admin Mike Mongilio ATK (Swales) Advisor Tom Modlin JSC
Program Support Steve Summit ATK (Iuka) Advisor Joe Pellicciotti GSFC
Advisor Tod Palm NGC
Chip McCann Wade Jackson David Sleight Craig Collier Ian Fernandez Dawson Vincent Randy Sparks Tristan Curry
JSC LARC LARC Collier Research Corp ARC NGC (MSFC) ATK (Clearfield) UAH
John Thesken Ben Rodini Jonathan Bartley-Cho Phil Yarrington Dave Paddock Mike Western Tom McCabe Elliott Cramer
GRC SGT Northrop Grumman Corp Collier Research Corp LARC Janicki ATK (Iuka) LARC
Donny Wang Ron Schmidt Eric Schleicher Jerry Stuart
Steve Rickman NGC Eric Friesen Chip Henderson Brad Parker
NGC LMC ATK (Swales) GSFC
JSC Janicki ATK (Iuka)
Marc Dinardo Luis Santos
Perry Wagner Laurie Carrillo Robert Boscia Fred Hall Jeff Stone
LMC GSFC
ATK (Swales) JSC Alcore ATK (Iuka) ATK (Iuka)
Dan Richardson
Wayne Sawyer Charles Kaprielian Sam Russell
Angel Alvarez- ATK (Swales) Terry Graham Touch (ATK)
AS&M ATK (Swales) MSFC
Hernandez ATK (MSFC) Stephen Williams
Bill Kelly
Jared Schoenly JSC Rance Jones James Walker
Brett Bednarcyk ATK (Swales) Mike Abel
AMA Cindy Sowards MSFC
GRC Ed Fasanella ATK
Doug Lenhardt Danny Lambert
LaRC Andrew Johnson Steven Johnson
KSC
Jerry Gray ATK (Iuka)
Al Tabiei Craig Bowser Phil Thompson
MPSE ATK Swales Scott Ragasa
UAH
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Virtual Engineering Enablers
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Co-location Floor Plan
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Materials Selection
• Adhesives
• FM 300 M film adhesive - high shear strength and high toughness
• EA 9394 paste adhesive - high strength room temperature cure
• FM 410-1 foaming adhesive - core splice adhesive
• EY-3010/Lord 4688 - potting compounds - low density, low CTE, RT cure
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Lower Shell Loading
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
New Technology - Cobonded Joints - Air Force CAI
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Pi Preform Comparison
Geometry
Tension
~900 lb/in ~2000 lb/in
Capability
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper Pressure Shell Tooling
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper Pressure Shell Tool
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper IML Processing
Autoclave cure
Layup IML
Bag Part
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Shell Core Installation
Film Adhesive
Install Core
Outer Skins
Debagging Tacked Ceiling Core
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Automatic Ultrasonic Inspection
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper Manufacturing Demonstration Unit Complete!
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Lower Shell
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper IML and OML Layup
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Upper IML Plies
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
1 IML Ply Segment
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
1 ply segment
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Flat Patterns
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Civil Servant “Hands On” Experience
Ian Fernandez,
Design Engineer
ARC
Dave Sleight,
Structural Analyst
LaRC
Cecilia Larrosa,
Aerospace engineering intern
ARC
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
T&V Objectives
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Critical Test Locations
LIDS/Tunnel
Main Parachute
Drogue Parachute
Attachment
Attachment
Splice
Backbone
Attachment
Crucifom
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Building Block Approach Tests
• Coupon
• Sandwich flatwise tension - complete
• Edgewise compression - complete
• Pi preform (1/8” clevis)
• pull off - complete
• shear - complete
• Visual impact study tests – on hold
• Permeability tests – before and after impact – in work
• Element
• LIDS/tunnel double lap joint - complete
• Splice
• Acreage - complete
• Longeron – complete
• Offset – ECD 12/08
• Backbone attachment pull-off
• 0° - complete
• 20°- complete
• Backbone attachment shear ECD – 1/09
• Cruciform - complete
• Component
• SM/ALAS simplified interface (flat panel)
• Non-potted core – complete
• Potted core - complete
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Full Scale Testing: Loads “Freebody”
Maximum Internal
Pressure, 31.1 psi
Maximum
Delta Load
76,000 lbs
Service
Module Load
101,000 lbs
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Combined Loads Test System (COLTS)
NASA Langley
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Overall Project Status
Engineering Excellence
This briefing is for status only and may not represent complete engineering information
Composite Crew Module
Engineering Excellence
This briefing is for status only and may not represent complete engineering information