B e s t M a n u f a c t u r i n g P r a c t i c e s

REPORT OF SURVEY CONDUCTED AT

NASA MARSHALLSPACE FLIGHT CENTER

HUNTSVILLE, AL

BEST MANUFACTURING PRACTICES CENTER OF EXCELLENCECollege Park, Maryland

www.bmpcoe.org

APRIL 1999

F o r e w o r d

This report was produced by the Office of Naval Research�s Best ManufacturingPractices (BMP) program, a unique industry and government cooperativetechnology transfer effort that improves the competitiveness of America�sindustrial base both here and abroad. Our main goal at BMP is to increase thequality, reliability, and maintainability of goods produced by American firms. Theprimary objective toward this goal is simple: to identify best practices, documentthem, and then encourage industry and government to share information aboutthem.The BMP program set out in 1985 to help businesses by identifying, researching,

and promoting exceptional manufacturing practices, methods, and procedures in design, test,production, facilities, logistics, and management � all areas which are highlighted in the Department ofDefense�s 4245.7-M, Transition from Development to Production manual. By fostering the sharing ofinformation across industry lines, BMP has become a resource in helping companies identify their weakareas and examine how other companies have improved similar situations. This sharing of ideas allowscompanies to learn from others� attempts and to avoid costly and time-consuming duplication. BMP identifies and documents best practices by conducting in-depth, voluntary surveys such as thisone at NASA Marshall Space Flight Center (MSFC), Huntsville, Alabama conducted during the week ofApril 26, 1999. Teams of BMP experts work hand-in-hand on-site with the company to examine existingpractices, uncover best practices, and identify areas for even better practices. The final survey report, which details the findings, is distributed electronically and in hard copy tothousands of representatives from industry, government, and academia throughout the U.S. and Canada� so the knowledge can be shared. BMP also distributes this information through several interactiveservices which include CD-ROMs, BMPnet, and a World Wide Web Home Page located on the Internet athttp://www.bmpcoe.org. The actual exchange of detailed data is between companies at their discretion. MSFC has a legacy of extraordinary advancements that help make the impossible become a reality.With its unique blend of knowledge and capabilities, the Center continues to be an innovative forcebehind many of NASA�s breakthroughs. Among the best examples were MSFC�s accomplishments inunsteady computational fluid dynamic analysis of turbines; rapid prototyping; plume inducedenvironments; NASA/Air Force cost model; the Collaborative Engineering Center; and the X-RayCalibration Facility. The Best Manufacturing Practices program is committed to strengthening the U.S. industrial base.Survey findings in reports such as this one on MSFC expand BMP�s contribution toward its goal of astronger, more competitive, globally-minded, and environmentally-conscious American industrialprogram. I encourage your participation and use of this unique resource.

Ernie RennerDirector, Best Manufacturing Practices

NASA Marshall Space Flight Center

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C o n t e n t s

1. Report Summary

Background......................................................................................................... 1

Best Practices ..................................................................................................... 2

Information ......................................................................................................... 5

Point of Contact ................................................................................................. 7

2. Best Practices

DesignAdaptive Optics Mirror Systems .......................................................................... 9Collaborative Engineering Center ...................................................................... 9Phased Array Mirror Extendible Large Aperture ............................................ 11Unsteady Computational Fluid Dynamics Analysis of Turbines ..................... 11

TestComputed Tomography Imaging ...................................................................... 12Docking and Berthing ........................................................................................ 12Electronic Shearography ................................................................................... 13Modal Test Facility ............................................................................................ 13Plume Induced Environments ........................................................................... 14Thermography Non-Destructive Evaluation .................................................... 14Unsteady Data Reduction and Analysis System .............................................. 15Vibration Development and Verification Testing ............................................. 15

ProductionComposite Structures Manufacturing ............................................................... 16Environmental Control and Life Support Systems .......................................... 16Marshall Convergent Coating ........................................................................... 18Rapid Prototyping .............................................................................................. 18Real-Time Expert Systems for Spacecraft Health Monitoring and Command.................................................................................................. 19Thermal Spray Coating and Forming Processes .............................................. 19

NASA Marshall Space Flight Center

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C o n t e n t s (Continued)

FacilitiesX-Ray Calibration Facility................................................................................. 20

ManagementISO-9001 Implementation ................................................................................. 20Marshall�s ElecTRonic Office ............................................................................. 21NASA Acquisition Internet Service .................................................................. 21NASA/Air Force Cost Model .............................................................................. 22New Technology Transfer Program................................................................... 23Reusable Launch Vehicle Case Study Model Initiative ................................... 24Space Leadership Council .................................................................................. 25Web-Based Data System Solutions.................................................................... 26

3. Information

DesignAdvanced Concept Research Facility ................................................................ 29Gas Dynamic Mirror Fusion Propulsion Engine .............................................. 29High Strength Aluminum Casting Alloy for High Temperature Applications ..................................................................................................... 30Marshall Electromagnetic Compatibility Design and Interference Control Handbook ........................................................................................... 31Quantitative Risk Assessment System .............................................................. 31Solar Thermal Propulsion .................................................................................. 32

TestArmy/NASA Virtual Innovations Laboratory .................................................. 32Cryogenic Bearing Testing ................................................................................ 33Integrated Space Sation Electromagnetic Compatibility Analysis System..... 33Long Term Vacuum Testing of Lubricants ....................................................... 33Nuclear Fuel Element Simulation .................................................................... 34Optical Plume Anomaly Detection .................................................................... 34Orbital Atomic Oxygen Simulation Facilities ................................................... 35Space Environmental Effects Testing Capabilities .......................................... 35Telemetry Processing Systems .......................................................................... 36

NASA Marshall Space Flight Center

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ProductionFriction Stir Welding ......................................................................................... 37Vacuum System Automation ............................................................................. 38

FacilitiesMetallurgical Diagnostics Facility .................................................................... 38Plating Research Facility .................................................................................. 38

ManagementNew Initiatives of NASA Acquisition Internet Service .................................... 39Payload Safety Readiness Review Board .......................................................... 39Project Light ....................................................................................................... 39Strategic and Implementation Planning .......................................................... 40

APPENDIX A - Table of Acronyms ........................................................................ A-1APPENDIX B - BMP Survey Team......................................................................... B-1APPENDIX C - Critical Path Templates and BMP Templates ........................ C-1APPENDIX D - BMPnet and the Program Manager�s WorkStation................ D-1APPENDIX E - Best Manufacturing Practices Satellite Centers .................... E-1APPENDIX F - Navy Manufacturing Technology Centers of Excellence ........F-1APPENDIX G - Completed Surveys ........................................................................ G-1

C o n t e n t s (Continued)

NASA Marshall Space Flight Center

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F i g u r e s

Figures

2-1 Technology Assessment (Bantam) - Phase 1 ........................................................... 102-2 Typical X-33 Body Point Distribution ..................................................................... 142-3 Space Station Regenerative ECLSS Flow Diagram ............................................... 172-4 X-Ray Calibration Facility ....................................................................................... 202-5 Current RLV Model Structure................................................................................. 252-6 Web-Based System Configuration ........................................................................... 263-1 Experimental Gas Dynamic Mirror ......................................................................... 293-2 Conventional versus Modified Piston Design ......................................................... 303-3 Aluminum Alloys Tensile Strength Comparison at 600° F .................................... 313-4 Heatpipe Bimodal System 5-pin Module ................................................................. 343-5 Combined Environmental Effects Test-Cell 3 ......................................................... 363-6 Improved Mechanical Properties ............................................................................. 37

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S e c t i o n 1

Report Summary

Background

Years before the National Aeronautics and SpaceAdministration (NASA) was established, a group ofscientists and engineers known as the von Braunteam became prominent in America�s fledgling spaceprogram. During World War II, Dr. Wernher vonBraun and his team developed the V-2 rocket forGermany. However, von Braun�s real interest lay indeveloping rockets for space exploration. By June1945, many of Germany�s experts surrendered toAllied forces and were sent to the United States viaOperation Paperclip. Eventually, a group (includingvon Braun) ended up at the U.S. Army�s RedstoneArsenal in Huntsville, Alabama. Between 1950 and1956, von Braun led the team at the DevelopmentOperations Division of the Army Ballistic MissileAgency (ABMA) in designing the Redstone and Jupi-ter-C rockets. Still dreaming of space exploration, vonBraun published articles (e.g., concepts of space sta-tions, lunar landing vehicles) in Collier�s and workedwith Disney Studios (e.g., space exploration films fortelevision) in hopes of bringing about greater publicinterest in a space program. On January 31, 1958,ABMA used a Jupiter-C rocket to launch Explorer 1,America�s first orbiting satellite. This event signaledthe start of the U.S. space program. Two years later,NASA established the Marshall Space Flight Center(MSFC) and named von Braun as its first CenterDirector.

Originally organized by obtaining buildings, land,space projects, and personnel from ABMA, MSFC wasofficially dedicated on September 8, 1960 by PresidentDwight D. Eisenhower. This NASA facility was namedin honor of General George C. Marshall, the ac-claimed Army Chief of Staff, Secretary of State, andNobel Prize winner who developed the Marshall Planfor rebuilding Europe after World War II. Not longafter MSFC opened, the United States sent its firstastronaut, Alan Shepard, into space onboard a Mer-cury-Redstone vehicle. Visitors can see the historicRedstone Test Stand where the rocket used for thissuborbital flight was tested. In addition, the Centerbuilt the Saturn V rockets that launched Apolloastronauts to the moon. Test firing of the Saturnrockets was an unparalleled spectacle of sight and

sound in the Land of the Earth Shakers. The eventwas described as total flame, total sound, and totalpower. Often the noise was heard in a radius in excessof 100 miles. The Saturn V Dynamic Test Stand isalso designated as a national historic landmark at theCenter. Throughout its history, MSFC participatedin many significant space projects including theRedstone, Juno, and Saturn rockets; Mercury, Gemini,and Apollo programs; Lunar Roving Vehicles; Apollo-Soyuz mission; Skylab space station; Redshift Experi-ment; Space Shuttle program; and the Hubble SpaceTelescope.

Today, MSFC is NASA�s Center of Excellence forSpace Propulsion, and specializes in three missionareas: (1) Space Transportation Systems Develop-ment, (2) Microgravity, and (3) Optics ManufacturingTechnology. In addition, MSFC provides its custom-ers with high quality products and services; activelyparticipates in the local community; adapts to changethrough innovative thinking and flexibility; and en-hances and sustains its highly skilled, diverse, andmotivated workforce. The Center employed 2,715personnel, encompassed 1,841 acres, and had a fiscalbudget of $2.33 billion in FY98. MSFC is a worldleader in access to space and the use of space forresearch and development to benefit humanity. Amongthe best practices documented were MSFC�s unsteadycomputational fluid dynamic analysis of turbines;rapid prototyping; plume induced environments;NASA/Air Force cost model; the Collaborative Engi-neering Center; and the X-Ray Calibration Facility.

MSFC has a legacy of extraordinary advancementsthat help make the impossible become a reality. Withits unique blend of knowledge and capabilities, theCenter continues to be an innovative force behindmany of NASA�s breakthroughs. In addition, MSFCpartners with local businesses and academia; pio-neers environmental and safety efforts; and fosterstechnology transfer. Current and future programsinvolve advanced space propulsion systems; chemicalengines; automated rendezvous and capture capabili-ties; reusable launch vehicles; tethersystems; theChandra X-Ray Observatory; and the InternationalSpace Station. The BMP survey team considers thefollowing practices to be among the best in industryand government.

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Item PageBest Practices

The following best practices were documented atNASA MSFC:

Adaptive Optics Mirror Systems 9

The very large space telescopes under study atNASA MSFC involve large-diameter mirrors.Disadvantages of conventional monolithic de-signs include reliance on large, expensive, power-demanding electronics for figure sensing andactuation; unnecessary risk of damaging themirrors due to difficulty in handling them; andthe need for large fabrication and test facilities.To resolve these drawbacks, MSFC�s AdvancedOptics Development Group is developing mirrorsystems that use ultra lightweight replicatedmirrors.

Collaborative Engineering Center 9

MSFC set up the Collaborative Engineering Cen-ter as a way to improve quality and reduce the costof its proposals and pre-projects. By using theCollaborative Engineering Center�s engineeringprocesses, the design team determines conceptsand costs for future space missions.

Phased Array Mirror Extendible Large 11Aperture

The Phased Array Mirror Extendible Large Aper-ture is the first telescope to have a fully-adaptivesegmented mirror. This mirror consists of 36hexagonal segments, each measuring seven cen-timeters across flats. Each mirror segment istripod-mounted on three voice coil actuators whichprovide automatic tip, tilt, and piston adjust-ments of each segment relative to its neighbors.

Unsteady Computational Fluid 11Dynamics Analysis of Turbines

MSFC�s Fluid Dynamics Analysis Branch devel-oped a process that utilizes Unsteady Computa-tional Fluid Dynamics analysis during the designcycle of a turbine to quantify, reduce, and/ormanage flowfield unsteadiness. This approachresults in an increased understanding of theturbine flow environment, produces a better de-sign, and reduces the amount of rework during thedevelopment cycle.

Computed Tomography Imaging 12

MSFC modernized its Computed Tomographyscanner at a fraction of its replacement cost byinstalling commercial-off-the-shelf imaging soft-ware and computer resources (e.g., dual processormotherboards, memory chips, video controllers).Future plans include upgrading the system toachieve higher resolution and constructing asmaller scanner from existing components.

Docking and Berthing 12

The International Space Station program hascreated new requirements for docking andberthing simulations. To meet these require-ments, MSFC adapted its V20 Thermal VacuumEnvironmental Test Chamber. This one-of-a-kindfacility performs tests using six-degrees-offreedom�s operational capabilities.

Electronic Shearography 13

The spaceflight industry is rapidly changing andintroducing stronger and lighter composites intovehicle designs. As a result, MSFC�s inspectionteams needed a more flexible and portable systemfor detecting defects beneath insulation, paint,and laminated composites. Electronicshearography is a video inspection method usedto detect debonds or separations in a testspecimen.

Modal Test Facility 13

The Modal Test Facility at MSFC employs threeprimary modal test beds, each used to obtaindynamic characteristics of flight structures byusing experimental modal testing methods. Noother facility is known to be capable of performingmodal testing on specimens that span up to 45feet in length and weigh up to 40,000 pounds.

Plume Induced Environments 14

Plume induced environments are the heated ar-eas on the launch vehicle�s base regions caused bypropulsive engine plumes. The ability to locateand characterize these hot spots is critical toensuring a safe and successful mission. To moni-tor these areas, MSFC employs an integratedmethodology that utilizes improved and inte-grated engineering codes; 3-D computational fluiddynamics; and modernized short duration con-vective and ground radiation test data.

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Thermography Non-Destructive 14Evaluation

Thermography is a non-destructive analysis tech-nique used to create thermal images. In 1996,MSFC upgraded its imaging system by install-ing a more sensitive camera capable of resolvingtemperature differences down to 0.025o C andcollecting images in a digital format. Other newcapabilities include scanning the entire pictureframe at one time; automating and synchronizinga predictable heating source with data acquisi-tion; and easily storing and enhancing the result-ing images.

Unsteady Data Reduction and Analysis 15System

Unsteady data must undergo significant pro-cessing before meaningful results can be ob-tained, which makes real-time analysis difficult.To speed up the process, MSFC implemented anUnsteady Data Reduction and Analysis systemin May 1998 to handle data generated by cold flowtesting of high flow-rate turbines and pumps.

Vibration Development and 15Verification Testing

By developing a method to correlate theaccelerometer response of the unit under testwith that of the shaker armature, MSFCsuccessfully performed three-axis randomvibration testing at extremely low, cryogenictemperatures. In addition, this method permitstesting over a wider temperature range, allowsthe use of control points that may be inaccessibleduring testing, and avoids the need for specializedinstrumentation.

Composite Structures Manufacturing 16

MSFC has a long and rich history as NASA�sleader in large space hardware manufacturing.Around 1983, the Center established the Produc-tivity Enhancement Complex as a full-scalemanufacturing environment which has evolvedinto nearly 50 dedicated research areas. TheComplex offers outstanding resources, expertise,and capabilities to produce a wide range of shapesand sizes of composite components.

Environmental Control and Life 16Support Systems

The International Space Station is the next-generation vehicle, and will require regenerativelife support systems to effectively remain inspace. MSFC is designing and testing the spacestation�s Environmental Control and Life Sup-port Systems, which will control the regenerativesystems for sustaining a crew. An extensive de-sign and test program is currently underway,including the development of the Core ModuleIntegration Facility which will test all life sup-port components and subsystems.

Marshall Convergent Coating 18

During a launch, the space shuttle�s solid rocketboosters are exposed to extreme heat generatedby wind resistance and engine exhaust. In Fall1993, MSFC teamed with United Technologies�USBI to develop an environmentally friendlyprotective coating. Using convergent spray tech-nology, they atomized epoxy and filler materialsto create an ablative insulation material calledMarshall Convergent Coating-1.

Rapid Prototyping 18

MSFC is successfully using Rapid Prototypingtechnology to fabricate engineering conceptmodels. More than just a 2-D drawing or printout,Rapid Prototyping models combine the benefitsof conventional prototyping and automatedfabrication processes to produce a physical 3-Dmodel of the actual design concept. These modelshave faster turnaround times, and are lessexpensive to produce than conventionallymachined models.

Real-Time Expert Systems for 19Spacecraft Health Monitoring andCommand

Intelligent software applications offer a way toreduce labor requirements so long-term opera-tions can be effectively managed. Through de-ployments, the Mission Operations Laboratoryhas already demonstrated the benefits of intelli-gent software systems for real-time telemetrymonitoring and commanding. MSFC�s integratedsystems engineering approach enhances designknowledge capture and retention for all missionphases, and allows the development cycle to beaccelerated.

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Thermal Spray Coating and Forming 19Processes

Thermal spray coating and forming is a processwhere a coating thickness of 0.001 to over 0.750inch is applied to a surface. In addition, thisprocess can layer dissimilar coating materials sothat their desired properties work together, suchas in functional gradient coatings. MSFC usesthree thermal spray coating and forming pro-cesses: Vacuum Plasma Spray; High-VelocityOxyfuel Spray; and Wire Arc Spray.

X-Ray Calibration Facility 20

MSFC�s X-Ray Calibration Facility is the largestx-ray, optical test site in the world. The facilityfeatures a 2,000 square foot, class 10,000 area forunpacking and assembling hardware; a 6,000-square foot, class 2,000 vertical laminar flowclean room; and a 24-foot by 75-foot stainlesssteel vacuum chamber capable of sustaining tem-peratures from -180°F to +180°F and vacuums to10-7 Torr.

ISO-9001 Implementation 20

In 1995, the NASA Administrator mandatedthat all NASA centers become registered to ISO-9001. MSFC began working on this objective inMay 1996 and completed it by February 1998.Aside from the directive, MSFC viewed ISO-9001registration as an opportunity to improve selfdiscipline and internal communications; facili-tate better communication among all NASA cen-ters; and attain better alignment with supportcontractors.

Marshall�s ElecTRonic Office 21

Marshall�s ElecTRonic Office is a website, estab-lished within the MSFC Procurement Library,that provides one-stop shopping for up-to-date,web-based information. This site operates as asingle point of access for electronic tools, MSFCinformation, and Internet/Intranet sites.

NASA Acquisition Internet Service 21

MSFC developed the NASA Acquisition InternetService as an agency-wide, on-line capability thatcommunicates procurement information to in-dustry. Specifically, this service provides real-time synopses of business opportunities, solici-

tations, and a repository of government acquisi-tion websites to vendors seeking opportunitieswith NASA.

NASA/Air Force Cost Model 22

MSFC, in conjunction with the Air Force, devel-oped the NASA/Air Force Cost Model to predictthe cost of space hardware at the subsystem andcomponent levels. This fully automated softwaretool consolidates numerous existing cost modelsand databases used throughout NASA, andbrings cost estimating into compliance withtoday�s state-of-the-art software environments.

New Technology Transfer Program 23

MSFC�s New Technology Transfer program wasset up as a flat organization with an integrated,cross-trained team. In addition, the programfocused on eight interdependent mission areas(Technology Development; Small BusinessPrograms; New Technology Reporting; FacilitiesCommercializations; Technology and SoftwareCommercialization; Technology DeploymentPartnerships; National, Regional, and LocalStrategic Alliances; and Technology Educationand Outreach Projects for Economic Development)to provide the Center with a more cost-effective,balanced portfolio of quality products andservices.

Reusable Launch Vehicle Case Study 24Model Initiative

MSFC�s Engineering Cost Office developed adiscounted cash flow model to analyze commer-cial business cases for the Reusable LaunchVehicle. As a result of this effort, NASA redefinedgovernment-industry relationships and envi-sioned a new way of investing in large scaletechnology development projects.

Space Leadership Council 25

Recognizing that traditional practices were nolonger conducive for the International Space Sta-tion program, MSFC and its partners estab-lished the Space Leadership Council in January1996. The Council is a way to provide contractu-ally compliant NASA products and services byimproving communications and key processes tothe satisfaction of its customers.

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Web-Based Data System Solutions 26

MSFC�s Engineering Systems Department de-veloped a series of Web-Based Data SystemSolutions for information and document man-agement applications. This arrangement enablesthe Center to establish a paperless environmentin support of ISO-9001 certification, and provideimmediate accessibility to information perNASA�s faster, better, cheaper approach.

Information

The following information items were documentedat NASA MSFC:

Advanced Concept Research Facility 29

MSFC�s Advanced Concept Research Facility isin the process of developing many alternativepropulsion systems for use in a space environ-ment. Most of these methods are still in thedevelopment stage and will, if accomplished,redefine the limit of travel which is possibletoday. Some of the cutting edge technologiesbeing studied include: Solar; Nuclear; Fusion;Pulsed Propulsion and Power; and Magnetohy-drodynamic Propulsion.

Gas Dynamic Mirror Fusion 29Propulsion Engine

One of the most critical aspects for performing amanned mission to Mars will be the space vehicle�spropulsion system. MSFC�s Gas Dynamic Mirrorsystem is an example of a magnetic mirror-basedfusion propulsion system. The Center maintainsthis system in steady state by injecting particlesin the region of the homogeneous magnetic fieldto effectively balance the plasma loss through themirrors.

High Strength Aluminum Casting 30Alloy for High TemperatureApplications

In 1995, MSFC�s metallurgists began workingwith Ford under a Space Act Agreement to de-velop a new, castable aluminum alloy that had a30% improvement in tensile strength during op-eration in the required temperature range. The

result was an aluminum-silicon alloy that meetsor exceeds all original automotive criteria.

Marshall Electromagnetic 31Compatibility Design and InterferenceControl Handbook

In 1995, MSFC developed the Marshall Electro-magnetic Compatibility Design and InterferenceControl handbook to help electrical engineers usepractical information in designing for the mitiga-tion of electromagnetic interference. The hand-book features guidelines, design techniques, prac-tical measurements and prediction techniques,and practical retrofit fixes.

Quantitative Risk Assessment System 31

Probabilistic risk assessment is a method usedto calculate an overall system risk by combininghigh level event probability distributions withprobability distributions from each lower levelitem or process. MSFC uses the QuantitativeRisk Assessment System to assess the reliabil-ity of the space shuttle and its major components;help perform trade-off evaluations; rank spaceshuttle failure modes; perform sensitivity analy-sis; assist in other analysis efforts; and evaluateproposed space shuttle upgrades (e.g., propulsionelement).

Solar Thermal Propulsion 32

In the distant future, low cost propulsion will beneeded for interplanetary travel and unmannedexploration. NASA foresees Solar ThermalPropulsion as a way to boost future payloads froma low earth orbit to a geosynchronous earth orhigher orbit. MSFC�s Solar Thermal Facility hasalready built the heliostat mirror, concentrator,quartz-windowed vacuum test chamber,absorber/thruster, and gaseous hydrogenplumbing.

Army/NASA Virtual Innovations 32Laboratory

MSFC�s Engineering Systems Department, inconjunction with the U.S. Army�s Redstone Arse-nal, has developed the Army/NASA Virtual Inno-vations Laboratory. This laboratory developseffective human-interface-to-hardware designsby combining human modeling and analysis toolswith virtual reality technologies.

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Cryogenic Bearing Testing 33

Cryogenic bearing testing requires special re-quirements such as bearing test rigs to duplicatecryogenic turbopump conditions, and computermodeling codes to design special bearings. In theearly 1980s, MSFC formed a multi-disciplineteam consisting of experts in tribology, design,test, materials, and fabrication to initiate aBearing Test program. The team fostered manyadvancements such as improved bearing materi-als and liquid hydrogen testing capability.

Integrated Space Station 33Electromagnetic CompatibilityAnalysis System

Six different international partners are design-ing and building major elements of the Interna-tional Space Station. To ensure compatibility,MSFC developed the Integrated Space StationElectromagnetic Compatibility Analysis System.This integrated database system keeps track ofelectromagnetic compatibility between devicesand systems on the space station, and enablesengineers to evaluate the effects of electromag-netic interference on flight systems.

Long Term Vacuum Testing of 33Lubricants

Lubricants used for space applications must beable to operate in a vacuum environment. Todetermine which ones are compatible for NASAmissions, MSFC performs long term vacuumtesting of lubricants, typically over a one-yearperiod.

Nuclear Fuel Element Simulation 34

MSFC is currently testing various forms of alter-native propulsion methods. One such method isthe Heatpipe Bimodal System, designed fornuclear thermal propulsion. The Center�s objec-tive is to fabricate and electrically test a modulein order to determine its design limits and opera-tional characteristics. Several modules will thenbe grouped together in a quarter core arrange-ment to investigate the interactions between themodules under various operational and faultmodes.

Optical Plume Anomaly Detection 34

The Optical Plume Anomaly Detection is a sys-tem that analyzes and characterizes emittedspectrum from rocket plumes by monitoring theultraviolet, visible, and near-infrared regions ofthe spectrum. Through the detection of metals inthe exhaust plume, information relative to thedegradation of hardware can be gathered andused for readiness and maintenance decisions.

Orbital Atomic Oxygen Simulation 35Facilities

MSFC has developed and implemented orbitalatomic oxygen simulation facilities based on thephysical characteristics of a low earth orbit envi-ronment. This capability is used to determine thelong term exposure characteristics of objectslaunched into space.

Space Environmental Effects Testing 35Capabilities

MSFC has established the Combined Environ-mental Effects Test-Cell 3, a space environmen-tal effects testing facility used to simulate com-bined space environments. This facility enablesthe Center to test, evaluate, and qualify materi-als for use on external surfaces in space.

Telemetry Processing Systems 36

MSFC�s Huntsville Operations Support Centermanages and processes telemetry data forpayloads such as real-time operations of theInternational Space Station. The Support Centeris comprised of four systems: Payload PlanningSystem; Payload Data Services System; EnhancedHuntsville Operations Support Center System;and Enhanced Mission Communications System.

Friction Stir Welding 37

MSFC is currently conducting studies to deter-mine the feasibility of using friction stir weldingto manufacture hydrogen fuel tanks and as areplacement process for situations where currentmaterial join methods are mechanically inferior.The Center has already demonstrated the com-mercial use of friction stir welding for manufac-turing aluminum 5454 wheel rims.

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Vacuum System Automation 38

MSFC�s Environmental Test Facility is currentlyimplementing the Vacuum System Automationproject. This project involves upgrading and au-tomating the facility�s 20 vacuum chambers. Au-tomation will be controlled with SupervisoryControl and Data Acquisition software, so opera-tors can access the chambers via the Internet fordata and via remote dial-ins for parameter ad-justments.

Metallurgical Diagnostics Facility 38

Beginning in 1994, MSFC identified four areas inwhich to improve its Metallurgical DiagnosticsFacility: (1) work request closure verification, (2)documentation and image storage and retrieval,(3) budget planning and justification, and (4)data access and distribution. Improvements inthese areas have eased MSFC�s transition toISO-9000 certification and to the recentlyimplemented NASA Full Cost Accountingrequirements.

Plating Research Facility 38

MSFC�s Plating Research Facility is currentlydeveloping a plating process which will allowmultiple replicated optical mirrors to be pro-duced from one mandrel. The developers havelearned to define and control multiple platingparameters including temperature, current den-sity, component placement in tanks, bath chem-istry and consumption rate, shielding, and fluidflow.

New Initiatives of NASA Acquisition 39Internet Service

In an effort to continue improving NASA Acqui-sition Internet Service, MSFC has embarked onseveral enhancements including the ProcurementData Warehouse System and the Request ForQuotes System. These initiatives represent thenext phases of how NASA is improving its pro-curement process.

Payload Safety Readiness Review Board 39

In July 1996, MSFC created an internal PayloadSafety Readiness Review Board to ensure thequality of its payload safety processes and prod-ucts. Additionally, the Safety and Mission As-

surance Office developed a Center Safety Readi-ness Review process to improve this aspect ofwork and provide a means of ensuring in-depthflight readiness of all payloads and experiments.Keys to the success of this process are a high levelof attention by management and the use of aformalized dry-run approach.

Project Light 39

In 1996, MSFC implemented Project Light as aCenter-wide program to bring about change andprocess improvement. The program employs aquality action team approach using Cross-Func-tional Employee Teams (providers and custom-ers from multiple organizational levels) and anExecutive Steering Committee (three centermanagers, four functional managers, one pro-gram manager, two employees).

Strategic and Implementation Planning 40

Enacted in 1993, the Government Performanceand Results Act requires all federal agencies todevelop strategic and performance plans whichoutline their goals and objectives in outcome-based terms. MSFC is complying with this act,and has implemented a strategic planning pro-cess that sets performance goals for the upcomingfiscal year and defines performance indicators tomeasure outcomes.

Point of Contact

For further information on items in this report,please contact:

Ms. Sally A. LittleNational Aeronautics and Space AdministrationGeorge C. Marshall Space Flight CenterCode CD30, Building 4666Marshall Space Flight Center, AL 35812Phone: (256) 544-4266Fax: (256) 544-1815E-mail: sally.little@msfc.nasa.gov

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S e c t i o n 2

Best Practices

9

Design

Adaptive Optics Mirror Systems

The very large space telescopes under study at theNational Aeronautics and Space Administration(NASA) Marshall Space Flight Center (MSFC) in-volve large-diameter mirrors. Disadvantages of con-ventional monolithic designs included reliance onlarge, expensive, power-demanding electronics forfuture sensing and actuation; unnecessary risk ofdamaging the mirrors due to difficulty in handlingthem; and the need for large fabrication and testfacilities. Floating point gate arrays are used forflexible, broad application, miniaturized electronics.Conventional labor-intensive grinding and polishingoperations often induce unacceptably large stressfields in the material. To resolve these drawbacks,MSFC�s Advanced Optics Development Group is de-veloping mirror systems that use ultra lightweightreplicated mirrors.

The redesigned mirror system has many improve-ments over its predecessor. Segmented mirrors nowexist as hexagonal tiles with diameters of less thanone meter, compared to the previous 1.5 to 3.5-metermonolith designs. These smaller mirrors featurethinner cross-sections, less mass, and easier, costeffective fabrication. MSFC�s system also uses modu-lar electronics with an extensible architecture forgrowth paths; a serial data loop originating at themaster timing module; and symmetrical card andconnector layouts. Modular electronics exist in seven,36, and 91 segments with an application currentlyunderway at a major observatory. Instead of usingsurface mount components, floating point gate arraysemploy flexible and programmable devices (e.g., ROMs,PROMs). As a result, these arrays operate moreefficiently and increase the bandwidth from nearly 0Hertz (Hz) to more than 100 Hz. Replicated mirrorsare now fashioned by depositing mass where needed,rather than by removing excess via mechanical means.This approach lowers internal stress fields, improvesmirror figures, and provides high quality products atless than $20,000. Additional enhancements resultfrom the electro-mechanical deposition on mandrel

with sub-nanometer micro-roughness and diffrac-tion-limited figure.

With these design changes, the Advanced OpticsDevelopment Group significantly revised optics mir-ror systems for space telescopes and gained valuableknowledge for future improvements. The Group de-termined that the optimum hexagon size is betweenseven centimeters and one meter; high quality testbed emulators become crucial during the develop-ment phase; new-generation floating point gate ar-rays continue to enhance the product design para-digm; and the tight radius of curvature specificationexceeds the capability of commercial sources of repli-cated mirror segments.

Collaborative Engineering Center

MSFC set up the Collaborative Engineering Center(CEC) as a way to improve quality and reduce the costof its proposals and pre-projects. By using the CEC�sengineering processes, the design team determinesthe composition and cost of a space mission�s proposaldevelopment.

The CEC�s engineering process differs fundamen-tally from traditional aerospace design processes.Using CEC�s networked tools and databases, thedesign team obtains the necessary supporting infor-mation to make immediate design decisions. Next,the team develops the conceptual mission design andassociated costs during three-hour, team design ses-sions. A minimum of two sessions is required todesign and cost a mission concept. Figure 2-1 showshow a baseline assessment (proven technology) isreduced in cost and advanced in technology by usinga systematic process of technology insertions.

Since implementing CEC�s capabilities, MSFC hassignificantly reduced the cycle time for early designconcepts while achieving more design iterations andidentifying lower cost systems. Many benefits fromthe concurrent engineering process are a result ofusing a standing design team � one team designsmany missions. In FY98, this team completed 57studies, thereby providing many opportunities for theteam to work together through a well-honed process.

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Figure 2-1. Technology Assessment (Bantam) - Phase 1

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Phased Array Mirror Extendible LargeAperture

The Phased Array Mirror Extendible Large Aper-ture (PAMELA) is the first telescope to have a fully-adaptive segmented mirror. This mirror consists of36 hexagonal segments, each measuring seven centi-meters across flats. Each mirror segment is tripod-mounted on three voice coil actuators which provideautomatic tip, tilt, and piston adjustments of eachsegment relative to its neighbors. In 1993, MSFCacquired PAMELA from the Command Sciences Cor-poration in Tucson, Arizona, and determined that thetelescope was functional but needed to be qualified.

MSFC decided to use PAMELA as a developmenttest bed. To achieve this goal, the Center madenumerous innovative improvements to the opticalperformance of the telescope. As received, some indi-vidual mirror segments exhibited peak-to-valley sur-face irregularities of up to 0.375 wave, as measured bya Wyco 6000 Interferometer. Consequently, MSFC�sOptics Group removed all mirror segments and mea-sured their radii of curvature. Eight segments werechosen to be refigured.

After reassembling the telescope, the Group discov-ered that actuator displacements as small as 0.005inch could introduce one-wave, peak-to-valley, sur-face perturbations. Stress analyses of the mirrorsegments, as mounted on their substrates, wereperformed to verify that stresses during actuatormovements were below yield or ultimate. The Groupreasoned that since the segments were easily dis-torted, this characteristic could be used for flatnessadjustment if a precision, repeatable method of ad-justment could be devised. A 0.024-inch thick ringgasket was installed between the three actuators andthe mirror segment substrate. This gasket acted as astiff spring when the actuators were reinstalled,allowing precise tip and tilt adjustments at eachactuator dependent on mounting screw torque. Thisadjustment capability reduced mirror segment flat-ness errors from 0.488 to 0.038 wave, approximatelya 13:1 improvement.

The resonant frequency of the mirror segment, asmounted on its substrate and tripod-supported by thethree voice coil actuators, was found to be in the 60 to70 Hz range. This resonance presented a stabilityproblem to the mirror segment positioning controller.A small, viscoelastic, multilayer, cantilever beamwas constructed and added to each interface of thevoice coil pistons with the mirror segment substrate.The resonance range of the mirror segment was

effectively damped at 9.4%. In addition, this optimallydamped system could be easily tuned and adjustedwith the existing controller gain.

Additionally, the introduction of a Blue Line QuadCell Wavefront Sensor calibration device permittedlinear calibration to be achieved, with a noise floorimprovement of 40 times better than the originalLateral Effect Diode Wavefront Sensor. Today, theimage sensor spot intensity profile of the six-phasedPAMELA has now been demonstrated as closelyapproaching theoretical reference accuracy.

Unsteady Computational Fluid DynamicsAnalysis of Turbines

MSFC�s Fluid Dynamics Analysis Branch devel-oped a process that utilizes Unsteady ComputationalFluid Dynamic (CFD) analysis during the designcycle of a turbine to quantify, reduce, and/or manageflowfield unsteadiness. Until the recent integration ofcurrent processing power, this process typically tookplace after a turbine was already designed. Themotivation for changing the process included: theability to achieve better designs, lower costs, and animproved overall understanding of turbine design;the added complexities of supersonic flow from cur-rent and future turbines (e.g., Fastrac, ReusableLaunch Vehicle); and the requirements for smaller,lightweight components which pushed turbines to-ward more compact, closely coupled designs magnify-ing the effects of flowfield unsteadiness.

The ability to accurately predict turbine flowfieldunsteadiness in a timely manner is crucial to produc-ing a design that meets a program�s objectives.Flowfield unsteadiness is a major factor in turbineperformance and durability. Unsteadiness is particu-larly important for several classes of turbines includ-ing supersonic, compact, counter rotor, high workdesigns, and designs using dense drive gases. Mostmodern rocket engine turbines fall within these classes.

The requirements of the Fastrac program drove thereal-time technology of Unsteady CFD analysis inturbine engines. The objective was to demonstrate areliable, low cost, turbopump-fed rocket engine usinga reduced number of parts, a simpler design, a singlestage with exit vanes, a supersonic flow, and commer-cial manufacturing techniques. To meet technical,cost, and schedule objectives of the Fastrac program,MSFC needed to run a series of Unsteady CFDanalyses during the design phase on various areasincluding coupled and uncoupled nozzles, blade con-figurations, and exit guide vanes.

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By using the Unsteady CFD analysis on the Fastracprogram, MSFC completed its configuration calcula-tions in approximately 14 weeks compared to the oldmethod which would have taken about a year. Un-steady results supplied in a timely manner enableengineers to make real-time decisions that affectturbine performance. The ability to use UnsteadyCFD analysis during the design phase results in anincreased understanding of the turbine flow environ-ment, produces a better design, and reduces theamount of rework during maintenance schedules.

Test

Computed Tomography Imaging

In 1988, MSFC purchased a state-of-the-art Com-puted Tomography (CT) scanner. Over the years, thisdevice increasingly began to fail, averaging a 50%downtime by 1996. Since replacement parts becamedifficult to locate, engineers resorted to troubleshoot-ing and replacing individual components on thememory boards. In addition, the customized com-puter operating system made the scanner difficult tomaster, the storage media (reel-to-reel) was bulky tomaintain, and a replacement would cost severalmillion dollars. A cost-effective alternative for MSFCwas to upgrade its own system.

A CT scanner is used to produce an internal struc-tural image by taking sequential, repetitive x-rayimages along the length of an object. Each imagerepresents an individual layer of the total picture. Bycombining these layers, a 3-D image of an object isproduced. MSFC�s primary use for its scanner is toanalyze composite solid rocket nozzles. By using a 3-D image, engineers can easily view the internalstructure of a rocket nozzle and identify potentialanomalies, such as cracks or voids. MSFC�s scanneris similar to those used in the medical industry forcreating 3-D images of the human body, but operatesat higher energy levels (420 keV tube with a 2-MeVlinear accelerator) to image through much densermaterial.

MSFC modernized its CT scanner system by usingcommercial-off-the-shelf (COTS) imaging softwareand computer resources (e.g., dual processormotherboards, memory chips, video controllers). Inaddition, the Center also upgraded the operatingsystem to UNIX; added special features such as a re-writeable CD-ROM drive and a backup tape drive;automated the diminish and measure capabilities foranalyzing suspected anomalies; and set up a Tagged

Image File Format for transporting images which areexternal to the system. The project took seven monthsand was completed in September 1997. The availabil-ity of the new system is currently at 95%.

The CT scanner was upgraded at a fraction of itsreplacement cost, approximately $225,000, whichresulted in considerable cost savings for MSFC. Withinthe last 20 months, the system produced 8,500 imagesprimarily for the Fastrac program. Prior to renova-tions, this scanner had produced only 13,300 imagesover a nine-year period. Future plans include upgrad-ing the system to achieve higher resolution andconstructing a smaller CT scanner from existingcomponents.

Docking and Berthing

NASA has successfully performed several docking/berthing maneuvers throughout the space program�shistory. In the early 1970s, MSFC created a six-degrees-of-freedom (6DOF) contact-dynamics simula-tion. This advanced technology process ensures theintegrity and reliability of space hardware during adocking/berthing maneuver. Until recently, all 6DOFtesting was performed at ambient temperature andatmospheric pressure. The development of the Inter-national Space Station (ISS) program, however, cre-ated a new dimension for testing. All remote fly-insand docking/berthing of space hardware must beconducted in a thermally-controlled vacuum environ-ment. In addition, the ISS Common Berthing Mecha-nism (CBM) requires testing to be performed underoperational vacuum and thermal conditions.

To meet these requirements, MSFC adapted its V20Thermal Vacuum Environmental Test Chamber toperform tests using 6DOF�s operational capabilities:

� Positional tolerance of +0.05 inch and +0.10degrees

� Motion range of +5 degrees for roll, pitch, andyaw; +6 inches for translation in the horizontalplane; and 24 inches for vertical travel

� Payload weight of 2,500 poundsThis one-of-a-kind test facility also provides visual

cues and pilot-in-the-loop studies; analytical contact-dynamics simulations; real-time anomaly resolutionfor ISS berthing; pilot-in-the-loop proximity operationto dock/berth mechanism hardware; and contact-dynamics testing of 1:1 scale to dock/berth hardwareunder operational thermal and vacuum conditions.

Since utilizing the V20 facility for docking/berthingsimulations, MSFC realized many benefits for the ISS

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program. These include testing hardware under op-erational vacuum and thermal conditions; redesign-ing the alignment guides and latches; identifyingmechanical interference problems; setting up func-tional testing of CBM; and determining operationalconstraints of CBM hardware. In addition, NASApilots gain familiarization with all aspects of dockingand berthing. The real-time anomaly resolution forISS berthing will provide a safety net for missionsthroughout ISS�s assembly.

Electronic Shearography

The spaceflight industry is rapidly changing andintroducing stronger and lighter composites into ve-hicle designs. As a result, MSFC�s inspection teamsneeded a more flexible and portable system for detect-ing defects beneath insulation, paint, and laminatedcomposites. Electronic shearography is a video in-spection method used to detect debonds or separationsin a test specimen. With the Center�s state-of-the-artequipment, images can be collected in real time andviewed on a charge coupled device camera. In the past,traditional film photography was used to documentand enhance material inspections. This method wastime consuming and often involved cumbersome la-sers and laborious manual processes.

In an electronic shearography system, a laser ispassed through a beam expander which breaks up thebeam and strikes the test specimen with divergentbeams. The beams are then reflected back through atelephoto lens and gathered in a Michelson interfer-ometer to provide variable image shear. The systemrecords two images: (1) the reference image and (2) thesheared image. These images will interfere with oneanother, resulting in a recorded image of a laserspeckle pattern indicative of the original testspecimen�s surface slope. The system can also detectsurface imperfections by recording the slope of thesurface. If a defect exists below the surface, it willeventually distort the surface profile as the deforma-tion reaches the surface.

Electronic shearography has proven to be an effec-tive means of inspecting a variety of materials fordefects in multiple environments. Since implement-ing this system, MSFC�s engineering staff can quicklyadapt and integrate new inspection technologies. Thesystem provides greater sensitivity, repeatable anduniform testing, and the ability to detect defects nearinner surfaces of a closed-body structure such as fueltanks. MSFC also uses electronic shearography toensure product conformance and flight safety.

Modal Test Facility

The Modal Test Facility at MSFC uses three pri-mary modal test beds: (1) the Shuttle Payload Univer-sal Modal Test Bed; (2) the ISS Rack Modal Test Bed;and (3) the Shuttle Spacelab Pallet Modal Test Bed.The purpose of each is to obtain dynamic characteris-tics of flight structures by using experimental modaltesting methods. Modal test data enable engineers todetermine the resonant frequency, damping, andmode-shape information about the tested structure.This information is used to verify finite elementanalysis (FEA) models of the flight vehicle with thetest article mounted in place. This verification isnecessary to assure that no unacceptable dynamicloads will be imposed on the flight vehicle by thestructural resonance of articles being carried intospace.

The Shuttle Payload Universal Modal Test Bed iscapable of mounting the test article in a fixed-freeconfiguration that represents the Shuttle trunnionmounting system. Typically, for a five-trunnion sys-tem with 30 degrees-of-

freedom, seven degrees-of-freedom are fixed and theremainder are free relative to the fixed condition. TheISS Rack Modal Test Bed is capable of mounting thetest article in a fixed configuration representingtypical rack mounting. The Shuttle Spacelab PalletModal Test Bed is capable of mounting a ShuttlePayload attached to a Spacelab Pallet in a free-freetest configuration. Up to 500 triaxial accelerometers(1,500 linear accelerometers) can be attached to thetest article before applying up to six independent,benign, low-level, vibrational inputs over a frequencyrange of 0 Hz to 100 Hz. Engineers then measure themodal response of the test article, and can record upto 224 channels of data simultaneously. The recordeddirectional accelerometer information is used to com-pute the frequency response functions which, whencurve-fitted, yield the desired modal parameters (e.g.,resonant frequencies, damping coefficients, modeshapes) for verifying the FEA models.

MSFC�s Modal Test Facility is considered a uniquecapability within the United States, and possibly theworld. No other facility is known to be capable ofperforming modal testing on specimens that span upto 45 feet in length and weigh up to 40,000 pounds.The Facility�s modal test data collecting, recording,and processing capabilities are considered unparallel.

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Plume Induced Environments

Plume induced environments are the heated areason the launch vehicle�s base regions caused by propul-sive engine plumes. The ability to locate and charac-terize these hot spots is critical to ensuring a safe andsuccessful mission. To monitor these areas, MSFCemploys an integrated methodology that utilizes im-proved and integrated engineering codes; 3-D compu-tational fluid dynamics; and modernized short dura-tion convective and ground radiation test data. Theprevious method was a non-integrated system basedon engineering and empirical techniques derivedfrom 1960s and 1970s launch vehicles. The change inphysical design of today�s launch vehicles dictated theneed for a new system which could accurately predictand monitor thermal hot spots.

Two primary heating phenomena are associatedwith plumes: (1) radiation heating where hot plumegases radiate at all altitudes, and (2) convectionheating where hot plume gases are re-circulatedaround the base of the launch vehicle. Analysis of theheating environment will involve 20 to 200 vehiclebody point measurements that are influenced byvariables including engine gimbal angle, trajectorychanges, and angle of attack. Figure 2-2 illustrates atypical body point distribution of the X-33 ReusableLaunch Vehicle for plume heating calculations.

Since the 1960s, engineering codes have been amajor area of development. Noted improvementsinclude user input and output simplified by graphicaluser interfaces; artificial intelligence analogs addedto mesh density selection and interpret result valid-ity; integration of output data so that it automaticallytransforms into input for subsequent code; and accep-

tance of computational fluid dynamic plumes as inputfor radiation codes. Today�s engineering codes involveband model gaseous radiation; nozzle and high alti-tude plume flowfields; reverse Monte Carlo radiation;the chemical equilibrium code; and the viscous shearlayer of the plume.

The improvement of engineering codes and the useof faster, more powerful computers greatly aid plumeenvironmental engineers in their work. As a result,MSFC reduced analysis time from weeks to hours,and significantly decreased testing costs from $6million in the 1970s to $750,000 today.

Thermography Non-DestructiveEvaluation

Thermography is a non-destructive analysis tech-nique where a material is thermally excited by a high-energy source (e.g., quartz lamps, high intensityflash). As the material cools, emitted infrared (IR)radiation can be analyzed with a thermal-imagingcamera. Different materials absorb and release IRenergy at different rates as heat propagates through,thereby creating a thermal image that can progres-sively penetrate deeper layers of the material. Ther-mography is particularly useful for examining com-posite materials because many are nearly invisible tox-rays. Delamination (voiding) inside the compositewill create air-filled pockets that act as insulators.The area inside and around this insulated area willcool at a different rate than the remainder of thematerial, thus creating a slightly altered thermalimage.

In the past, MSFC used analog methods to collectthermal images, and then stored them on VCR tapes.

Figure 2-2. Typical X-33 Body Point Distribution

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Heating was done through manual means. Thisapproach had several limitations because the result-ing image was affected by the scan rate of the camera,and the camera could only scan the image in a left-to-right, top-to-bottom fashion. Also, the temperaturesensitivity of the camera was relatively low (less than0.1o C), and post-processing of the analog image waslimited. As a result, engineers had difficulty in en-hancing images and identifying potential problems.

In 1996, MSFC upgraded its imaging system byinstalling a more sensitive camera capable of resolv-ing temperature differences down to 0.025o C andcollecting images in a digital format. Other newcapabilities include scanning the entire picture frameat one time; automating and synchronizing a predict-able heating source with data acquisition; and easilystoring and enhancing the resulting images. Theupgraded system can also quantify the size andseverity of lamination and porosity anomalies, whichaids in determining the size of a delamination (bothinterply unbonding and core/facesheet unbonding)and the porosity of the bonding material. This featurewas achieved by developing defect standards. MSFCintentionally created delamination on coupons byinserting Teflon tape between bonding layers to simu-late delamination, and used microballons and varia-tions in vacuum bagging operations to simulate po-rosity during the fabrication process. The Centerfabricated defects in various sizes, and took thermo-graphic images of them. These images were thenexamined to determine the limitation of the tech-nique, and to correlate the size of the defect on theimage with the actual defect size.

By upgrading to a thermograpic, non-destructiveevaluation process, MSFC can now analyze compositematerials for potential delamination problems andquantify delamination/porosity within compositematerial. This process was also used to qualify thenose cone for the space shuttle�s external fuel tank, aswell as the space shuttle�s main engine nozzle and theBantam RP-1 fuel tank.

Unsteady Data Reduction and AnalysisSystem

Unsteady data is produced by many natural phe-nomena such as fluctuating pressure loads, flowinstabilities, cavitation noise, and sonic booms. How-ever, this type of data must undergo significantprocessing before meaningful results can be obtained,which makes real-time analysis difficult. To speed upthe process, MSFC implemented an Unsteady DataReduction and Analysis system in May 1998 to handle

data generated by cold flow testing of high flow-rateturbines and pumps. In the past, the Center�s analy-sis method involved collecting cold flow test data onanalog tapes and sending them to another building forprocessing. Here, engineers converted the data froman analog to a digital format, loaded the informationinto a computer, and performed various analyses.Extra time was often spent importing data intovarious software packages to do data summary andgraphing. Results took at least a full day or longer,which could create delays if the next test was depen-dent on the preceding test�s results.

MSFC�s Unsteady Data Reduction and Analysissystem performs near-real-time analysis by usingthree systems: the Computer Aided Dynamic DataMonitoring and Analysis System (CADDMAS); theOperator Interactive Signal Processing System(OISPS); and the Coherent Phase Cavitation Monitor-ing System (CPCMS). CADDMAS is a parallel proces-sor with 32 high frequency input channels thatcollects, stores, and performs real-time data analysis.OISPS performs conventional and advanced signalanalysis on the data, and CPCMS determines thecavitation intensity.

Since implementing the Unsteady Data Reductionand Analysis system, MSFC realized faster testthroughput, real-time identification of measurementproblems, monitoring capabilities for anomalousresults, and a user-friendly format for data. Althoughthis system was designed for cold flow testing of highflow-rate turbines and pumps, the concept could beused on other tests where unsteady data is collected.Future plans include making the Unsteady DataReduction and Analysis system able to handle systemupgrades and be accessible by multiple code developers.

Vibration Development and VerificationTesting

NASA requirements called for the liquid hydrogenliquid level sensors for the space shuttle�s superlightweight external tank to undergo three-axis ran-dom vibration testing at -423° F. During testing, thevibration levels also need to be monitored to ensurethat the power spectral density stays within specifiedvalues. MSFC, however, discovered that the acceler-ometers used to measure the vibrations were unreli-able at this extremely low, cryogenic temperature.Specifically, the accelerometers exhibited random DCshifts and high frequency spikes below -200° F. TheCenter concluded that it was not possible to chill theaccelerometers to the required temperature and stillget an accurate output.

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MSFC first approached this issue by performingrandom vibration testing at room temperature andusing a power spectral density, six decibels down fromthe required vibration level to guard against hard-ware damage. One accelerometer was mounted on theshaker armature and another on the unit under test(UUT). The resulting power spectral density levelswere then measured. Next, MSFC derived the trans-missibility (Q factor) between the armature and theUUT (and its mounting configuration) by examiningthe difference between the responses of the two accel-erometers. Using the Q factor to adjust the inputvibration levels of the shaker table, MSFC predictedthat the output vibration levels would stay withinparameters. To test the concept, MSFC performedrandom vibration testing at -200° F, the lowesttemperature at which the accelerometers had provedreliable. Results confirmed that measurements in-side the UUT agreed with the test criteria. Based onthese results, MSFC concluded that its approach wasviable and would have no appreciable effects as thetemperature was further lowered. The UUT was thensuccessfully isolated and chilled to -400°F + 30°F.

By developing a method to correlate the accelerom-eter response of the UUT with that of the shakerarmature, MSFC successfully performed three-axisrandom vibration testing at extremely low, cryogenictemperatures. In addition, this method permits test-ing over a wider temperature range, allows the use ofcontrol points that may be inaccessible during test-ing, and avoids the need for specialized instrumenta-tion. This technique was successfully used on theanti-vortex baffle sensors as well as an X-33 valve, andwas extended to acoustic testing.

Production

Composite Structures Manufacturing

MSFC has a long and rich history as NASA�s leaderin large space hardware manufacturing. Around1983, the Center established the Productivity En-hancement Complex (PEC) as a full-scale manufac-turing environment for developing and qualifyingautomated manufacturing processes and materials tomeet future requirements and launch schedules.PEC began as a single research cell, and has evolvedinto nearly 50 dedicated research areas locatedthroughout the Huntsville complex. Since the 1980s,the Center has also developed and produced variouscomposite components for the space program, and is

recognized as a national leader in this field. TheCenter offers outstanding resources, expertise, andcapabilities to produce a wide range of shapes andsizes of composite components. Because of these at-tributes and its unique, cooperative working relation-ships with industry, MSFC is approached by manycontractors to develop and demonstrate the feasibilityof using composite components in their programs.

The industrial infrastructure for composite manu-facturing, however, is slowly evolving throughout theNation due to the high costs and risks associated withqualifying new materials for spaceflight. This situa-tion, along with a small market for large compositecomponents, have caused MSFC to become even moreself-sufficient in this field. The continued investmentin composite materials technologies at MSFC is es-sential, if new and advanced materials are to beutilized confidently in the next-generation space ve-hicle systems. NASA has already set goals to reducecosts by at least an order of magnitude. The newlydeveloped Fastrac engine is an example of this costreducing effort. When put into production, this enginecan be delivered for approximately one-tenth the costof a comparable engine built using yesterday�s prac-tices and materials.

The need to find affordable and reliable access tospace continues to be a vital requirement for NASAand industry so they can remain competitive in theworld market. MSFC, with its unique capabilities incomposite manufacturing, is devoted to the advance-ment of composite materials and processes. By main-taining its partnership with industry, the Center cancontinue to provide the technological breakthroughsnecessary for the next-generation systems of spacetransportation, thus assuring the Nation�s continuedleadership position in space technologies.

Environmental Control and Life SupportSystems

One of MSFC�s capabilities is developing and test-ing life support systems for manned space missions.Typical systems include oxygen for breathing; foodstorage; filtering canisters for removing contami-nants within the vehicle; stored water for drinkingand washing; collection/storage containers for urine;and collection/treatment/storage containers for solidwaste. As the manned space program grew, require-ments changed and new technologies were developed.Early missions such as Mercury, Gemini, and Apolloused expendable throwaway systems because of the

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vehicles� weight constraints and short flight dura-tions. Regenerative systems and techniques were alsoimpractical due to size, weight, and cost. However,the Space Shuttle program introduced a new era formanned space missions. As flights became longer induration, systems were needed to support the regen-eration of life support resources within the spacevehicle. The continued use of expendables for thesesystems became too costly in terms of logisticalsupport.

ISS is the next-generation vehicle, and will requireregenerative life support systems to effectively re-main in space. The design concept of the space stationincludes separate modules, airlocks, and nodes whichare docked and assembled together to form a largepressurized enclosure. This enclosure must be ca-pable of supporting manned operations for indefiniteperiods of time. Provisions (Figure 2-3) for sustaininga crew on ISS will be controlled by the space station�sEnvironmental Control and Life Support Systems(ECLSS). NASA has delegated the responsibility ofdesigning and testing ECLSS to MSFC. To supportthis assignment, an extensive design and test pro-gram is underway, including the development of theCore Module Integration Facility (CMIF) which willtest ECLSS and its subsystems:

� Water Reclamation System � Has undergoneanalysis since 1990 with extensive testing and acontinuous, 146-day cycle of operation.

� Vapor Compression Distillation Unit � Designedto process urine, has completed life testingrequirements, and is now being used as adevelopment unit to support a future spaceflightexperiment.

� Biofilm Test � Determines if buildups areoccurring by circulating clean and dirty waterthrough onboard plumbing components.

� Internal Thermal Control System � Simulatesthe temperature and humidity control system ofthe space station, and is used to test fans, blowers,pumps, heat exchangers, etc.

The CMIF also contains the Common Module Simu-lator which is the same shape and diameter as the ISScore module. This unit contains all services (e.g.,water, electrical, gas) needed to operate the varioussubsystems independently or as an integrated sys-tem. A new addition to the CMIF is a HabitationModule Simulator which is currently being outfittedto support ISS-sustaining engineering efforts. A com-plete set of ECLSS hardware will be installed in thissimulator, so parallel operations can be performedwith ISS operations to respond quickly to any on-orbitsituation that might occur.

Figure 2-3. Space Station Regenerative ECLSS Flow Diagram

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Marshall Convergent Coating

During a launch, the space shuttle�s solid rocketboosters (SRBs) are exposed to extreme heat gener-ated by wind resistance and engine exhaust. In themid-1980s, MSFC developed Marshall SprayableAblator-2 (MSA-2) as an ablative insulation materialto protect the SRBs� forward assembly, systems tun-nel covers, and aft skirt. During the MSA-2 process,nine ingredients are mixed with the adhesive andthen applied to the desired area. Although effective,MSA-2 had many drawbacks. Each batch was costlyand had a five-hour pot life. The application processwas often interrupted which ruined some or all of abatch. The tensile strength of MSA-2 was difficult toregulate, and the material tended to come off the SRBsduring the flight and especially at splashdown. Thecost of investigating this anomaly added to the ex-pense of using this insulation material. In addition,MSA-2 contained two chlorinated hydrocarbon sol-vents which were harmful to the environment.

The Space Act Agreement fosters the transfer oflaboratory technology to real-world applications. InFall 1993, MSFC teamed with United Technologies�USBI to investigate an alternative to MSA-2. Usingconvergent spray technology (CST), they atomizedepoxy and filler materials to create an ablative insu-lation material called Marshall Convergent Coating-1 (MCC-1). This environmentally friendly coating issuperior to MSA-2, and consists of 8% hollow spheri-cal glass, 9% cork, and 83% two-part epoxy by weight.During the MCC-1 process, materials are mixed atthe point of release from a specialized spray gun at thetime of application. This solventless approach pre-vents interruptions from ruining a pre-made batch.The first SRB flight hardware sprayed with MCC-1was a left-hand skirt for the Space Shuttle Atlantis(STS-79). The excellent performance during this Sep-tember 1996 mission led to the full implementation ofMCC-1 on all subsequent flights. Virtually no missingMCC-1 has been noted during the post-flight inspec-tions of recovered SRBs.

Besides the SRBs, MCC-1 was used on the U.S. AirForce�s Titan IV payload fairing trisectors and Boeing�sSea Launch, and has been selected for Boeing�s DeltaIV. There is potential to qualify MCC-1 for multi-flight use on the SRBs and to determine if CST can beused on the space shuttle�s external tank as well asother SRB applications. Tested spin-offs of CST in-

clude acrylic filled with recycled rubber for roofsurfaces on industrial buildings, and epoxy filled withabrasive flint as a skid-resistant coating for the roadsurfaces of the Bankhead Tunnel and a highwaybridge on Interstate 65 in Alabama.

Rapid Prototyping

MSFC is successfully using Rapid Prototyping (RP)technology to fabricate engineering concept models.More than just a 2-D drawing or printout, RP modelscombine the benefits of conventional prototyping andautomated fabrication processes to produce a physical3-D model of the actual design concept. These modelshave faster turnaround times and are less expensiveto produce than conventionally machined models.Traditionally, solid models were created by usingcommonplace methods such as hand carving, manualmachining, and/or the use of computer numericalcontrol machine tools. Though successful, these meth-ods are labor intense and require more time and skillthan RP techniques. Models that usually took days orweeks to produce are now being completed in a fewhours. In addition, the design engineer gets to see,hold, and examine the concept part much earlier inthe design stages, thereby reducing costly rework ofmating parts and assemblies due to design changes.

Since implementing RP technology, MSFC hasimmediately realized many benefits. One exampleinvolves investment casting patterns for three enginechambers. After the Center fabricates these patterns,an on-site contractor uses them to produce an Inconel718 casting for each engine chamber. By using RPtechniques, the fabricated patterns and castings costabout $3,500 each. MSFC estimates the cost at $30,000each, if done using forged and machined parts. RPtechniques enabled these products to be delivered andinstrumented for hot-fire testing within four weeks,compared to 16 weeks using conventional methods.The overall savings on this project alone amounts to$79,500.

RP technology significantly reduces the cost andtime to develop solid models and evaluate their form,fit, and performance prior to manufacturing thefinished part. With MSFC�s unique RP capabilities,the need for mock-ups and other intermediate steps(required to produce flight quality products) are beingphased out as new materials are developed and largersize parts become more feasible to produce.

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Real-Time Expert Systems for SpacecraftHealth Monitoring and Command

NASA realizes that its current approach to payloadoperations will be significantly changed because ofcontinuing fiscal pressures. Since 1994, MSFC hasfunded the development of intelligent software appli-cations for payload ground operations. These applica-tions offer a way to reduce labor requirements so long-term operations, like ISS, can be effectively managed.Through deployments, the Mission Operations Labo-ratory (MOL) has already demonstrated the benefitsof intelligent software systems for real-time telemetrymonitoring and commanding. Seven test sets haveflown on missions throughout 1998, and will culmi-nate in a major development project to provide real-time command and control of scientific experiments(Express Racks). This project is slated to begin withISS launch 6A in the second quarter of 2000.

G2 is the technology that enables object-orienteddevelopment of software applications, so MSFC cancreate intelligent control and diagnostic monitoringsystems in a time-critical environment. This technol-ogy operates on Unix workstations and Windows NTPCs, and incorporates COTS software and an Opti-mized Advanced System Integration and Simulation(OASIS) programming shell. MSFC uses G2 acrossits program lifecycles, and integrates lifecycle datainto this tool as libraries (Conceptual; Requirements;Design; Fabrication and Test; Training and Opera-tions). This Common Lifecycle Toolset features sub-elements and reusable software steps which willevolve into the operational fidelity phase (optimallevel of certainty) for life-critical decisions. G2�s opera-tor interface is done through text language andsimulation technology. Because of the interface�sflexibility and intuitiveness, no extensive knowledgeof programming is required. Inference knowledge andgeneric object libraries, combined with OASIS, createseveral advantages for efficiencies and project costsrelated to programming.

During mission operations, a real-time expert sys-tem provides schematic-based telemetry monitoring,data trending, expected state monitoring, malfunc-tion procedure execution, and high/low (analog) moni-toring. Updated once per second, the system displaysoperator messages via graphics and prioritizes faultsby using color schemes. Ground control personnel canmonitor the system via remote, through the MOL, orwith routed messages (e.g., e-mail, pager) based onpredetermined parameters. In addition, faults arequickly traced to the component level through point-and-click commands, which provides the engineerwith additional minutes for resolving a problem.

MSFC�s integrated systems engineering approachenhances design knowledge capture and retention forall mission phases, and allows the development cycleto be accelerated. By using G2, MOL reduced laborneeds, promoted communications, and achieved aten-fold increase in productivity. MSFC expects greatersavings once the fault detection and control systemsare implemented on ISS.

Thermal Spray Coating and FormingProcesses

Thermal spray coating and forming is a processwhere a coating thickness of 0.001 to over 0.750 inchis applied to a surface. In addition, this process canlayer dissimilar coating materials so that their desiredproperties work together, such as in functional gradientcoatings. A typical example is the coating of aluminaon tungsten and molybdenum. Thermal spray coatingand forming is applicable to many metallic and non-metallic substrates. The process may also be a suitablealternative to electro-plating and organic paints,especially if portability, high deposition rate, orenvironmental issues are important.

MSFC uses three thermal spray coating and form-ing processes:

� Vacuum Plasma Spray can apply exotic metals inthick layers, but is costly and is limited to vacuumchamber operations. In an inert environment,plasma is generated by ionizing gas via aninternally conducted arc and accelerates thecoating material through the plasma flame to thesubstrate.

� High-Velocity Oxyfuel Spray can apply manymaterial types and is cost effective. This methodhas no coating thickness restrictions nor noiseconsiderations. The supersonic gas velocity froma combustion process propels the powder. Thepowder then melts as it passes through the flameand is deposited on the workpiece surface. Theintense kinetic energy results in a dense, well-adhered coating.

� Wire Arc Spray is the most cost-effective methodfor material applications. To apply the coating,this method melts two advancing wires throughan electrical arc, then introduces a high velocitygas that propels the coating toward the substrate.Another strength of this method is the rapidprototyping of parts by coating a foam mandreland subsequently washing out the foam, leavinga working prototype that can be tested andassembled if desired.

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The main differences among MSFC�s thermal spraycoating and forming processes are layering thickness,operation/equipment cost, and type of base materialbeing coated. Many techniques can remove thesecoatings, including abrasion and machining as thesemethods do not produce molecular bonds. MSFC�swebsite at http://map1.msfc.nasa.gov offers additionalinformation on these processes as well as collabora-tion opportunities.

Facilities

X-Ray Calibration Facility

MSFC�s X-Ray Calibration Facility (XRCF) is aworld-class, one-of-a-kind operational site that wasconstructed in 1975. Over the years, it has gonethrough many changes to make it a highly flexiblefacility with a multi-disciplined workforce. As thelargest x-ray, optical test site in the world, the XRCF(Figure 2-4) features a 2,000-square foot, class 10,000area for unpacking and assembling hardware and a6,000-square foot, class 2,000 vertical laminar flowclean room. The XRCF�s vacuum chamber is a 24-footby 75-foot stainless steel compartment, capable ofsustaining temperatures from -180°F to +180°F andvacuums to 10-7 Torr. The chamber can accommodatein-flight configurations of any payload to be launchedfrom the space shuttle.

The facility�s x-ray system produces a nearly paral-lel beam that travels down a 1,700-foot long, stainlesssteel guide tube with gate valve isolation from thecalibration chamber. The guide tube varies in diam-eter from three feet at the source of the beam to fivefeet at the chamber. Internal baffles prevent thescattering of the beam by eliminating rays that hitthe sides of the tube. The x-ray source and thechamber are isolated from the surrounding buildingand the ground to remove any possible interferencefrom seismic disturbances. The high vacuum levels ofthe chamber can be achieved in six hours, first bymechanical pumps (also isolated from the chamberand the ground) and then by cryogenic and turbo-molecular pumps. Additionally, MSFC can isolate thecalibration chamber from the guide tube to performthermal vacuum testing of space shuttle payloads,leak testing of space station modules, space simula-tion testing, and large space structure bake-outs.

The XRCF is strategically located near the RedstoneArsenal Airport, the Tennessee River, and majorinterstate highways. As a result, materials and com-ponents for testing can be easily delivered to the

facility. All buildings within the XRCF maintain acontrolled access and are connected by a secure localarea network. Manning levels for normal operationsis two to four employees per shift. MSFC�s ability totest and calibrate instruments prior to their launch isa significant benefit, thereby reducing unexpectedand costly problems/failures before they occur inspace.

Management

ISO-9001 Implementation

In 1995, the NASA Administrator mandated thatall NASA centers become registered to ISO-9001.MSFC began working on this objective in May 1996and completed it by February 1998. Aside from thedirective, MSFC viewed ISO-9001 registration as anopportunity to improve self discipline and internalcommunications; facilitate better communicationamong all NASA centers; and attain better alignmentwith support contractors.

The key to successful implementation was fosteringeffective communications at every level and throughevery stage of the process. MSFC�s quest began withcommitment from top management and personalinvolvement by the Center�s Director. ISO was viewedas a management system, not just a quality system.Everyone was involved in the implementation pro-cess, which soon became an inherent way of perform-ing MSFC�s day-to-day business. The Center estab-lished an effective implementation organization andset up teams. An electronic, web-based documentcontrol system was also created with an electronic

Figure 2-4. X-Ray Calibration Facility

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review and approval process, making instant access/retrieval a reality and improving the currency ofpolicies and procedures. Frequent internal auditswere conducted to build accountability and drive thebaselining process. MSFC put in place a single correc-tive action system for the entire Center, where previ-ously ten had been. A capable and trusted outsideconsultant provided guidance and assistance through-out the implementation and certification processes.General awareness training was conducted as soon aspossible in the early stages for 100% of the Center�spersonnel. This helped minimize any misinformationor misunderstanding. Process specific training wasalso conducted to address procedure changes and newISO processes. Continuous communication was ap-plied in multiple media modes (e.g., memos, websites,newsletters, e-mail, posters, organizational represen-tatives).

By far, the single, most effective communicationtool at MSFC is its ISO-9000 website (http://iso9000.msfc.nasa.gov:9001/index.html). This siteprovides a single source for generic and specificinformation about MSFC�s ISO-9000 issues, and isalso an excellent reference for other NASA centers oranyone wishing to obtain data on the implementationprocess. MSFC�s ISO-9000 website provides generalinformation on every possible aspect of ISO-9000 plusevery detail of MSFC�s experience (e.g., historicalpublications, presentations, clarifications, audit notes,findings). This site is extremely valuable for anyonecontemplating or undergoing ISO certification.

The ISO-9001 preparation and certification pro-cesses provided MSFC with many lasting benefits.The most important is improved communications.The Procurement Department experienced a 65%reduction in procedures, and other departments havehad similar reductions. The Center now has greaterrigor in project planning and configuration controlplanning. Contractor accountability and control hasalso greatly improved. The ISO process promptedscrutiny and formal mapping of internal processes byorganizations, often for the first time. Redundantfunctions and documents were eliminated, and morediscipline was achieved in the control of records,documents, and procedures. Others can benefit fromthe lessons and experience of MSFC by exploring itsISO-9000 website.

Marshall�s ElecTRonic Office

Over the past few years, MSFC has seen a surge inthe number of available electronic tools and Internet/Intranet sites. With so many choices, users often

waste valuable time trying to locate the appropriateresource for their work. The need to access pertinenttools, websites, and MSFC-specific documents andregulations led to the development of Marshall�sElecTRonic Office (METRO).

METRO is a website, established within the MSFCProcurement Library, that provides one-stop shop-ping for up-to-date, web-based information. The site isdesigned for total coverage and maximum usabilityfor procurement and non-procurement personnel alike.METRO operates as a single point of access forelectronic tools, MSFC information, and Internet/Intranet sites. Each site is password protected asappropriate. Internet sites include: NASA Acquisi-tion Internet Service; Federal Acquisition Regula-tions (FAR) and NASA FAR Supplement; ElectronicPosting System; Small Business Innovation ResearchProgram; NASA Procurement Library; ConsolidatedContracting Initiative; standardized industrial codes;on-line purchasing sites; and per diem rates. Intranetsites include: ISO-9000 documents; On-line CreditCard Program; Procurement News and Special Events;MSFC Intranet site; Personnel Contact List for Pro-curement/Finance; and downloading of special docu-ments and forms. Future METRO links are beingdeveloped which feature training aids for contractspecialists and technical personnel.

METRO has proven to be an invaluable tool forcarrying out daily activities at MSFC. Key aspects tointroducing METRO to users were its prototype demon-stration model to management and its identificationof a point of contact for the content/technical aspectsof the site. METRO is recognized by MSFC users asthe one-stop shop for web-based resources, and isconstantly updated to provide the latest and mostaccurate information. The name, itself, suggests it isa vehicle for going to the right place. METRO savesvaluable time for its users, provides user-friendlyaccessibility, offers unlimited potential for expansion,and operates as the main communication tool for theProcurement Directorate.

NASA Acquisition Internet Service

In 1993, a presidential memorandum was issuedwhich required all government agencies to stream-line their procurement processes via electronic com-merce. Previously, vendors seeking to do businesswith NASA had to search through the CommerceBusiness Daily (CBD). Reviewing this publicationwas a laborious process, and many small businesseshad limited access to the CBD. To comply with thememorandum and provide small businesses with

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greater accessibility, MSFC developed the NASAAcquisition Internet Service (NAIS). This service isan agency-wide, on-line capability that communi-cates procurement information to industry. Specifi-cally, NAIS provides real-time synopses of businessopportunities, solicitations, and a repository of gov-ernment acquisition websites to vendors seeking op-portunities with NASA.

In 1994, NAIS began as NASA�s Midrange PilotProgram. The program�s objectives were to establisha new set of tools and processes for streamlining theacquisition process, and to exchange informationbetween NASA and potential offerors via the Internet.The original setup used procurements between $25,000and $500,000, an 80% representation of NASA�spurchases. Vendors received electronic messages re-garding synopsis information, advance procurementnotices, contract award notices, solicitations, andamendments. The Midrange Pilot Program wasstarted at MSFC and, once the concept proved suc-cessful, was implemented throughout NASA in 1995.Today, NAIS is mandatory for all competitive acqui-sitions over $25,000. Procurements of $25,000 or lesshave the option of using NAIS.

A team approach was employed to design NAISusing representatives from each NASA Center. Teammembers worked part time on this project in additionto their other duties. The team communicated viaweekly teleconferences and monthly video teleconfer-ences, and established an on-line discussion forum,the first of its kind. NAIS was developed by integrat-ing and standardizing the best ideas from all theNASA Centers� websites. Since NAIS was imple-mented, additional features have been added:

� Search Capability � Allows vendors to search forspecific business opportunities.

� E-mail Notification � Allows vendors to receiveinstant notification of an opportunity once theycomplete an on-line registration form detailingprocurement interests.

� Federal Acquisition Jumpstation � Providesvendors with a single source for governmentacquisitions. First-ever listing of links to othergovernment agency acquisition websites.

� Financial and Contractual Status System �Provides Internet access to contract summarydata. Vendors and congressional staffers canbuild their own query to obtain information onNASA�s current procurement activities. Querycriteria include product/service code, dollar value,contract type, contract number, geographicinformation, and Standardized Industrial Codes.

� Electronic Posting System � Allows contractspecialists to post synopses and solicitationsdirectly to the NASA website from their desktops,eliminating the need for a webmaster. In addition,an electronic version of the synopsis is generatedand sent to the Government Printing Office forinclusion in the CBD. The success of this systemhas led to an interagency initiative for a pilotprogram, which will provide vendors with anelectronic web source for all governmentprocurement opportunities.

By implementing NAIS, NASA has made its pro-curement process more efficient and competitive.This streamlined capability conveys procurementinformation to vendors on an immediate basis. As aresult, NAIS decreased procurement leadtime by 40%and increased the average number of offers per solici-tation from 6.1 to 7.2. In addition, NASA and industryrealize an overall cost savings of approximately $4.5million by using NAIS.

NASA/Air Force Cost Model

Prior to 1990, no standardized cost estimating toolexisted at NASA. Instead, numerous spreadsheetmodels were used. These models relied heavily onvolumes of historical data that were searched, ana-lyzed, and inserted into formulas. Additional draw-backs included no formalized training for users,inconsistencies between models, difficulty in showingdata traceability, need for engineering judgement,and limited detailed relational analysis capabilities.These models, however, did perform Cost EstimatingRelationship (CER) estimates, but provided little morein additional services. As a result, managementfrequently had to review the findings after cost esti-mates were generated. In 1990, MSFC�s EngineeringCost Office visualized a better process using a singlemodel to meet all needs. Within a few years, MSFC,in conjunction with the Air Force, implemented aviable prototype known as the NASA/Air Force CostModel (NAFCOM). Since then, NAFCOM has evolvedinto a cutting-edge cost analysis, modeling, and esti-mating tool.

NAFCOM consolidates numerous existing costmodels and databases used throughout NASA, andbrings cost estimating into compliance with today�sstate-of-the-art software environments. This fullyautomated software tool employs an easy-to-use spread-sheet environment to predict the cost of space hard-ware at the subsystem and component levels. Theinformation within NAFCOM represents the best of

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the aerospace project data from the Resource DataStorage and Retrieval (REDSTAR) library, NASA�smajor repository of cost, technical, and programmaticinformation dating back to the 1960s. The REDSTARlibrary contains over 22,000 documents and onemillion pages of information, and maintains a website-based user interface to coordinate these componentsinto a single user-friendly interface.

Creating cost estimates within NAFCOM are basedon specific analogy and database averaging tech-niques. Specific analogy CERs are created by select-ing analogous data points from the database withinNAFCOM. The database�s average CER representsthe average of the data population. To create a specificanalogy CER, the user first selects the appropriatedatabase (e.g., manned spacecraft, unmanned orbit-ing or planetary spacecraft, launch vehicles, liquidrocket engines) and then the appropriate data level(e.g., group, subsystem, component, unit). Withineach data level, the user selects:

� Group level items (e.g., structures, thermal, andmechanisms; electrical power and distribution;command, control, and data handling);

� Subsystem level items such as typical aerospacehardware (e.g., thermal communications, attitudecontrol); and

� Component level data (e.g., batteries, supportstructure, rate gyros, cabling).

After making these selections, the user furtherrefines the CER database by choosing from more than100 filters within the cost model that relate to thetechnical and programmatic characteristics of thedata points. The available filters are determined bythe system and subsystem choices at the data levelentry. Once the data levels and filters are applied, theuser selects specific programs from a list of missions,enters weights, and applies complexity factors soNAFCOM can determine the estimated cost. All usersare trained on this tool.

Currently released as version NAFCOM99, thistool is consistent, efficient, and effective at defendingcost estimates. NAFCOM operates as a single costestimating system that meets users� needs, and pro-vides management with a standardized format forreviewing estimates. As a result, this tool reduced thefrequency of reviews and greatly improved the credit-ability of the system.

New Technology Transfer Program

Technology transfer has always been a major thrustfor the NASA Centers. In the past, MSFC focused itstechnology transfer resources on assisting industryand small businesses, whereby NASA field agentslocated industry problems and provided companieswith up to 40 hours of free technical assistance.However, such services eventually put a strain onMSFC�s resources and detracted from the Center�sprimary mission focus areas. Inadequate resourceswere applied to technology development and deploy-ment partnerships, intellectual property manage-ment, patent licensing, technology transfer educationand outreach, and success story case studies. Tobetter meet the needs of internal and external custom-ers, MSFC restructured its technology transfer pro-gram in 1997.

The structure of the New Technology Transferprogram was changed from a hierarchical, stovepipeframework with little communication/interactionamong units to a flat organization with an integrated,cross-trained team. In addition, the Center shifted itsprimary focus away from gratuitous extension ser-vices and set up eight interdependent mission areas:Technology Development; Small Business Programs;New Technology Reporting; Facilities Commercial-izations; Technology and Software Commercializa-tion; Technology Deployment Partnerships; National,Regional, and Local Strategic Alliances; and Technol-ogy Education and Outreach Projects for EconomicDevelopment. These areas provide MSFC with a morecost-effective, balanced portfolio of quality productsand services. New objectives were identified to helpU.S. industry become more globally competitive,specifically through national goals for the civilianspace program and responsibilities associated withtransferring NASA technology. Under this new ap-proach, MSFC applied business principles to govern-ment technology transfer processes to gain efficien-cies, improve performance, and align with missionrequirements. The infusion of this strategy into NASA�straditional technology transfer mechanisms revital-ized the overall program. As a result, numerousmethods and agreements now exist for transferringNASA technology to the private sector:

� Research and Development Agreements �Arrangement between NASA and privatecompanies, whereby the expenses associated withNASA facilities, personnel, equipment, technology,

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and/or capabilities are fully reimbursable, partiallyreimbursable, or non-reimbursable by the privatecompanies.

� Joint Research Agreements�Arrangement thatis jointly funded and undertaken by NASA andone or more private sector companies.

� Small Business Innovation Research Programand Small Business Technology TransferContracts�Programs designed to benefit smalland disadvantaged businesses.

� Cooperative Agreements, Grants, and Contracts�Methods used to stimulate technology developmentand commercialization. Many NASA technologiesare available for licensing with flexible agreementsand mutually beneficial exclusive and non-exclusive arrangements.

NASA uses various publications to highlight itstechnology transfer opportunities and success stories.NASA Tech Briefs is a monthly magazine that fea-tures technical articles on emerging technologiesfrom the NASA Centers. This magazine is publishedelectronically (http://www.nasatech.com) and in hardcopy. Aerospace Technology is a bi-monthly newssummary on how NASA technology is being applied,and covers the intricacies of actual technology trans-fer. This news summary is accessible at http://www.nctn.hq.nasa.gov. NASA Spinoffs is an annualcompilation of success stories of NASA technologybeing applied to improve medical, environmental,manufacturing, construction, transportation, safety,consumer, and computer products. This publicationis available electronically (http://www.sti.nasa.gov/tto) and in hard copy. Users who visit the website willfind a searchable database for browsing technologytransfer case studies. Additional information can beobtained directly from the MSFC Technology Trans-fer Office by visiting its website (http://www.nasasolutions.com) or by contacting the office at(256) 544-6700.

Since implementing its new approach to technologytransfer, MSFC has compiled success stories in alleight mission areas and achieved greater customersatisfaction, both internally and externally. Technol-ogy transfer now operates across all mission areasinteractively and synergistically. During the pastyear, the number of patent licenses increased by 108%and the number of partnerships increased by 67%.The entire effort is contributing directly to U.S.national objectives for developing and commercializ-ing space technology.

Reusable Launch Vehicle Case StudyModel Initiative

MSFC�s Engineering Cost Office developed a dis-counted cash flow model to analyze commercial busi-ness cases for the Reusable Launch Vehicle (RLV). Asa result of this effort, NASA redefined government-industry relationships and envisioned a new way ofinvesting in large scale technology developmentprojects. Traditionally, government and industry jus-tify these types of projects on the basis of a cost-benefitanalysis. However, the economics of a cost-benefitanalysis are different for government and industry.Large scale technology development projects are usu-ally long-term, high-cost investments which are ac-ceptable to government, but not industry. The differ-ence is the cost of capital which is a significant factorfor industry. Government can afford to wait 40 or 50years to realize a payback, but industry�s horizons forreturn-on-investment are much shorter.

Typically, government relies on industry to shoul-der much of the development cost and risk for majorsystems. However, some technologies are too impor-tant to wait for a market-driven development effort.Historical examples include railroads, aviation, andelectrical power. In these cases, the governmentprovided assistance in funding, incentives, and othermechanisms to spur development. Revolutionary tech-nologies create new industries and open up vast newfrontiers of economic development. RLV is such atechnology and will enable NASA to reduce launchcosts by an order of magnitude, thereby increasinglaunch activity and further driving down launchcosts. Lower commercial RLV prices should lead toincreased U.S. market shares in the global launchbusiness and development of commercial space indus-tries. This situation, in turn, will provide increasedexports, employment, and tax revenues.

MSFC�s model employs discounted cash flow analy-sis to determine the level and type of incentives and/or investments that NASA can make to encouragecommercial development and reduce risks to an ac-ceptable level for industry. This model is an out-growth of the X-33 and follow-on programs in whichindependent industry teams each developed their owntools for modeling the business cases for the RLV.These cases were then integrated by MSFC into theRLV Case Study Model to provide NASA with ananalytical capability to independently examine thebusiness plans being proposed by industry. The RLVCase Study Model was designed to quantify the busi-ness risks involved in a commercial RLV, define key

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business parameters, and gauge the sensitivity ofbusiness variability to these parameters. The modelprovides flexibility to analyze the effects of variouslaunch parameters and incentive schemes, and ad-dresses both government and industry perspectives.In addition, MSFC�s model is expandable for definingand calculating metrics (e.g., internal rates of return,net present values, life cycle cost), and takes intoaccount microeconomic metrics (e.g., industry profit-ability, government savings) and macroeconomic con-siderations (e.g., jobs, corporate and personal taxes).Figure 2-5 depicts the current RLV model structure.New enhancements being added include market elas-ticity considerations and NASA�s life cycle costs of aspace transportation architecture.

The shift to commercial launchers enables NASA tofocus on the new frontier of space transportationtechnology development and the organization�s ulti-mate customers: the infant space transportation in-dustry and the yet-to-be-developed human space trans-portation industry. MSFC�s model shows NASA thevalue of providing appropriate incentives, invest-ments, grants, direct capitalization, and in-kind con-tributions to industry. This initiative has proven thatlong term investment in technology and transporta-tion infrastructure is an appropriate role for govern-ment. In return, the investment will reduce launchcosts for the government and spur the development of

the commercial space market with significant macro-economic benefits to the country. MSFC�s approachcan be easily adapted for use by other governmentagencies as well.

Space Leadership Council

Improving customer satisfaction has always beenembedded in MSFC�s enterprise goals and objectives.In the 1990s, the Center entered into a new era ofdoing business through better leveraging and part-nerships where each partner is considered to be acustomer. One of the first tests of using a leveraging/partnership approach was ISS involving MSFC; NASAJohnson Space Center (JSC); Teledyne Brown Engi-neering; Boeing; and Defense Contract ManagementCommand, Birmingham. Recognizing that traditionalpractices were no longer conducive to this arrange-ment, MSFC and its partners established the SpaceLeadership Council (SLC) in January 1996. The SLCis a way to provide contractually compliant NASAproducts and services by improving communicationsand key processes to the satisfaction of its customers.

To ensure the project�s success, the SLC wanted tomake improvements in communications, processes,proactive teamwork, performance and recognition,and employee development. Therefore, the group ex-amined the common enterprise missions, goals, and

Figure 2-5. Current RLV Model Structure

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objectives of its respective organizations to formulatea council that operated within these parameters. TheSLC next set goals to establish, facilitate, and main-tain a common communications network; meet orexceed NASA requirements and expectations for de-livery of products and services; establish a viablecommitment to achieve an honest focus on commongoals; and improve the performance of all participantswho supported the NASA project. To achieve thesegoals, the SLC formulated strategies that wouldidentify customer needs and concerns, determine rootcauses and develop solutions, localize recurring prob-lems, eliminate errors, plan for continuous improve-ment, and communicate successes and lessons learned.The SLC process consists of monthly meetings thatrotate from partner to partner, where critical issuesare addressed and mutually agreed priorities are set.Plans are jointly developed in pursuit of the group�svision. Process action teams were also formed toproduce fundamental change and process improve-ments. The SLC recognizes the performance andaccomplishments of significant contributors at alllevels throughout the partnership.

Since the SLC was implemented, the process actionteams have actively pursued and impacted variousissues such as personnel training needs, improve-ments in the acceptance data package process, thehandling/shipping of high-dollar hardware, and aprocess for handling Alert Bulletins. The SLC isaccomplishing its goals, and continues to evolve. As aresult, communications have greatly improved and acommon understanding is shared among all thepartners. Other accomplishments include the estab-lishment of a structured cooperation, collocation ofpartners to facilitate teamwork, and the sharing ofquality assurance databases.

Web-Based Data System Solutions

MSFC�s Engineering Systems Department devel-oped a series of Web-Based Data System Solutions forinformation and document management applications.Prior to these systems, various uncontrolled, undocu-mented processes as well as hardware and softwareplatforms were used at the Center. This situationcreated problems in processing and accessing infor-mation; handling security; and changing or develop-ing systems. As MSFC began downsizing, these prob-lems became more acute. Web-based data systemswere recognized as a way to establish a paperlessenvironment in support of ISO-9001 certification, andprovide immediate accessibility to information perNASA�s faster, better, cheaper approach.

MSFC�s systems are based on a web developmenttool called Tango designed by Pervasive Software, Inc.in Austin, Texas. Tango is a cross-platform, visualproductivity tool for the distributed electronic enter-prise. This tool allows developers and organizations toefficiently and cost effectively tie distributed data andcomputing resources into practical, web-based Intranetinformation systems. Tango is one of several COTStools that provides a programming environment tofacilitate the creation of distributed knowledge man-agement or systems management applications. Tra-ditional mainframe and client server architecturesare too inflexible for implementing close, but fluid,inter-business integration which is driving the in-creased adoption of more flexible, loosely coupled web-distributed systems. The goal of multi-tier web-dis-tributed applications like Tango is to deliver all of acorporation�s information assets and resources to thepoint of use or need with real-time responsiveness.For the web-based system applications developed atMSFC, Tango was used as a translator (Figure 2-6)between a user�s web browser and any source data-base. Unlike static networks in which the user re-

Figure 2-6. Web-Based System Configuration

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mains connected to the server, a web-based systemonly requires the user to be connected to the webserver when completing an action, then the connec-tion is broken. This approach allows the user to drawinformation from any accessible database over theInternet.

To date, more than seven major web-based systemapplications have been developed at MSFC. One ex-ample is the Program/Project Data System (PDS).This tool provides project managers with a docu-mented, ISO-compliant system to review and approvein-house and external documentation. Features in-clude identification and tracking of data require-ments, on-line status reports, and automatic feedingof information into Document Control Board inputscreens to prevent re-entry of information. PDS alsoprovides the capability to reserve and track the status

of MSFC document numbers and program/project-specific document numbers. This system uses a se-cure electronic documentation review process and isbeing upgraded to include a configuration controldocumentation review process.

All of MSFC�s web-based systems are ISO compli-ant. They provide documented control; electronicreview and approval capability; security; and accessi-bility which is not platform dependent. The onlyrequirement for access is a web browser, and thesystems are fully compatible with existing user pro-cesses and software. These systems also enable MSFCto realize significant savings as a result of reducedtime required for system development and changes,and reduced resources required for operation andmaintenance.

S e c t i o n 3

Information

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Design

Advanced Concept Research Facility

MSFC�s Advanced Concept Research Facility is inthe process of developing many alternative propulsionsystems for use in a space environment. Most of thesemethods are still in the development stage and will, ifaccomplished, redefine the limit of travel which ispossible today. Some of the cutting edge technologiesbeing studied include: Solar; Nuclear; Fusion; PulsedPropulsion and Power; and MagnetohydrodynamicPropulsion. Many breakthroughs and discoveries havebeen uncovered during this research. Another methodof potential propulsion being studied at this facility isthe modification of Gravity Utilizing Superconductors.

The Pulsed Propulsion and Power research is stillin the development stages and should have applica-tions in power generation as well as propulsion. TheMagnetohydrodynamic Propulsion research is facingfunding constraints due to this technology�s physicallimitations (e.g., weight), current configuration, andnon-applicability to the space program. The modifica-tions of Gravity Utilizing Superconductors shouldlead to many potential uses including bearing mate-rial as applicable to cryogenic bearing development.

Gas Dynamic Mirror Fusion PropulsionEngine

One of the most critical aspects for perform-ing a manned mission to Mars will be the spacevehicle�s propulsion system. To minimize thecrew�s physical degradation and exposure tohazardous galactic radiation, this propulsionsystem must be able to complete the trip in arelatively short time. Other requirements in-clude moderate size and the ability to producelarge values of specific impulses and thrust.The best propulsion system currently availableis nuclear fusion. This method produces im-pulses of 130,000 seconds, compared to nuclearfission at 950 seconds and chemical propulsionat 450 seconds. A space vehicle using a nuclearfusion system could complete a round trip toMars in months rather than years.

MSFC�s Gas Dynamic Mirror (GDM) system is anexample of a magnetic mirror-based fusion propulsionsystem (Figure 3-1). The Center maintains this sys-tem in steady state by injecting particles in the regionof the homogeneous magnetic field to effectively bal-ance the plasma loss through the mirrors. GDM�sdesign is relatively simple, primarily consisting of along slender solenoid that surrounds a vacuum cham-ber containing plasma. The bulk of the fusion plasmais confined by magnetic fields which are generated bya series of toroidal-shape magnets in the centralsection of the device. Stronger end magnets calledmirror magnets prevent the plasma from escaping tooquickly out the ends.

On October 23, 1998, MSFC tested the plasmainjector system of its GDM Fusion Propulsion experi-ment, and successfully produced a plasma. The pur-pose of the plasma injector is to introduce a gas intothe GDM system and heat it until it becomes plasma.The injector operates by using a microwave antennaoperating at 2.45 GHz to induce electron cyclotronresonance heating of the gas. As the hot electronsstream out of the injector in response to the imposedmagnetic fields, they create an electric field whichdrags the ions along this path. This phenomenon iscalled ambipolar diffusion and is used here to raise theion temperature. The effect requires that the mag-netic fields produced by the solenoid magnets bepresent. For this test, however, these magnets werenot installed so the ions remained in a cold state.

Figure 3-1. Experimental Gas Dynamic Mirror

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High Strength Aluminum Casting Alloyfor High Temperature Applications

A hypereutectic alloy such as A390 is a conventionalaluminum alloy used to make pistons in U.S. automo-tive engines. This alloy has adequate strength, iseasily cast, and is low in cost. However, new congres-sional regulations require U.S. automobile manufac-turers to continue to lower hydrocarbon emissions.

In a Conventional Piston Design, the large crevicevolume between the piston and the cylinder at the topof the piston is a significant contributor to hydrocar-bon emissions. A small volume of unburned gasoline/air mixture is trapped in this crevice volume duringeach firing stroke, and a portion of this unburnedmixture is then expelled on the subsequent exhauststroke of the piston. These unburned gases contributedirectly to hydrocarbon emissions of the automobile.The Ford Motor Company in Dearborn, Michigan hasdeveloped and tested a Modified Piston Design. Asexpected, the thinner piston topland with its greatlyreduced crevice volume significantly lowered hydro-carbon emissions. However, a typical alloy such as

A390 aluminum alloy used in the design has inad-equate tensile strength in the required 500° to 600° Ftemperature range. Figure 3-2 shows a comparisonbetween the Conventional and Modified Piston De-signs.

In 1995, MSFC�s metallurgists began working withFord under a Space Act Agreement to develop a new,castable aluminum alloy that had a 30% improve-ment in tensile strength during operation in therequired temperature range. The result was an alu-minum-silicon alloy that meets or exceeds all originalautomotive criteria. Figure 3-3 shows a 600° F,tensile strength comparison of available aluminumalloys against the NASA alloy. The projected cost ofthe aluminum-silicon alloy is 95¢ per pound versus87¢ per pound for A390. Since less of the new alloymaterial is required due to its higher strength, thecost per piston is expected to be comparable. MSFChas currently filed a patent on the aluminum-siliconalloy, and negotiations are ongoing with Ford andother U.S. automobile manufacturers regarding itsuse.

Figure 3-2. Conventional versus Modified Piston Design

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Marshall Electromagnetic CompatibilityDesign and Interference ControlHandbook

Previously at MSFC, electromagnetic interference(EMI) issues were sometimes not addressed duringthe design phase. Only after a unit experiencedfailures during testing were the EMI engineeringstaff called into the situation. This approach led toexpensive redesign costs and/or waivers being issuedbefore the unit could be fielded. In 1995, MSFCdeveloped the Marshall Electromagnetic Compatibil-ity Design and Interference Control (MEDIC) hand-book to help electrical engineers use practical infor-mation in designing for the mitigation of EMI.

The MEDIC handbook was tailored to the needs ofthe NASA community and provided:

� Guidelines to translate EMI requirements intoelectrical design requirements.

� Design techniques to minimize the potential forEMI.

� Practical measurements and predictiontechniques to identify potential EMI problemsduring the early design phase.

� Practical retrofit fixes for EMI problems discoveredafter the design phase was completed.

The handbook was developed independently fromqualification or acceptance testing. In addition, theEMI engineering staff used a separate laboratory toprove-out techniques, and used common electricaltest equipment to measure results. This approachenabled electrical engineers to prove-out the designbefore performing expensive EMI testing.

Since 1995, the EMI engineering staff has distrib-uted at least 1,000 copies of the MEDIC handbook.Electrical engineers from organizations external toMSFC now commonly contact the staff to discuss EMIdesign issues as well as test problems. The MEDIChandbook has been a useful tool in the EMI designarea, and demonstrates practical approaches to ad-dressing EMI in the spaceflight industry.

Quantitative Risk Assessment System

Probabilistic risk assessment is a method used tocalculate an overall system risk by combining highlevel event probability distributions with probabilitydistributions from each lower level item or process.Although complicated and laborious, this powerfultool provides accurate results for quantifying thedegree of risk. In 1996, NASA recognized the need forsuch a tool to assess overall system and upgrade risksof the space shuttle. Under contract to MSFC, theUniversity of Maryland developed the software for theQuantitative Risk Assessment System (QRAS).

MSFC uses QRAS to assess the reliability of thespace shuttle and its major components; help performtrade-off evaluations; rank space shuttle failure modes;perform sensitivity analysis; assist in other analysisefforts; and evaluate proposed space shuttle upgrades(e.g., propulsion element). QRAS is particularly use-ful for large, complex systems because it arrangesdata in a hierarchical, tree-like structure. The hier-archy format documents the relationship betweenelements, components, and failure modes or basicevent. Next, a functional event sequence diagram(FESD) is developed for each basic event, showingwhere each process is inspected, tested, or evaluated.Probability parameters are inserted into each processin the FESD, along with the appropriate justificationfor using the probability selected. A powerful capabil-ity of QRAS is that probabilities can be entered as timebased, and various distribution functions can beincluded. This approach allows users to evaluate riskover a specific time period as well as obtain confidencelevels on the resulting system risk.

Figure 3-3. Aluminum Alloys TensileStrength Comparison at 600° F

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Concurrent with the above procedures, an eventprobability distribution is inserted into the model.The event probability distribution defines failureprobability during operation and is based on flight testdata, probabilistic structural models, and generalengineering judgement. QRAS then calculates theresulting system level risk based on the input datausing Monte Carlo simulation techniques. Since therisk is expressed as a probability density function, aconfidence level can be associated with the end result.QRAS also operates as a database which allows usersto input the justification and source of each riskprobability used in the model. The hierarchical for-mat lets users manipulate the information to exam-ine the lower levels of the system architecture.

QRAS calculates an overall system risk by combin-ing the probability of occurrence of all system failuremodes. This tool�s windows-based, user friendly de-sign makes it advantageous over traditional probabi-listic risk assessment methods. MSFC uses the endresults to project system life, estimate inspectionintervals, and determine flight readiness support.Repetitive iterations of the risk assessment can alsobe used to perform trade studies by comparing eithertwo design concepts or a new proposed design againsta baseline. Although specifically designed for NASA�sSpace Shuttle program, QRAS can be used on almostany program where probabilistic risk assessment isneeded. The tool is currently undergoing a sequenceof peer reviews, and a final baseline is expected byOctober 1999.

Solar Thermal Propulsion

In the distant future, low cost propulsion will beneeded for interplanetary travel and unmanned ex-ploration. NASA foresees Solar Thermal Propulsionas a way to boost future payloads from a low earthorbit to a geosynchronous earth or higher orbit. Thesepayloads would also undergo round trips of 30 days totransit between orbits. Solar Thermal Propulsion isan excellent choice because it requires only one propel-lant gas and combines moderate thrust with moder-ate propellant efficiency. For more distant travel, asolar thermal engine using this propulsion would actlike a simple, efficient tugboat in space.

In the operation of a solar thermal engine, theabsorber functions as a heat exchanger. Sunlight isconcentrated via a lens or mirror, and then focusedinto the absorber cavity. This cavity is comprised ofthree, vacuum plasma, spray-formed coaxial shellswith two, double helical flow passages through which

the propellant gas flows. As the gas flows through thehelical channels, it absorbs energy, expands, andthen exits the nozzle. Through this process, solarenergy is converted to kinetic energy-thrust. The testunits built at MSFC are designed to produce two totwo-and-one-half Newtons of thrust using hydrogenas the propellant. The intended service temperatureof the ground test absorber cavity is 2450° C, with aninternal gas pressure of 170 kPa, using hydrogen asthe working fluid.

MSFC�s Solar Thermal Facility has built theheliostat mirror, concentrator, quartz-windowedvacuum test chamber, absorber/thruster, and gas-eous hydrogen plumbing. The mirror measures 20feet by 24 feet, and is positioned 200 feet from theconcentrator. During a test, the mirror follows thesun via tracking software and redirects the solarenergy to an 18-foot diameter concentrator. Using 144hexagonal reflective sections, the mirror focuses inci-dent solar radiation through the test chamber�s front-fused silica window and into the opening of theabsorber/thruster.

Test

Army/NASA Virtual InnovationsLaboratory

MSFC�s Engineering Systems Department, in con-junction with the U.S. Army�s Redstone Arsenal, hasdeveloped the Army/NASA Virtual Innovations Labo-ratory (ANVIL). This laboratory develops effectivehuman-interface-to-hardware designs by combininghuman modeling and analysis tools with virtualreality technologies. The process involves importingcomputer aided design (CAD) models into an analysispackage, where the creation of human models evalu-ate the reach, work, and visibility envelopes. Analysisentails partially-immersive or fully-immersive expe-riences for the user. The former permits the humanengineer designer to evaluate the design from theobserver�s perspective by means of a computer screen.The latter allows the designer to see and touch theelements of the human model.

ANVIL uses a variety of virtual reality and humanengineering software including CAD packages formodel translation and modification; virtual realitytools; and human factors analysis applications. Sup-porting hardware consists of high-end workstationsand virtual reality input/output devices such as gloves,navigation aids, head-mounted display monitors, bodyposition sensors, and auditory simulators. MSFC has

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used ANVIL�s capabilities for spacelab hardwaredesign, ISS hardware development of extra-vehicleactivity, ground support of propulsion systems, andworkstation layout. ANVIL also supports immersivecollaboration over networks which allows users inremote locations to interactively train with one an-other, while being monitored by training personnel.

ANVIL provides a virtual reality environment sousers can evaluate interface designs and determinethe most effective setup prior to actual contact. Sinceestablishing this virtual innovations laboratory,MSFC has realized significant savings in design timeand fabrication costs.

Cryogenic Bearing Testing

Cryogenic bearing testing requires special require-ments such as bearing test rigs to duplicate cryogenicturbopump conditions, and computer modeling codesto design special bearings. In the early 1980s, MSFCformed a multi-discipline team consisting of expertsin tribology, design, test, materials, and fabrication toinitiate a Bearing Test program. The team addressedthe cryogenic requirements, fabricated a test rig, andbegan testing. Contracts were also awarded to compa-nies to design low friction lubricating cages, developbetter bearing materials, and refine the bearingmodeling codes.

MSFC�s Bearing Test program fostered many ad-vancements such as improved bearing materials.New low friction lubricating cages consisting of LOXcompatible oils, carbon composite cages, and Saloxcage inserts were also developed. Test results led to abetter understanding of heat generation, hertzianstresses, wear life factors, dynamics of elements, andinternal geometry changes. This information wasincorporated into the computer bearing design codesof SHABERTH/SINDA, ADORE, and AB JONES.

Future turbopumps will spin faster and requiremore power, and the new hydrostatic bearings arewell suited for this application. MSFC also designedand built a test rig that can run hydrostatic bearingsand, with modifications, can run rolling elementbearings in liquid nitrogen, liquid oxygen, and liquidhydrogen (LH2). The LH2 testing capability is uniqueto MSFC. Although it was not directly related tomanufacturing, the Bearing Test program led to newbearing technologies and improved computer-model-ing codes for these types of bearings. Applications forthis technology include aerospace bearings, high-speed spindle bearings, industrial air conditioning,and high-speed turbo vacuum pumps.

Integrated Space StationElectromagnetic Compatibility AnalysisSystem

Six different international partners are designingand building major elements of ISS. As a result of thisarrangement, electromagnetic compatibility (EMC)and electromagnetic interference (EMI) become vitalkeys to successfully completing the space station. Toaddress these issues, MSFC developed the IntegratedSpace Station Electromagnetic Compatibility Analy-sis System (ISEAS). This integrated database systemkeeps track of EMC between devices and systems onISS, and enables engineers to evaluate the effects ofEMI on flight systems. Potential EMC problems canthen be identified and resolved in a timely manner.

ISEAS operates by matching the EMI test resultson individual hardware items with their wiring con-figuration and physical location within ISS. Thisinformation permits EMC engineers to assess variousparameters (e.g., transient effects; conducted emis-sions versus conducted susceptibilities; radiated emis-sions versus radiated susceptibilities) and focus onareas of potential concern.

Early verification of EMC is essential to the ISSproject. MSFC is currently using ISEAS to analyzeEMC for ISS Flight 2A, the second module of ISS to gointo orbit. The �A� designates that this component issupplied by the United States. The full benefit ofISEAS will be realized in about five years when thenumber of avionics systems and components on theISS significantly increases. Once fully implemented,ISEAS will facilitate the timely identification andresolution of potential EMC problems.

Long Term Vacuum Testing ofLubricants

Lubricants used for space applications must be ableto operate in a vacuum environment. Parametersinclude low vapor pressure, wide temperature range,and minimal outgassing. To determine which onesare compatible for NASA missions, MSFC performslong term vacuum testing of lubricants. In mostcases, these lubricants are evaluated in a vacuumenvironment over a one-year period.

Lubricants in a vacuum environment tend to out-gas at a much higher rate. This phenomena causesthem to loose their beneficial properties and, in somecases, condense on nearby objects. Finding lubricantswhich possess superior space operational properties

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can best be accomplished in a vacuum test appa-ratus (bell jar). Each bell jar contains four samplesof five different lubricants, which are tested in 20small motors. During the test period, the motorsare periodically examined for failure. At the end ofone year, the bearings of each motor are removedand examined. MSFC then identifies the cause offailure (motor armature or lubricant); measuresthe lubricant�s mass loss to determine the outgas-sing effect; performs a visual inspection with anoptical microscope; and calculates the bearingwear (depth of wear track on bearing races) via aTaly-Surf Profilometer. Due to the ban on ozonedepleting cleaners, MSFC is currently investigat-ing other ways of cleaning the bearings. Similartesting is performed on oils, but the setup typi-cally uses one motor (sometimes two) per work-station.

MSFC�s long term vacuum testing of lubri-cants is a unique capability. The Center incorpo-rates all test data into a central lubricant data-base, which engineers extensively use to selectlubricants for space applications.

Nuclear Fuel Element Simulation

MSFC is currently testing various forms of alterna-tive propulsion methods. One such method is theHeatpipe Bimodal System (HBS), designed for nuclearthermal propulsion. The Center�s objective is to fabri-cate and electrically test an HBS module in order todetermine its design limits and operational charac-teristics. Several modules will then be grouped to-gether in a quarter core arrangement to investigatethe interactions between the modules under variousoperational and fault modes.

The HBS uses specially designed fuel pins whichessentially allow for complete system testing usingelectrical heaters. This approach eliminates the needfor large, expensive nuclear qualified test facilities. Inaddition, the HBS is designed with proven fuel tech-nologies in a modular system which reduce costs anddevelopment risks. The HBS is a near-term, low-cost,nuclear electric power and thermal propulsion sys-tem that can provide moderate levels of thrust andpower for many space applications. Heat generated inthe fuel is transferred by conduction to the primarymodule heatpipes. Propulsion is obtained by flowinghydrogen through the interstitials of the core. Thesystem (Figure 3-4) is a 100 kWt-uranium oxidefueled concept that can deliver 250 Newtons of thrustat a specific impulse of 800 seconds. A vacuum gap

surrounds the heatpipe to prevent hydrogen ingressand undesirable heat transfer.

Currently at MSFC, an electrically heated fuelelement in a power-only configuration HBS has beentested to 1400° K in a vacuum. The Center is also inthe process of constructing an HBS module along witha test chamber, that will be capable of electricallytesting a full core HBS. Over the next two years,MSFC plans to electrically test a quarter core andpossibly a full core HBS configuration to understandthe details of heat transfer and fluid flow interactionswithin the core. The Center also expects to conductzero power critical testing of an HBS module todetermine the neutron flux distributions and critical-ity limits.

Optical Plume Anomaly Detection

The Optical Plume Anomaly Detection (OPAD) is asystem that analyzes and characterizes emitted spec-trum from rocket plumes by monitoring the ultravio-let, visible, and near-infrared regions of the spectrum.Through the detection of metals in the exhaust plume,information relative to the degradation of hardwarecan be gathered and used for readiness and mainte-nance decisions. Although spectrum analysis wascommonplace in the jet engine industry, the size andweight of the monitoring devices excluded this tech-nology from the space industry. Today, the instru-mentation is much smaller and lighter.

Figure 3-4. Heatpipe Bimodal System 5-pin Module

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In 1986, MSFC�s engineering staff began investi-gating the use of spectrum analysis as a possiblemethod of determining the readiness status of rocketengines. This method is expected to foster rapiddecisions, independent of other physical inspections,regarding an engine�s readiness. The Center is devel-oping OPAD in three phases:

� Phase A � Concept proven with test stand off-mounted optics and spectrometer using baselinesoftware.

� Phase B � Feasibility proven with test nozzlemounted optics and vehicle mounted COTSspectrometer, and complete/integrate datasoftware modules and analysis package.

� Phase C � Space shuttle flight experimentscheduled for mid-2000 and use on subsequentspace shuttle flights.

In Phase A, MSFC collaborated with universities,Air Force/AEDC, and other NASA organizations todefine goals, identify problems to be solved, decidewhat skills were needed, and determine the overallmethodology and processes needed to address hard-ware and data analysis tools. In Phase B, the use ofCOTS hardware proved the feasibility of being able tomount the system on flight hardware due to small andlight instrumentation. Phase C is now being plannedwith flights on space shuttle missions starting in mid-2000.

OPAD has proved to be a successful method ofmonitoring the status of a rocket engine by studyingthe existence of anomalous material in the engineplume. This method has been approved for spaceshuttle missions, and will enable MSFC engineers tomake more informed decisions regarding mainte-nance and engine readiness.

Orbital Atomic Oxygen SimulationFacilities

MSFC has developed and implemented orbital atomicoxygen simulation facilities based on the physicalcharacteristics of a low earth orbit environment. Thiscapability is used to determine the long term exposurecharacteristics of objects launched into space. Previ-ously, no means existed for examining the interactionof materials with orbital atomic oxygen. In November1982, the Center first began studying this area via theEvaluation of Oxygen Interaction with Materials(EOIM)-1 on STS-5. Subsequent studies include EOIM-2 (August 1983); EOIM-3 (August 1992); the STS-41GAtomic Oxygen Interaction Experiment (October 1994);and the Long Duration Exposure Facility (April 1984to January 1990).

Orbital atomic oxygen simulation involves the gen-eration of atomic oxygen. MSFC employs three meth-ods for achieving this task: (1) thermal plasma ashers;(2) out-of-field atomic oxygen drift tube simulators;and (3) 5 eV neutral via the Atomic Oxygen BeamFacility. Each method generates atomic oxygen plasmaon the surface of the material under test. The radia-tion within the plasma represents the spectral line ofatomic oxygen. By measuring the magnitude of thespectral line intensity, MSFC can calculate a relativefigure-of-merit that is proportional to the strength ofinteraction between the atomic oxygen and the testmaterial. Each method has different strengths andweaknesses based on cost, safety, the atomic oxygenpurity in the plasma, and the sample�s heating char-acteristics. MSFC�s current atomic testing activitiesinvolve materials qualification for anodized and alodinealuminum and nickel; kynar shrink tubing; aplix;super beta; labels; O-rings; slidewire; targets; teflonovercoats; pro seds; and the NASA Jet PropulsionLaboratory�s flight experiments. Future activitiesinclude continued support for ISS and solar sails.

MSFC�s orbital atomic oxygen simulation facilitiesprovide a robust means for simulating orbital atomicoxygen in a low earth environment. The Centerperforms this service for NASA missions as well asvendors and contractors. This unique capability en-ables the space industry to determine the long termexposure characteristics of objects launched into space.

Space Environmental Effects TestingCapabilities

MSFC has established the Combined Environmen-tal Effects Test-Cell 3 (CEETC3), a space environmen-tal effects testing facility used to simulate combinedspace environments. The CEETC3 enables the Centerto test, evaluate, and qualify materials for use onexternal surfaces in space. Typically, materials areexposed to laboratory simulations of space environ-ments followed by flight experiments, when possible.

The CEETC3 exposes temperature-controlledsamples to simultaneous multi-environmental sourcessuch as protons, high energy electrons, low energyelectrons, vacuum ultraviolet (VUV) radiation andnear ultraviolet (NUV) radiation. The facility (Figure3-5) generates protons of 30 to 700 keV energy andelectrons from 0.22 to 2.5 MeV energy by using twoparticle linear accelerators. Electrons ranging from 1to 50 keV energy are generated from an electron gun.Two ultraviolet radiation sources are used: a mercury-xenon lamp for NUV and a deuterium lamp for VUV.

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The NUV source is external to the test chamber andproduces photons over the range of 200 to 2,500 nm.This source can also produce ten times the sun�s NUVradiation (250 to 400 nm) for accelerated testing.

The CEETC3 provides designers, engineers, andscientists with valuable information on the behaviorof materials in a space environment. MSFC has usedthis facility to qualify materials for the space shuttle,ISS, and the Solar X-Ray Imager. The CEETC3 wasalso used in post-flight analysis of experiments, suchas the Long Duration Exposure Facility (LDEF)which was exposed to a space environment for 5.5years. Material samples from LDEF were then exam-ined to determine the changes in optical, mechanical,and electrical properties. The synergistic effects ofthese property changes are still not completely under-stood, and continues to be investigated by spaceenvironmental effects testing facilities.

Telemetry Processing Systems

MSFC�s Huntsville Operations Support Center(HOSC) manages and processes telemetry data forpayloads such as real-time operations of ISS. Pay-loads typically consist of multiple experiments. HOSCreceives Ku-band and S-band telemetry data throughthe NASA Integrated Services Network, and sendscommands, data loads, and file uplink data for the ISS

payloads to the Space Station Control Center (SSCC).In return, SSCC sends command responses, down-link files, and planning data/procedures to HOSC.MSFC�s support center can also distribute encapsu-lated packet data to other payload telemetry sites(e.g., international partners, telescience support cen-ters, remote facilities).

HOSC is comprised of four systems:� Payload Planning System � Provides a unique

payload operations and integration architecturesubsystem with software capabilities to automatepayload planning and scheduling activities.

� Payload Data Services System � Acquires,distributes, and stores ISS data for other payloadtelemetry sites.

� Enhanced HOSC System � Performs on-command and real-time telemetry processing forprelaunch integration/checkout, simulations,training, and flight operations.

� Enhanced Mission Communications SystemBy processing telemetry data, HOSC enables users

to operate and control ISS payloads and experiments.All users can access the support center�s capabilitiesvia a workstation as well as voice, video, and datanetwork services. Remote users can access HOSC bylogging on with a password through X-windows andweb services.

Figure 3-5. Combined Environmental Effects Test-Cell 3

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Production

Friction Stir Welding

Friction stir welding is under development as analternative to fusion welding. Improved mechanicalproperties (Figure 3-6) are inherent in this alterna-tive process as fine grain microstructures comparableto ASTM No. 10, and tensile and elongation propertiesfar exceed fusion weld practices. To date, the panelspecimens have been comprised of aluminum alloys2195 and 2219. In all cases, the welds generated hadgreater ductility and up to 50% less shrinkage thanthose produced by fusion welding.

Friction stir welding is a simplistic process thatoperates at low spindle speeds (300 to 400 rpm)without any filler materials or shielding gases, yet iscapital intensive with tooling and equipment. Theprimary set up requires excessive use of clampingdevices along either side of the weld spindle to offsetdistortions imparted by the high pressure (1,000 psi)needed to create plasticity at 800° F for metal flow. Asthe spindle head penetrates the work piece at four to

five inches per minute, a patented pin tool descends tothe workpiece at an angle of 2.5° away from thespindle�s travel path. The weld penetration depth hasbeen predetermined, but should not travel deeperthan 0.005 inches from the opposite baseplate surface.Tooling is reusable and usually shows no discerniblewear. To alleviate the pin retraction marks, MSFCdeveloped and patented a retraction tool.

MSFC is currently conducting studies to determinethe feasibility of using friction stir welding to manu-facture hydrogen fuel tanks and as a replacementprocess for situations where current material joinmethods are mechanically inferior. The Center hasalready demonstrated the commercial use of frictionstir welding for manufacturing aluminum 5454 wheelrims. Additional projects are underway includingusing this process to fabricate large circumferential(16-foot diameter) parts. Friction stir welding hasalready been perfected for other materials includingcopper and titanium. Additional information on thesepractices can be obtained through the original devel-oper of friction stir welding, the Weld Institute inCambridge, England.

Figure 3-6. Improved Mechanical Properties

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Vacuum System Automation

MSFC�s Environmental Test Facility (ETF) is cur-rently implementing the Vacuum System Automa-tion project. This project involves upgrading andautomating the facility�s 20 vacuum chambers. Auto-mation will be controlled with Supervisory Controland Data Acquisition (SCADA) software, so operatorscan access the chambers via the Internet for data andvia remote dial-ins for parameter adjustments.

The project is designed to expand ETF�s operatingefficiencies, especially during evenings and week-ends. MSFC�s goal is to have all chamber functions(e.g., chamber evacuation, re-pressurization, ther-mal conditioning, data retrieval) controlled through acomputer. Each workstation will be capable of con-trolling any chamber and provide limited accessibil-ity via remote control. Although the computing tech-nologies (Windows NT 4.0 with networking TCP/IP)have COTS capabilities, the SCADA software is alicensed commercial product (by Fixed Dynamics)which costs about $6,000 per workstation. The ETFteam is in the early stages of debugging the newsoftware interface to the input/output hardware. Thisupgrade is expected to cost between $22,500 and$35,000 per chamber.

The Vacuum System Automation project is cur-rently in its first year of a six to seven-year implemen-tation cycle. Once the project is completed, MSFCexpects to realize cost avoidance by not hiring newtechnicians and supervisors for night/weekend opera-tions; decrease overtime through off-site monitoring;enable customer and management monitoring fromremote computers; and reduce operator errors viacomputer monitoring and Graphical User Interfaces.

Facilities

Metallurgical Diagnostics Facility

Prior business practices at MSFC�s MetallurgicalDiagnostics Facility caused its work planning processto be labor intensive and cumbersome. Documenta-tion of tasks was erratic and difficult to retrieve. Workrequests could not be queried in support of newinvestigations. Photographic negatives were loggedand stored in the areas associated with the equipmentused to do the work. The system was highly dependenton the availability and recollections of individuals.Beginning in 1994, MSFC identified four areas inwhich to make improvements: (1) work request clo-sure verification, (2) documentation and image stor-

age and retrieval, (3) budget planning and justifica-tion, and (4) data access and distribution.

Consequently, MSFC formed a multi-discipline teamto identify specific improvement issues and develop along-term organizational and facility plan for imple-mentation. By using various tools (e.g., Quality Func-tion Deployment, brainstorming), the team also es-tablished a scope and format that focused on a failureanalysis database; an electronic work request sys-tem; conversion from photographic to digital imag-ing; and the development of a branch web presence.All these objectives have now been implemented. TheFacility�s Failure Analysis Database is a cross-refer-enced tool that can be searched via keywords. Workrequests, active tasks, and completed projects are setup as easily accessible, computer-based documenta-tion. All imaging is now in a digital format and storedin the searchable Electronic Database. A website(http://eh22web.msfc.nasa.gov) has also been estab-lished for the Metallurgical Diagnostics Facility.

These advancements have eased MSFC�s transitionto ISO-9000 certification and to the recently imple-mented NASA Full Cost Accounting requirements. Inaddition, the Metallurgical Diagnostics Facility ex-panded its customer base to include other NASAenterprises, government agencies, universities, andindustry.

Plating Research Facility

MSFC�s Plating Research Facility is currentlydeveloping a plating process which will allow multiplereplicated optical mirrors to be produced from onemandrel. Once finalized, this process will be imple-mented in the Constellation X and Next GenerationSpace Telescope programs. The previous process in-volved multiple mandrels of the same shape and sizeon which the mirror material was plated and pol-ished. The challenge for the Plating Research Facilityis to develop the processing for space-based opticalsystems with much larger apertures and greaterresolution, which does not require post-polishing.

The technical objective is to demonstrate a repli-cated optical systems manufacturing process thatuses a single process flow: polish a single mandrel;apply electroless nickel-phosphorus; diamond turnand polish; apply gold coating; electroform nickelalloy shell; separate the shell; clean the mandrel; andrepeat for next shell. Criteria for alloy selectioninclude high specific strength, ultra-low durability,high elastic modulus, and the ability to maintain theoptical figure without deformation. Technical prob-

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lems encountered include the measurement of zerostress environment during plating, weight budgetversus optical performance, and support structuresneeded to stabilize the shell.

MSFC�s Plating Research Facility is well on its wayto finalizing the process. The developers have learnedto define and control multiple plating parametersincluding temperature, current density, componentplacement in tanks, bath chemistry and consumptionrate, shielding, and fluid flow. The process is expectedto help industry manufacture more accurate spacetelescopes.

Management

New Initiatives of NASA AcquisitionInternet Service

The NASA Acquisition Internet Service (NAIS) isan agency-wide, on-line capability that communi-cates procurement information (e.g., synopsis infor-mation, advance procurement notices, contract awardnotices, solicitations, amendments) to industry. In aneffort to continue improving NAIS, MSFC has em-barked on several enhancements. Two such initia-tives are the Procurement Data Warehouse System(PDWS) and the Request For Quotes System (RFQS).

PDWS is an effort to gather all the procurementdata from each NASA Center, centrally located it ona NASA website, and make it available to procure-ment professionals. Previously, this information wasstored in numerous databases among all the Centers.By using PDWS, contract specialists can search thevendor source database to obtain data on those firmsthat conduct business with NASA. In addition, thissystem provides NASA procurement managementwith metric data such as procurement productivity,contract status, and buyer productivity levels. Thefirst phase of PDWS has recently been deployed to theworkforce at MSFC.

RFQS allows vendors to submit on-line quotationsto business solicitations. In addition, vendors whoregistered their business interests with NAIS willreceive e-mail notification of upcoming opportunities.This system will reduce procurement paperwork andincrease communication between NASA procurementprofessionals and industry. RFQS is in the pilot stageand has not yet been deployed.

MSFC continues to develop innovative ways fordoing business. PDWS and RFQS represent the nextphases of how NASA is improving its procurementprocess.

Payload Safety Readiness Review Board

NASA�s Enterprise Strategic Goals rank safety asa high priority in the exploration and development ofspace. Likewise, safety is an integral part of all MSFCprograms and operations. Safety engineers activelyparticipate in the design and development of payloadsto ensure the safety of astronauts, ground personnel,launch vehicles, and other instrumentation. Hazardanalyses are the primary tool in determining thesafety level of payload designs and operations. Previ-ously, projects submitted for phased safety panelreviews at NASA JSC were often subjected to hur-riedly prepared dry-run presentations. Occasionally,the project team openly debated the design details atthese reviews. The JSC Safety Panel perceived thesediscussions as a lack of knowledge on the team�sbehalf, and were concerned about the accuracy of theinformation being presented. This concern was re-ported back to MSFC as an unacceptable level ofperformance.

In July 1996, MSFC created an internal PayloadSafety Readiness Review Board (PSRRB) to ensurethe quality of its payload safety processes and prod-ucts. Additionally, the Safety and Mission AssuranceOffice developed a Center Safety Readiness Reviewprocess to improve this aspect of work and provide ameans of ensuring in-depth flight readiness of allpayloads and experiments. Each PSRRB is chaired bya senior technical manager and utilizes membersfrom appropriate engineering disciplines. The Boardis responsible for issuing changes and makes the finaldecision for acceptance.

MSFC is using the PSRRB review process on a widerange of payloads and flight experiments, rangingfrom relatively simple microgravity experiments tohighly complex systems such as the Chandra X-RayObservatory. Keys to the success of this process are ahigh level of attention by management and the use ofa formalized dry-run approach. Data captured be-tween March 1995 and November 1998 indicates thatthe PSRRB review process has significantly improvedthe outcomes at the JSC Safety Review Panel. Thenumber of unsigned hazard reports decreased from31.7% to 15.7%, and the number of assigned actionitems dropped from 8.15 to 3.37 per review.

Project Light

In the past, total quality management practicesand quality circles were standard methods for imple-menting change at MSFC. However, downsizing,

40

budget reductions, and the need to develop moreefficient work processes caused the Center to look foranother approach. In 1996, MSFC implementedProject Light as a Center-wide program to bringabout change and process improvement. Theprogram�s name is an acronym for:

� Listen to our customers� Identify where we need to change� Guide our future� Help our team members� Transform our processMSFC chose a quality action team approach as the

methodology for Project Light. The program�s struc-ture consists of Cross-Functional Employee Teams(providers and customers from multiple organiza-tional levels) and an Executive Steering Committee(three center managers, four functional managers,one program manager, two employees). The Teamsidentify issues, review processes for possible improve-ment, and make recommendations to the ExecutiveSteering Committee. The Committee provides guid-ance to the Teams and can grant on-the-spot approvalfor a process change. Project Light debuted with 53employees who met offsite to brainstorm ideas ofimprovement. As a result, 18 action teams were set upand 350 ideas were generated, categorized, and priori-tized. Additional employees later joined these teamsas supplemental resources were needed. To date,more than 250 employees, representing 10% of MSFC�sworkforce, have participated on these teams.

Changes implemented through Project Light fallinto three categories: (1) Enhanced Communications,(2) Employee Development, and (3) Work Processes.Improvements for Enhanced Communications in-clude Inside MSFC, an Intranet website that postscurrent events and vacancy announcements; IDEAs,an employee suggestion plan; and a new directoratethat focuses on internal communication issues andcommunity outreach. Improvements for EmployeeDevelopment include core competencies for all posi-tions; individual development plans; a pilot mentoringprogram to pass along corporate knowledge to newMSFC employees; a three-fold increase in the trainingbudget; and an upgrade of secretarial positions tooffice managers which allows for pay increases andcareer advancement. Improvements for Work Pro-cesses include ISO-9000 project and a flexi-place pilotprogram.

MSFC�s Project Light has been instrumental inbringing about effective changes to the organization.Constant communication throughout the Centergreatly facilitates the improvement process. In addi-

tion, the structured team approach fosters innovativeimprovements as employees are now empowered toinitiate change.

Strategic and Implementation Planning

Enacted in 1993, the Government Performance andResults Act (GPRA) requires all federal agencies todevelop strategic and performance plans which out-line their goals and objectives in outcome-based terms.MSFC is complying with this act, and has imple-mented a strategic planning process that sets perfor-mance goals for the upcoming fiscal year and definesperformance indicators to measure outcomes. Prior toFY98, no formal strategic planning activity existed.

MSFC receives its strategic direction from NASAHeadquarters. In its Agency Strategic Plan, NASAidentifies four Strategic Enterprises: (1) human ex-ploration and development of space, (2) aerospacetechnology, (3) space science, and (4) earth science.Collectively, these enterprises drive NASA�s Perfor-mance Plan, which is the strategic planning docu-ment that outlines short-term goals and objectivesrequired to support the mission. In turn, each NASACenter develops an implementation plan that outlinesthe steps that their organization will take to enactthese goals.

Through its strategic planning process, MSFCproduces a Center Implementation Plan and a Perfor-mance Report. The Center Implementation Plan liststhe steps that each MSFC program will undertake tosupport the NASA mission, and ensures a linkagebetween MSFC�s activities and NASA�s StrategicEnterprises. The plan is developed annually in earlyMay, reviewed by the customer in mid-July, anddistributed electronically in mid-August. The Centeralso uses a feedback loop to obtain input at theprogram level. The Performance Report summarizesthe progress of each MSFC program, and evaluatesthem against performance indicators. A detailed re-view of these indicators are included in MSFC�sAnnual Report. This report is developed annually inearly November and published in late March. MSFCcommunicates all strategic planning information toits employees. These documents are available forreview on MSFC�s website, and all employees receivea copy of the Center Implementation Plan.

MSFC�s strategic planning process represents anorganized approach to comply with GPRA require-ments, and creates synergy throughout the Center.By showing employees how their efforts contribute tothe NASA mission, MSFC ensures that all elementsof the organization are familiar with the Center�sstrategic direction.

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A p p e n d i x A

Table of Acronyms

Acronym Definition

6DOF Six-Degrees-Of-Freedom

ABMA Army Ballistic Missile AgencyANVIL Army/NASA Virtual Innovations Laboratory

CAD Computer Aided DesignCADDMAS Computer Aided Dynamic Data Monitoring and Analysis SystemCBD Commerce Business DailyCBM Common Berthing MechanismCEC Collaborative Engineering CenterCEETC3 Combined Environmental Effects Test-Cell 3CER Cost Estimating RelationshipCFD Computational Fluid DynamicsCMIF Core Module Integration FacilityCOTS Commercial-Off-The-ShelfCPCMS Coherent Phase Cavitation Monitoring SystemCST Convergent Spray TechnologyCT Computed Tomography

ECLSS Environmental Control and Life Support SystemsEMC Electromagnetic CompatibilityEMI Electromagnetic InterferenceEOIM Evaluation of Oxygen Interaction with MaterialsETF Environmental Test Facility

FAR Federal Acquisition RegulationsFEA Finite Element AnalysisFESD Functional Event Sequence Diagram

GDM Gas Dynamic MirrorGPRA Government Performance and Results Act

HBS Heatpipe Bimodal SystemHOSC Huntsville Operations Support CenterHz Hertz

IR InfraredISEAS Integrated Space Station Electromagnetic Compatibility Analysis SystemISS International Space Station

JSC Johnson Space Center

LDEF Long Duration Exposure FacilityLH2 Liquid Hydrogen

Acronym Definition

MCC-1 Marshall Convergent Coating-1MEDIC Marshall Electromagnetic Compatibility Design and Interference ControlMETRO Marshall�s ElecTRonic OfficeMOL Mission Operations LaboratoryMSA-2 Marshall Sprayable Ablator-2MSFC Marshall Space Flight Center

NAFCOM NASA/Air Force Cost ModelNAIS NASA Acquisition Internet ServiceNASA National Aeronautics and Space AdministrationNUV Near Ultraviolet

OASIS Optimized Advanced System Integration and SimulationOISPS Operator Interactive Signal Processing SystemOPAD Optical Plume Anomaly Detection

PAMELA Phased Array Mirror Extendible Large AperturePDS Program/Project Data SystemPDWS Procurement Data Warehouse SystemPEC Productivity Enhancement ComplexPSRRB Payload Safety Readiness Review Board

QRAS Quantitative Risk Assessment System

REDSTAR Resource Data Storage and RetrievalRFQS Request For Quotes SystemRLV Reusable Launch VehicleRP Rapid Prototyping

SCADA Supervisory Control and Data AcquisitionSLC Space Leadership CouncilSRB Solid Rocket BoosterSSCC Space Station Control Center

UUT Unit Under Test

VUV Vacuum Ultraviolet

XRCF X-Ray Calibration Facility

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A p p e n d i x B

BMP Survey Team

Team Member Activity Function

Larry Robertson Crane Division Team Chairman(812) 854-5336 Naval Surface Warfare Center

Crane, IN

Cheri Spencer BMP Center of Excellence Technical Writer(301) 403-8100 College Park, MD

Design/Test Team 1

Nick Keller Naval Surface Warfare Center Team Leader(812) 854-5331 Crane, IN

Michael Ripp Naval Warfare Assessment Station(909) 273-4939 Corona, CA

Huston Singletary Lockheed Martin Energy Systems(423) 574-6394 Oak Ridge, TN

Design/Test Team 2

Ron Cox Naval Surface Warfare Center Team Leader(812) 854-5330 Crane, IN

John Suhan Applied Research Laboratory,(814) 865-7223 Penn State

State College, PA

Nicholas Clarke Pente Naval Warfare Assessment Station(909) 273-4990 Corona, CA

Production/Facilities Team

Darrel Brotherson Rockwell Collins Team Leader(319) 295-3768 Avionics & Communications

Cedar Rapids, IA

Jack Tamargo BMP Satellite Center(707) 642-4267 Vallejo, CA

B-2

David Snow Indiana Business(317) 635-3058 Modernization & Technology

Indianapolis, IN

Management/Logistics Team

Rick Purcell BMP Center of Excellence Team Leader(301) 403-8100 College Park, MD

Larry Halbig BMP Field Office(317) 891-9901 Indianapolis, IN

Stephanie Shattuck NRO, Acquisition Center of Excellence(703) 808-6928 Chantilly, VA

A p p e n d i x C

Critical Path Templates and BMP Templates

This survey was structured around and concen-trated on the functional areas of design, test, produc-tion, facilities, logistics, and management as pre-sented in the Department of Defense 4245.7-M, Tran-sition from Development to Production document.This publication defines the proper tools�or tem-plates�that constitute the critical path for a success-ful material acquisition program. It describes tech-niques for improving the acquisition process by ad-

dressing it as an industrial process that focuses on theproduct�s design, test, and production phases whichare interrelated and interdependent disciplines.

The BMP program has continued to build on thisknowledge base by developing 17 new templatesthat complement the existing DOD 4245.7-M tem-plates. These BMP templates address new oremerging technologies and processes.

�CRITICAL PATH TEMPLATESFOR

TRANSITION FROM DEVELOPMENT TO PRODUCTION�

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A p p e n d i x D

BMPnet and the Program Manager�s WorkStation

The BMPnet, located at the Best ManufacturingPractices Center of Excellence (BMPCOE) in CollegePark, Maryland, supports several communicationfeatures. These features include the ProgramManager�s WorkStation (PMWS), electronic mail andfile transfer capabilities, as well as access to SpecialInterest Groups (SIGs) for specific topic informationand communication. The BMPnet can be accessedthrough the World Wide Web (athttp://www.bmpcoe.org), through free software thatconnects directly over the Internet or through amodem. The PMWS software isalso available on CD-ROM.

PMWS provides users withtimely acquisition and engineer-ing information through a seriesof interrelated software environ-ments and knowledge-basedpackages. The maincomponents of PMWS areKnowHow, SpecRite, the Tech-nical Risk Identification and Miti-gation System (TRIMS), and theBMP Database.

KnowHow is an intelligent,automated program that pro-vides rapid access to informationthrough an intelligent search ca-pability. Information currentlyavailable in KnowHow handbooks includes Acquisi-tion Streamlining, Non-Development Items, ValueEngineering, NAVSO P-6071 (Best Practices Manual),MIL-STD-2167/2168 and the DoD 5000 series docu-ments. KnowHow cuts document search time by 95%,providing critical, user-specific information in underthree minutes.

SpecRite is a performance specification generatorbased on expert knowledge from all uniformed ser-

vices. This program guides acquisition personnel increating specifications for their requirements, and isstructured for the build/approval process. SpecRite�sknowledge-based guidance and assistance structure ismodular, flexible, and provides output in MIL-STD961D format in the form of editable WordPerfect® files.

TRIMS, based on DoD 4245.7-M (the transitiontemplates), NAVSO P-6071, and DoD 5000 event-oriented acquisition, helps the user identify and ranka program�s high-risk areas. By helping the userconduct a full range of risk assessments throughout

the acquisition process, TRIMShighlights areas where correc-tive action can be initiated beforerisks develop into problems. Italso helps users track key projectdocumentation from conceptthrough production includinggoals, responsible personnel, andnext action dates for future ac-tivities.

The BMP Database con-tainsproven best practices from in-dustry, government, and the aca-demic communities. These bestpractices are in the areas of de-sign, test, production, facilities,management, and logistics. Eachpractice has been observed, veri-

fied, and documented by a team of government expertsduring BMP surveys.

Access to the BMPnet through dial-in or on Internetrequires a special modem program. This program canbe obtained by calling the BMPnet Help Desk at (301)403-8179 or it can be downloaded from the World WideWeb at http://www.bmpcoe.org. To receive a user/e-mail account on the BMPnet, send a request tohelpdesk@bmpcoe.org.

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A p p e n d i x E

Best Manufacturing Practices Satellite Centers

There are currently ten Best Manufacturing Practices (BMP) satellite centers that provide representation forand awareness of the BMP program to regional industry, government and academic institutions. The centersalso promote the use of BMP with regional Manufacturing Technology Centers. Regional manufacturers can takeadvantage of the BMP satellite centers to help resolve problems, as the centers host informative, one-day regionalworkshops that focus on specific technical issues.

Center representatives also conduct BMP lectures at regional colleges and universities; maintain lists ofexperts who are potential survey team members; provide team member training; and train regional personnelin the use of BMP resources such as the BMPnet.

The ten BMP satellite centers include:

California

Chris MatzkeBMP Satellite Center ManagerNaval Warfare Assessment DivisionCode QA-21, P.O. Box 5000Corona, CA 91718-5000(909) 273-4992FAX: (909) 273-4123cmatzke@bmpcoe.org

Jack TamargoBMP Satellite Center Manager257 Cottonwood DriveVallejo, CA 94591(707) 642-4267FAX: (707) 642-4267jtamargo@bmpcoe.org

District of Columbia

Chris WellerBMP Satellite Center ManagerU.S. Department of Commerce14th Street & Constitution Avenue, NWRoom 3876 BXAWashington, DC 20230(202) 482-8236/3795FAX: (202) 482-5650cweller@bxa.doc.gov

Illinois

Thomas ClarkBMP Satellite Center ManagerRock Valley College3301 North Mulford RoadRockford, IL 61114(815) 654-5515FAX: (815) 654-4459adme3tc@rvcux1.rvc.cc.il.us

Iowa

Bruce ConeyProgram ManagerIowa Procurement Outreach Center200 East Grand AvenueDes Moines, IA 50309(515) 242-4888FAX: (515) 242-4893bruce.coney@ided.state.ia.us

Louisiana

Al KnechtDirectorMaritime Environmental Resources & Information

CenterGulf Coast Region Maritime Technology CenterUniversity of New Orleans810 Engineering BuildingNew Orleans, LA 70148(504) 626-8918 / (504) 280-6271FAX: (504) 727-4121atk@neosoft.com

Michigan

Jack PokrzywaSAE/BMP Satellite Center Manager755 W. Big Beaver Road, Suite 1600Troy, MI 48084(248) 273-2460FAX: (248) 273-2494jackp@sae.org

Roy T. TrentSAE/BMP Automotive Manufacturing Initiative

Manager755 W. Big Beaver Road, Suite 1600Troy, MI 48084(248) 273-2455FAX: (248) 273-2494bounder@ees.eesc.com

E-2

Ohio

Karen MaloneBMP Satellite Center ManagerEdison Welding Institiute1250 Arthur E. Adams DriveColumbus, Ohio 43221-3585(614) 688-5111FAX: (614) 688-5001karen_malone@ewi.org

Pennsylvania

Sherrie SnyderBMP Satellite Center ManagerMANTEC, Inc.P.O. Box 5046York, PA 17405(717) 843-5054, ext. 225FAX: (717) 854-0087snyderss@mantec.org

Tennessee

Tammy GrahamBMP Satellite Center ManagerLockheed Martin Energy SystemsP.O. Box 2009, Bldg. 9737M/S 8091Oak Ridge, TN 37831-8091(423) 576-5532FAX: (423) 574-2000tgraham@bmpcoe.org

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A p p e n d i x F

Navy Manufacturing Technology Centers of Excellence

The Navy Manufacturing Sciences and Technology Program established the following Centers of Excellence(COEs) to provide focal points for the development and technology transfer of new manufacturing processes andequipment in a cooperative environment with industry, academia, and Navy centers and laboratories. TheseCOEs are consortium-structured for industry, academia, and government involvement in developing andimplementing technologies. Each COE has a designated point of contact listed below with the individual COEinformation.

Best Manufacturing Practices Centerof Excellence

The Best Manufacturing Practices Center of Excel-lence (BMPCOE) provides a national resource to iden-tify and promote exemplary manufacturing and busi-ness practices and to disseminate this information tothe U.S. Industrial Base. The BMPCOE was estab-lished by the Navy�s BMP program, Department ofCommerce�s National Institute of Standards and Tech-nology, and the University of Maryland at CollegePark, Maryland. The BMPCOE improves the use ofexisting technology, promotes the introduction of im-proved technologies, and provides non-competitivemeans to address common problems, and has becomea significant factor in countering foreign competition.

Point of Contact:Mr. Ernie RennerBest Manufacturing Practices Center ofExcellence4321 Hartwick RoadSuite 400College Park, MD 20740(301) 403-8100FAX: (301) 403-8180ernie@bmpcoe.org

Center of Excellence for CompositesManufacturing Technology

The Center of Excellence for Composites Manufactur-ing Technology (CECMT) provides a national resourcefor the development and dissemination of compositesmanufacturing technology to defense contractors andsubcontractors. The CECMT is managed by the GreatLakes Composites Consortium and represents a col-laborative effort among industry, academia, and gov-ernment to develop, evaluate, demonstrate, and testcomposites manufacturing technologies. The techni-cal work is problem-driven to reflect current andfuture Navy needs in the composites industrial com-munity.

Point of Contact:Mr. James RayCenter of Excellence for Composites ManufacturingTechnologyc/o GLCC, Inc.103 Trade Zone DriveSuite 26CWest Columbia, SC 29170(803) 822-3708FAX: (803) 822-3710jrglcc@glcc.org

Electronics Manufacturing ProductivityFacility

The Electronics Manufacturing Productivity Facility(EMPF) identifies, develops, and transfers innovativeelectronics manufacturing processes to domestic firmsin support of the manufacture of affordable militarysystems. The EMPF operates as a consortium com-prised of industry, university, and government par-ticipants, led by the American Competitiveness Insti-tute under a CRADA with the Navy.

Point of Contact:Mr. Alan CriswellElectronics Manufacturing Productivity FacilityOne International PlazaSuite 600Philadelphia, PA 19113(610) 362-1200FAX: (610) 362-1290criswell@aci-corp.org

National Center for Excellence inMetalworking Technology

The National Center for Excellence in MetalworkingTechnology (NCEMT) provides a national center forthe development, dissemination, and implemen-tationof advanced technologies for metalworking productsand processes. The NCEMT, operated by ConcurrentTechnologies Corporation, helps the Navy and defensecontractors improve manufacturing productivity and

part reliability through development, deployment,training, and education for advanced metalworkingtechnologies.

Point of Contact:Mr. Richard HenryNational Center for Excellence in MetalworkingTechnologyc/o Concurrent Technologies Corporation100 CTC DriveJohnstown, PA 15904-3374(814) 269-2532FAX: (814) 269-2501henry@ctc.com

Navy Joining Center

The Navy Joining Center (NJC) is operated by theEdison Welding Institute and provides a nationalresource for the development of materials joiningexpertise and the deployment of emerging manufac-turing technologies to Navy contractors, subcontrac-tors, and other activities. The NJC works with theNavy to determine and evaluate joining technologyrequirements and conduct technology developmentand deployment projects to address these issues.

Point of Contact:Mr. David P. EdmondsNavy Joining Center1250 Arthur E. Adams DriveColumbus, OH 43221-3585(614) 688-5096FAX: (614) 688-5001dave_edmonds@ewi.org

Energetics Manufacturing Technology Center

The Energetics Manufacturing Technology Center(EMTC) addresses unique manufacturing processesand problems of the energetics industrial base toensure the availability of affordable, quality, and safeenergetics. The focus of the EMTC is on processtechnology with a goal of reducing manufacturingcosts while improving product quality and reliability.The EMTC also maintains a goal of development andimplementation of environmentally benign energeticsmanufacturing processes.

Point of Contact:Mr. John BroughEnergetics Manufacturing Technology CenterIndian Head DivisionNaval Surface Warfare Center101 Strauss AvenueBuilding D326, Room 227Indian Head, MD 20640-5035(301) 744-4417DSN: 354-4417FAX: (301) 744-4187mt@command.ih.navy.mil

Institute for Manufacturing andSustainment Technologies

The Institute for Manufacturing and SustainmentTechnologies (iMAST), was formerly known as Manu-facturing Science and Advanced Materials ProcessingInstitute. Located at the Pennsylvania StateUniversity's Applied Research Labortory,the primary objective of iMAST is to address chal-lenges relative to Navy and Marine Corps weaponsystem platforms in the areas of mechnical drivetransmission techologies, materials science technolo-gies, high energy processing technologies, and repairtechnology.

Point of Contact:Mr. Henry WatsonInstitute for Manufacturing and SustainmentTechnologiesARL Penn StateP.O. Box 30State College, PA 16804-0030(814) 865-6345FAX: (814) 863-1183hew2@psu.edu

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National Network for Electro-OpticsManufacturing Technology

The National Netowork for Electro-Optics Manufac-turing Technology (NNEOMT), a low overhead virtualorganization, is a national consortium of electro-opticsindustrial companies, universities, and governmentresearch centers that share their electro-optics exper-tise and capabilities through project teams focused onNavy requirements. NNEOMT is managed by the BenFranklin Technology Center of Western Pennsylva-nia.

Point of Contact:Dr. Raymond V. WickNational Network for Electro-Optics ManufacturingTechnologyOne Parks BendBox 24, Suite 206Vandergrift, PA 15690(724) 845-1138FAX: (724) 845-2448wick@nneomt.org

Gulf Coast Region Maritime TechnologyCenter

The Gulf Coast Region Maritime Technology Center(GCRMTC) is located at the University of New Orleansand focuses primarily on product developments insupport of the U.S. shipbuilding industry. A sister siteat Lamar University in Orange, Texas focuses onprocess improvements.

Point of Contact:Dr. John Crisp, P.E.Gulf Coast Region Maritime Technology CenterUniversity of New OrleansCollege of EngineeringRoom EN-212New Orleans, LA 70148(504) 280-5586FAX: (504) 280-3898jncme@uno.edu

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Manufacturing Technology Transfer Center

The focus of the Manufacturing Technology TransferCenter (MTTC) is to implement and integrate defenseand commercial technologies and develop a technicalassistance network to support the Dual Use Applica-tions Program. MTTC is operated by Innovative Pro-ductivity, Inc., in partnership with industry, govern-ment, and academia.

Point of Contact:Mr. Raymond ZavadaManufacturing Technology Transfer Center119 Rochester DriveLouisville, KY 40214-2684(502) 452-1131FAX: (502) 451-9665rzavada@mttc.org

As of this publication, 117 surveys have been conducted and published by BMP at the companies listed below.Copies of older survey reports may be obtained through DTIC or by accessing the BMPnet. Requests for copiesof recent survey reports or inquiries regarding the BMPnet may be directed to:

Best Manufacturing Practices Program4321 Hartwick Rd., Suite 400

College Park, MD 20740Attn: Mr. Ernie Renner, Director

Telephone: 1-800-789-4267FAX: (301) 403-8180ernie@bmpcoe.org

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1986

1985

A p p e n d i x G

Completed Surveys

1987

Litton Guidance & Control Systems Division - Woodland Hills, CA

Honeywell, Incorporated Undersea Systems Division - Hopkins, MN (Alliant TechSystems, Inc.)Texas Instruments Defense Systems & Electronics Group - Lewisville, TXGeneral Dynamics Pomona Division - Pomona, CAHarris Corporation Government Support Systems Division - Syosset, NYIBM Corporation Federal Systems Division - Owego, NYControl Data Corporation Government Systems Division - Minneapolis, MN

Hughes Aircraft Company Radar Systems Group - Los Angeles, CAITT Avionics Division - Clifton, NJRockwell International Corporation Collins Defense Communications - Cedar Rapids, IAUNISYS Computer Systems Division - St. Paul, MN (Paramax)

Motorola Government Electronics Group - Scottsdale, AZGeneral Dynamics Fort Worth Division - Fort Worth, TXTexas Instruments Defense Systems & Electronics Group - Dallas, TXHughes Aircraft Company Missile Systems Group - Tucson, AZBell Helicopter Textron, Inc. - Fort Worth, TXLitton Data Systems Division - Van Nuys, CAGTE C3 Systems Sector - Needham Heights, MA

McDonnell-Douglas Corporation McDonnell Aircraft Company - St. Louis, MONorthrop Corporation Aircraft Division - Hawthorne, CALitton Applied Technology Division - San Jose, CALitton Amecom Division - College Park, MDStandard Industries - LaMirada, CAEngineered Circuit Research, Incorporated - Milpitas, CATeledyne Industries Incorporated Electronics Division - Newbury Park, CALockheed Aeronautical Systems Company - Marietta, GALockheed Corporation Missile Systems Division - Sunnyvale, CAWestinghouse Electronic Systems Group - Baltimore, MDGeneral Electric Naval & Drive Turbine Systems - Fitchburg, MARockwell International Corporation Autonetics Electronics Systems - Anaheim, CATRICOR Systems, Incorporated - Elgin, IL

Hughes Aircraft Company Ground Systems Group - Fullerton, CATRW Military Electronics and Avionics Division - San Diego, CAMechTronics of Arizona, Inc. - Phoenix, AZBoeing Aerospace & Electronics - Corinth, TXTechnology Matrix Consortium - Traverse City, MITextron Lycoming - Stratford, CT

1988

1989

1990

G-2

Resurvey of Litton Guidance & Control Systems Division - Woodland Hills, CANorden Systems, Inc. - Norwalk, CTNaval Avionics Center - Indianapolis, INUnited Electric Controls - Watertown, MAKurt Manufacturing Co. - Minneapolis, MNMagneTek Defense Systems - Anaheim, CARaytheon Missile Systems Division - Andover, MAAT&T Federal Systems Advanced Technologies and AT&T Bell Laboratories - Greensboro, NC and Whippany, NJResurvey of Texas Instruments Defense Systems & Electronics Group - Lewisville, TX

Tandem Computers - Cupertino, CACharleston Naval Shipyard - Charleston, SCConax Florida Corporation - St. Petersburg, FLTexas Instruments Semiconductor Group Military Products - Midland, TXHewlett-Packard Palo Alto Fabrication Center - Palo Alto, CAWatervliet U.S. Army Arsenal - Watervliet, NYDigital Equipment Company Enclosures Business - Westfield, MA and Maynard, MAComputing Devices International - Minneapolis, MN(Resurvey of Control Data Corporation Government Systems Division)Naval Aviation Depot Naval Air Station - Pensacola, FL

NASA Marshall Space Flight Center - Huntsville, ALNaval Aviation Depot Naval Air Station - Jacksonville, FLDepartment of Energy Oak Ridge Facilities (Operated by Martin Marietta Energy Systems, Inc.) - Oak Ridge, TNMcDonnell Douglas Aerospace - Huntington Beach, CACrane Division Naval Surface Warfare Center - Crane, IN and Louisville, KYPhiladelphia Naval Shipyard - Philadelphia, PAR. J. Reynolds Tobacco Company - Winston-Salem, NCCrystal Gateway Marriott Hotel - Arlington, VAHamilton Standard Electronic Manufacturing Facility - Farmington, CTAlpha Industries, Inc. - Methuen, MA

Harris Semiconductor - Melbourne, FLUnited Defense, L.P. Ground Systems Division - San Jose, CANaval Undersea Warfare Center Division Keyport - Keyport, WAMason & Hanger - Silas Mason Co., Inc. - Middletown, IAKaiser Electronics - San Jose, CAU.S. Army Combat Systems Test Activity - Aberdeen, MDStafford County Public Schools - Stafford County, VA

Sandia National Laboratories - Albuquerque, NMRockwell Defense Electronics Collins Avionics & Communications Division - Cedar Rapids, IA(Resurvey of Rockwell International Corporation Collins Defense Communications)Lockheed Martin Electronics & Missiles - Orlando, FLMcDonnell Douglas Aerospace (St. Louis) - St. Louis, MO(Resurvey of McDonnell-Douglas Corporation McDonnell Aircraft Company)Dayton Parts, Inc. - Harrisburg, PAWainwright Industries - St. Peters, MOLockheed Martin Tactical Aircraft Systems - Fort Worth, TX(Resurvey of General Dynamics Fort Worth Division)Lockheed Martin Government Electronic Systems - Moorestown, NJSacramento Manufacturing and Services Division - Sacramento, CAJLG Industries, Inc. - McConnellsburg, PA

City of Chattanooga - Chattanooga, TNMason & Hanger Corporation - Pantex Plant - Amarillo, TXNascote Industries, Inc. - Nashville, ILWeirton Steel Corporation - Weirton, WVNASA Kennedy Space Center - Cape Canaveral, FLDepartment of Energy, Oak Ridge Operations - Oak Ridge, TN

1994

1992

1991

1993

1995

1996

1997

G-3

Headquarters, U.S. Army Industrial Operations Command - Rock Island, ILSAE International and Performance Review Institute - Warrendale, PAPolaroid Corporation - Waltham, MACincinnati Milacron, Inc. - Cincinnati, OHLawrence Livermore National Laboratory - Livermore, CASharretts Plating Company, Inc. - Emigsville, PAThermacore, Inc. - Lancaster, PARock Island Arsenal - Rock Island, ILNorthrop Grumman Corporation - El Segundo, CA(Resurvey of Northrop Corporation Aircraft Division)Letterkenny Army Depot - Chambersburg, PAElizabethtown College - Elizabethtown, PATooele Army Depot - Tooele, UT

United Electric Controls - Watertown, MAStrite Industries Limited - Cambridge, Ontario, CanadaNorthrop Grumman Corporation - El Segundo, CACorpus Christi Army Depot - Corpus Christi, TXAnniston Army Depot - Anniston, ALNaval Air Warfare Center, Lakehurst - Lakehurst, NJSierra Army Depot - Herlong, CAITT Industries Aerospace/Communications Division - Fort Wayne, INRaytheon Missile Systems Company - Tucson, AZNaval Aviation Depot North Island - San Diego, CAU.S.S. Carl Vinson (CVN-70) - Commander Naval Air Force, U.S. Pacific FleetTobyhanna Army Depot - Tobyhanna, PA

Wilton Armetale - Mount Joy, PAApplied Research Laboratory, Pennsylvania State University - State College, PAElectric Boat Corporation, Quonset Point Facility - North Kingston, RINASA Marshall Space Flight Center - Huntsville, AL

1998

1999