NASA University Student Launch University of Alabama in Huntsville 2013-2014 Flight Readiness Review April 18, 2014 Propulsion Research Center, Huntsville, AL 35805, 256.701.4665 Contents 1 Summary of FRR Report .......................................................................................................... 8 1.1 Team Summary ............................................................................................................... 8 1.2 Launch Vehicle Summary ................................................................................................ 8 1.3 Milestone Review Flysheet .............................................................................................. 8 1.4 Payload Summary ............................................................................................................ 8 2 Changes made since CDR ........................................................................................................ 9 2.1 Vehicle Changes .............................................................................................................. 9 2.2 Payload Changes ............................................................................................................. 9 2.3 Project Plan Changes ..................................................................................................... 10 2.4 CDR Feedback ................................................................................................................ 10 3 Vehicle Criteria ...................................................................................................................... 11 3.1 Design and Construction of Vehicle............................................................................... 11 3.2 Buckling Analysis ........................................................................................................... 21 3.3 Fin Flutter Analysis ........................................................................................................ 21 3.4 Recovery Subsystem...................................................................................................... 23 3.5 Mission Performance Predictions .................................................................................. 33 3.6 Verification (Vehicle) ..................................................................................................... 38 3.7 Safety and Environment (Vehicle) ................................................................................. 38 3.8 Payload Integration ....................................................................................................... 44 4 Payload Criteria ..................................................................................................................... 47 4.1 Nanolaunch 1200 .......................................................................................................... 47 4.2 Dielectrophoresis .......................................................................................................... 69 4.3 Landing Hazard Detection System ................................................................................. 78 4.4 Landing Hazard Detection System ................................................................................. 79 4.5 Paint Payload ................................................................................................................. 85 5 Launch Operations Procedures ............................................................................................. 89 5.1 Checklist ........................................................................................................................ 89 6 Project Plan ........................................................................................................................... 89 6.1 Budget ........................................................................................................................... 89 6.2 Timeline ......................................................................................................................... 97 6.3 Outreach ..................................................................................................................... 101 6.4 Programmatic Challenges ............................................................................................ 103 7 Conclusion ........................................................................................................................... 105 8 Appendix A: CRW Safety Plan .............................................................................................. 106 8.1 Management, Leadership, and Employee Participation Policy.................................... 106 8.2 Goals and Objectives ................................................................................................... 106 8.3 Team Leadership Roles ................................................................................................ 106 8.4 Team Member Involvement ........................................................................................ 107 8.5 Training ....................................................................................................................... 108 8.6 Material Hazard Communication Program .................................................................. 108 8.7 Hazardous Materials Inventory ................................................................................... 108 8.8 Purchasing and Procurement ...................................................................................... 108 8.9 Workplace Analysis ..................................................................................................... 109 8.10 Inspections .............................................................................................................. 109 8.11 Employee Reports of Hazards ................................................................................. 109 8.12 Mishap Reporting and Investigation........................................................................ 109 8.13 Hazard Prevention and Control ............................................................................... 109 8.14 Propulsion Research Center Procedures ................................................................. 111 8.15 Supervision .............................................................................................................. 111 8.16 Buddy System .......................................................................................................... 112 8.17 Accountability.......................................................................................................... 112 8.18 Emergency Response............................................................................................... 112 8.19 Periodic Safety Meetings ......................................................................................... 112 8.20 State and Federal Regulations ................................................................................. 112 9 Appendix B: Johnson Research Center Evacuation Plan ...................................................... 113 10 Appendix C, Student t-Distribution ..................................................................................... 114 11 Appendix D: Sample Altimeter Data .................................................................................... 115 12 Appendix E: Launch Operations Checklist ........................................................................... 116 13 Appendix F: Launch Items Checklist .................................................................................... 120 14 Appendix G: State and Federal Regulations ........................................................................ 121 15 Appendix H: Hazardous Materials Inventory ....................................................................... 128 16 Appendix I: EMI Test Plan .................................................................................................... 141 17 Appendix J: Black Powder Ejection System Standard Operating Procedure ........................ 144 18 Appendix K: Technology Readiness Level ............................................................................ 164 19 Appendix L: Launch Operation Procedures ....................................................................... 165 20 Appendix M: Material Safety Data Sheets ........................................................................... 172 21 Appendix N – Pinlist for PCBs .............................................................................................. 252 22 Appendix O: Milestone Review Flysheet ............................................................................. 264 23 Appendix P: Statement of Work Requirements Table ......................................................... 267 Figures Figure 3-1 Payload Section Cross Section ..................................................................................... 12 Figure 3-2: Thrust Plate ................................................................................................................ 12 Figure 3-3: Fin Bracket ................................................................................................................. 13 Figure 3-4: Cross section of revised pitot probe design ............................................................... 13 Figure 3-5: Carbon Fiber Body Tube 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