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A History of Aerospace Problems, Their Solutions, Their Lessons R.S

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A History of Aerospace Problems, Their Solutions, Their Lessons R.S NASA Technical Paper 3653 A History of Aerospace Problems, Their Solutions, Their Lessons R.S. Ryan September 1996 NASA Technical Paper 3653 A History of Aerospace Problems, Their Solutions, Their Lessons R.S. Ryan Marshall Space Flight Center • MSFC, Alabama National Aeronautics and Space Administration Marshall Space Flight Center • MSFC, Alabama 35812 September 1996 TABLE OF CONTENTS Page I. INTRODUCTION ..................................................................................... 1 II. GENERAL.............................................................................................. 2 A. Why Study Problems.............................................................................. 2 B. Classification of Problems........................................................................ 11 C. Pictorial of Problems .............................................................................. 13 III. AEROSPACE PROJECT/PROGRAM DEVELOPMENT ........................................ 13 A. Redstone and Jupiter .............................................................................. 13 1. Characteristics ................................................................................. 13 2. Evolution/Creativity/Innovation ............................................................. 18 3. Problem Examples ............................................................................ 21 B. Saturn/Saturn Apollo/Skylab Launch Vehicles................................................. 25 1. Characteristics ................................................................................. 25 2. Evolution/Creativity/Innovation ............................................................. 34 C. HEAO ............................................................................................... 36 1. Characteristics ................................................................................. 36 2. Evolution/Innovations/Creativity ............................................................ 37 3. Problems ....................................................................................... 37 D. IUS/PAM-S/TOS .................................................................................. 40 1. Characteristics ................................................................................. 40 2. Creativity/Innovations ........................................................................ 40 3. Problems ....................................................................................... 40 E. Skylab, America’s First Space Station .......................................................... 42 1. Characteristics ................................................................................. 42 2. Evolution, Innovation, Creativity ........................................................... 46 3. Problems ....................................................................................... 48 F. Space Shuttle....................................................................................... 51 1. Space Shuttle System ......................................................................... 51 a. Characteristics.............................................................................. 51 b. Evolution/Creativity/Innovation ......................................................... 54 c. Problems.................................................................................... 60 d. Future Implications........................................................................ 62 2. Space Shuttle Main Engine................................................................... 63 a. Characteristics.............................................................................. 63 b. Creativity/Innovation...................................................................... 64 c. Developmental Problem Examples ...................................................... 67 3. Solid Rocket Motors/Boosters............................................................... 93 a. Characteristics.............................................................................. 93 b. Evolution/Creativity/Innovation ......................................................... 98 c. Problem Examples......................................................................... 98 4. External Tank .................................................................................. 108 a. Characteristics.............................................................................. 108 b. Evolution/Innovation...................................................................... 116 c. Problems.................................................................................... 116 iii TABLE OF CONTENTS (Continued) Page G. Hubble Space Telescope .......................................................................... 122 1. Characteristics ................................................................................. 122 2. Evolution/Creativity/Innovation ............................................................. 123 3. Problems ....................................................................................... 126 H. Spacelab............................................................................................. 133 1. Characteristics ................................................................................. 133 2. Evolution/Creativity/Evolution............................................................... 139 3. Problems ....................................................................................... 139 I. International Space Station........................................................................ 139 1. Characteristics ................................................................................. 140 2. Evolution/Innovation/Creativity ............................................................. 142 3. Problems ....................................................................................... 149 J . Titan Viking ........................................................................................ 149 K. Experiments ........................................................................................ 150 1. Safe Solar Array/Dynamic Augmentation Experiment (SAFE/DAE).................... 150 2. Tethers in Space ............................................................................... 152 3. Problems ....................................................................................... 158 L. National Launch System/Space Transportation Main Engine (NLS/STME)................ 161 IV. CONCLUSIONS....................................................................................... 162 APPENDIX A ................................................................................................... 169 I. REDSTONE/JUPITER................................................................................ 169 II. SATURN/SATURN APOLLO/SATURN SKYLAB.............................................. 171 III. SKYLAB SPACE STATION......................................................................... 171 IV. SPACE SHUTTLE SYSTEMS ...................................................................... 176 A. Space Shuttle Main Engine ....................................................................... 177 B. Solid Rocket Motor/Boosters (RSRM/RSRB) ................................................. 209 C. External Tank....................................................................................... 213 V. HUBBLE SPACE TELESCOPE..................................................................... 221 VI. SPACELAB............................................................................................. 225 VII. TETHERS IN SPACE (TSS-1) ...................................................................... 225 VIII. INTERNATIONAL SPACE STATION............................................................. 225 REFERENCES.................................................................................................. 230 iv LIST OF ILLUSTRATIONS Figure Title Page 1. The dynamics of innovation ....................................................................... 3 2. Performance of an established and an invading product (burst of improvement in established product) ............................................................................. 3 3. The organizational requirement for product success............................................ 5 4. Systems approach................................................................................... 7 5. It only hurts at resonance .......................................................................... 8 6. Design compromises ............................................................................... 9 7. So that decimal point was a fly speck! ........................................................... 9 8. Change in what specs? ............................................................................. 10 9. SSME “buzz” words ............................................................................... 10 10. Heritage .............................................................................................. 14 11. Project evolution .................................................................................... 15 12a. V–2 configuration................................................................................... 16 12b. Redstone configuration............................................................................. 17 13. Jupiter configuration...............................................................................
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