Kirsch.mike

This briefing is for status only and may not represent complete engineering informationEngineering Excellence

Broad-Based TeamsCase Study #1 - Composite Crew Module (CCM)

Mike Kirsch, CCM Project ManagerNASA Engineering and Safety Center

Principal Engineer

Project Management Challenge 2009Daytona Beach, Florida

February 24-25, 2009


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

NESC Overview


NESC emphasis is to create broad-based teams to enable networks that discourage silos

• Recruit team membership from a broad community

• Increase inter-Center knowledge and information flow

• Facilitate inter-Center collaboration

• Encourage inter-Center relationships and communities of practice

NESC Background


NESC Composite Crew Module


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.


Composite Crew Module Overview

Upper Pressure Shell

Lower Pressure Shell

Splice Joint

Pressure Module = Upper Pressure Shell + Splice Joint + Lower Pressure Shell


System Dimensions


Project Attributes

• Broad NASA Center representation• ARC, DFRC, GRC, GSFC, JPL, JSC, KSC, LaRC, MSFC

• Aerospace structures and composites industry collaborative participation

• Alcore – Honeycomb core• ATK – Design, Tooling, Manufacturing• Bally Ribbon Mills – 3D woven structures• Collier Industries – Hypersizer structural analysis software• Genesis Engineering - Design• Janicki Industries - Tooling• Lockheed Martin – Design, Tooling, Manufacturing• Northrop Grumman – Design, Tooling, Manufacturing

• Industry partners within each discipline and across all of the disciplines

• 18 months from vision to delivery of testable full scale hardware• Production slow down May 2008 – September 2008 (NESC Budget

realignment)


Project ManagementProject Manager Mike Kirsch LARCDeputy Project Mgr--Technical Integration Jeff Stewart GSFCDeputy Project Mgr--Technology Dev. Paul Roberts LARCAdministrative Assistant Terri Derby ATK (Swales)

AdvisorsAdvisor Damodar Ambur LARCAdvisor Tom Modlin JSCAdvisor Joe Pellicciotti GSFCAdvisor Tod Palm NGC

SupportResource Analyst Pamela Throckmorton LARCPro-E & IT Admin Mike Mongilio ATK (Swales)Program Support Steve Summit ATK (Iuka)

LeadLarry Pelham

MSFC

NDELead

Ken HodgesJSC

LeadSotiris Kellas

LARC

Testing Design Engineering

Dan RichardsonATK (Swales)

Luis SantosGSFC

Ian FernandezARC

Lead Jeff Stewart

GSFC

Dave PaddockLARC

Jerry StuartNGC

AnalysisLead

Jim JeansGenesis Engineering

Jonathan Bartley-ChoNorthrop Grumman Corp

David SleightLARC

Craig CollierCollier Research Corp

Brett BednarcykGRC

Phil YarringtonCollier Research Corp

ManufacturingLead

Dan PolisGSFC

Materials

Jeff StoneATK (Iuka)

Bill KellyATK (Swales)

Doug LenhardtKSC

Tom McCabeATK (Iuka)

Eric FriesenJanicki

Elliott Cramer LARC

Brad Parker GSFC

Eric SchleicherATK (Swales)

Wade JacksonLARC

Dawson VincentNGC (MSFC)

Terry GrahamATK (MSFC)

Ben RodiniSGT

Donny WangNGC

John TheskenGRC

Marc DinardoLMC

Ron SchmidtLMC

Chip McCannJSC

James WalkerMSFC

Sam RussellMSFC

Steven JohnsonATK (Iuka)

Perry WagnerATK (Swales)

Mike WesternJanicki

Fred HallATK (Iuka)

Randy SparksATK (Clearfield)

Craig BowserATK Swales

Charles KaprielianATK (Swales)

Tristan Curry UAH

Scott RagasaUAH

Chip HendersonATK (Iuka)

Robert BosciaAlcore

Touch (ATK)Stephen WilliamsRance JonesCindy SowardsDanny LambertAndrew JohnsonJerry GrayPhil Thompson

Steve RickmanJSC

Laurie CarrilloJSC

Angel Alvarez-Hernandez

JSC

Ed FasanellaLaRC

Mike AbelATK

Al TabieiMPSE

Wayne SawyerAS&M

Jared SchoenlyAMA


Virtual Engineering Enablers

• Goal – Create a virtual environment that promotes communications as ifthe team were in the same room

• Nearly 100% dedicated team• Drives proactive rather than reactive behaviors

• Extensive co-locations - 18 of 52 weeks with contractor partners and vendors during the first 12 months

• 7 of the first 9 weeks co-located – long hours through the weekend• Understanding individuals and building relationships• Used weekly bowling as a team social (fun for all abilities)

• Co located approximately 2 weeks every 2 months, thereafter• Web based calendar for managing personal and professional schedules

• When dispersed we used daily virtual design sessions through Secure Meetings/WebEx

• Windchill Web-based file management• Electronic drawing and model review, approval, and configuration control• Instant Messaging (Chat)• Desktop sharing (2 clicks)• Smart Boards/tablets


Co-location Floor Plan


Materials Selection

• Prepreg - IM7/977-2 tape and 4-harness satin fabric• High strength fiber• Toughened epoxy resin • Extensive data available for determining material properties.

• 3D woven Pi preforms - IM7/MTM45-1• Extensive data on IM7 woven Pi preform joints (CAI and JSF database). • MTM45-1 resin was formulated for out-of-autoclave cure, providing manufacturing flexibility.

• Core Selection - aluminum non-perforated core.• Non-perforated core provides some level of pressure containment redundancy.

• 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


Lower Shell Loading

• Backbone carries pressure load –no ring frame (~100 lbs savings)

• Membrane pressure head lobe shapes (~50 lbs savings)

• Leverages and enhances SM/ALAS reinforcements

• Backbone connection allows load sharing with Heat Shield (~1000 lbs heat shield savings)

50% load sharing on backbone

Internal Pressure

Water Landing


New Technology - Cobonded Joints - Air Force CAI

• Replaces bonded or bolted joints

• 3D-woven “Pi” shape preform• Cobonded Pi preforms

comprise majority of connections

• Lobe core tapers out before Pi• Also used to bond Gussets to

upper shell


Pi Preform Comparison

pi preform technologytraditional back-to-back L-clipsJoint type

Geometry

~2000 lb/in~900 lb/inTension Capability

1 step cobond2 step paste bondBonding process

2 pre-cured details:web and skin

5 pre-cured details: web, skin, closeout, two L-clips

Pre-cured part count

NESC Composite Crew ModuleHST's Super Lightweight Interchangeable CarrierProgram


Upper Pressure Shell Tooling

• Use Temperature: 400F• Use Pressure: 100psi• CTE: Chop Carbon

laminate• Slight elevation in

CTE contributed to ease of part de-mold

• Dimensional Accuracy: • Critical Zones +/-

.010”• Non-critical Zones +/-

030”• Durability: 30 cycles

(300+ hours)• Schedule: 12-16 weeks• Cost: $375K

Tool nickname: “Big Plunger”


Upper Pressure Shell Tool


Upper IML Processing

Layup IML

Bag Part

Autoclave cure


Shell Core Installation

Debagging Tacked Ceiling Core

Film Adhesive

Install Core

Outer Skins


Automatic Ultrasonic Inspection


Upper Manufacturing Demonstration Unit Complete!


Lower Shell


Upper IML and OML Layup

• Between 4 and 39 plies thick• Approximately 400 ply segments per skin• Manage ply orientation, 0, 90, +45, -45 degrees• Manage wrinkles over complex curvature and

core tapers• Manage ply segment overlaps .75” – 1.25”• Manage material yield• Manage material “out time” < 30 days


Upper IML Plies


1 IML Ply Segment


1 ply segment


Flat Patterns

• Integrated electronic process flow exists• Design, Manufacturing, and Inspection via

• CAD, NASTRAN, FiberSIM, flat patterns, laser projection, layup, inspection


Civil Servant “Hands On” Experience

Ian Fernandez, Design EngineerARC

Dave Sleight, Structural AnalystLaRC

Cecilia Larrosa,Aerospace engineering internARC


T&V Objectives

• Show, through destructive testing, that allowable material properties are conservative

• For given worst-case load environments, obtain structural test responses to correlate with analysis models

• Verify structural design robustness, and understand failure modes


Main ParachuteAttachment

Drogue ParachuteAttachment

Splice

Backbone Attachment

LIDS/Tunnel

Crucifom

Critical Test Locations


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


Full Scale Testing: Loads “Freebody”

Main Chute Load64,400 lbs

Drogue Load34,200 lbs

Maximum Internal Pressure, 31.1 psi

Launch abort Load134,000 lbs

Service Module Load101,000 lbs

Maximum Delta Load76,000 lbs


Combined Loads Test System (COLTS) NASA Langley


Overall Project Status

• 24 months into the project• Independent reviews conducted throughout project life cycle

• Conceptual design - March 2007• Preliminary design – June 2007• Detailed design – December 2007• Manufacturing plan – May 2008• Test plan – TBD (March 2009)

• Full scale tooling delivered January 2008• Building block fabrication and testing ongoing• Full scale upper pressure shell manufacturing demonstration unit completed in

December 2008• Upper and lower full scale subassemblies started October 1, 2009

• Sandwich systems cured the week of December 15• Post cure operations currently underway, with completion expected in March 09• Full scale testing planned at LaRC using COLTS facility beginning in Spring 09• Full scale static tests completion expected in July 09• CCM Final Report completion expected in September 09


Composite Crew Module

Business

Kirsch.mike