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- 1. Broad-Based Teams Case Study #1 - Composite Crew Module (CCM) Project Management Challenge 2009 Daytona Beach, Florida February 24-25, 2009 Mike Kirsch, CCM Project Manager NASA Engineering and Safety Center Principal Engineer Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 2. NESC Overview Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 3. NESC Overview • In 2003, the NASA Engineering & Safety Center (NESC) was formed as a response to a Columbia Accident Investigation Board observation • The NESC mission is to provide the Agency’s Programs and Projects with rigorous independent technical perspectives on their most critical technical issues Five years later – The NESC remains independent: • Centrally managed and funded through the Office of Chief Engineer • Small staff of senior leaders and technical experts to lead broad based engineering teams in “tiger team” fashion • Unaffiliated with and unbiased by any specific NASA Program or Center • Has an independent engineering chain of command to assure an avenue for consideration of all points of view • Facilitating hands-on design and development experience Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 4. NESC Background NESC emphasis is to create broad-based teams to enable networks that discourage silos • Recruit team membership • Facilitate inter-Center from a broad community collaboration • Increase inter-Center • Encourage inter-Center knowledge and information relationships and flow communities of practice Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 5. NESC Composite Crew Module Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 6. January 2007 NASA Administrator chartered the NESC to form an agency team to… • design and build a composite crew module, • gain hands-on design, build, and test experience, • in anticipation that future exploration system may be made of composite materials. Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 7. Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module = Upper Pressure Shell + Splice Joint + Lower Pressure Shell Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 8. System Dimensions Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 9. Project Attributes • Broad NASA Center representation • ARC, DFRC, GRC, GSFC, JPL, JSC, KSC, LaRC, MSFC • Aerospace structures and composites industry collaborative participation • Alcore – Honeycomb core • ATK – Design, Tooling, Manufacturing • Bally Ribbon Mills – 3D woven structures • Collier Industries – Hypersizer structural analysis software • Genesis Engineering - Design • Janicki Industries - Tooling • Lockheed Martin – Design, Tooling, Manufacturing • Northrop Grumman – Design, Tooling, Manufacturing • Industry partners within each discipline and across all of the disciplines • 18 months from vision to delivery of testable full scale hardware • Production slow down May 2008 – September 2008 (NESC Budget realignment) Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 10. Project Management Project Manager Mike Kirsch LARC Deputy Project Mgr--Technical Integration Jeff Stewart GSFC Deputy Project Mgr--Technology Dev. Paul Roberts LARC Administrative Assistant Terri Derby ATK (Swales) Support Advisors Resource Analyst Pamela Throckmorton LARC Advisor Damodar Ambur LARC Pro-E & IT Admin Mike Mongilio ATK (Swales) Advisor Tom Modlin JSC Program Support Steve Summit ATK (Iuka) Advisor Joe Pellicciotti GSFC Advisor Tod Palm NGC Testing Materials Analysis Design Engineering Manufacturing NDE Lead Lead Lead Lead Lead Lead Sotiris Kellas Dan Polis Jim Jeans Jeff Stewart Larry Pelham Ken Hodges LARC GSFC Genesis Engineering GSFC MSFC JSC Chip McCann Wade Jackson David Sleight Craig Collier Ian Fernandez Dawson Vincent Randy Sparks Tristan Curry JSC LARC LARC Collier Research Corp ARC NGC (MSFC) ATK (Clearfield) UAH John Thesken Ben Rodini Jonathan Bartley-Cho Phil Yarrington Dave Paddock Mike Western Tom McCabe Elliott Cramer GRC SGT Northrop Grumman Corp Collier Research Corp LARC Janicki ATK (Iuka) LARC Donny Wang Ron Schmidt Eric Schleicher Jerry Stuart Steve Rickman NGC Eric Friesen Chip Henderson Brad Parker NGC LMC ATK (Swales) GSFC JSC Janicki ATK (Iuka) Marc Dinardo Luis Santos Perry Wagner Laurie Carrillo Robert Boscia Fred Hall Jeff Stone LMC GSFC ATK (Swales) JSC Alcore ATK (Iuka) ATK (Iuka) Dan Richardson Wayne Sawyer Charles Kaprielian Sam Russell Angel Alvarez- ATK (Swales) Terry Graham Touch (ATK) AS&M ATK (Swales) MSFC Hernandez ATK (MSFC) Stephen Williams Bill Kelly Jared Schoenly JSC Rance Jones James Walker Brett Bednarcyk ATK (Swales) Mike Abel AMA Cindy Sowards MSFC GRC Ed Fasanella ATK Doug Lenhardt Danny Lambert LaRC Andrew Johnson Steven Johnson KSC Jerry Gray ATK (Iuka) Al Tabiei Craig Bowser Phil Thompson MPSE ATK Swales Scott Ragasa UAH Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 11. Virtual Engineering Enablers • Goal – Create a virtual environment that promotes communications as if the team were in the same room • Nearly 100% dedicated team • Drives proactive rather than reactive behaviors • Extensive co-locations - 18 of 52 weeks with contractor partners and vendors during the first 12 months • 7 of the first 9 weeks co-located – long hours through the weekend • Understanding individuals and building relationships • Used weekly bowling as a team social (fun for all abilities) • Co located approximately 2 weeks every 2 months, thereafter • Web based calendar for managing personal and professional schedules • When dispersed we used daily virtual design sessions through Secure Meetings/WebEx • Windchill Web-based file management • Electronic drawing and model review, approval, and configuration control • Instant Messaging (Chat) • Desktop sharing (2 clicks) • Smart Boards/tablets Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 12. Co-location Floor Plan Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 13. Materials Selection • Prepreg - IM7/977-2 tape and 4-harness satin fabric • High strength fiber • Toughened epoxy resin • Extensive data available for determining material properties. • 3D woven Pi preforms - IM7/MTM45-1 • Extensive data on IM7 woven Pi preform joints (CAI and JSF database). • MTM45-1 resin was formulated for out-of-autoclave cure, providing manufacturing flexibility. • Core Selection - aluminum non-perforated core. • Non-perforated core provides some level of pressure containment redundancy. • Adhesives • FM 300 M film adhesive - high shear strength and high toughness • EA 9394 paste adhesive - high strength room temperature cure • FM 410-1 foaming adhesive - core splice adhesive • EY-3010/Lord 4688 - potting compounds - low density, low CTE, RT cure Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 14. Lower Shell Loading • Backbone carries pressure load – no ring frame (~100 lbs savings) • Membrane pressure head lobe shapes (~50 lbs savings) • Leverages and enhances SM/ALAS reinforcements • Backbone connection allows load Internal Pressure sharing with Heat Shield (~1000 lbs heat shield savings) 50% load sharing on backbone Water Landing Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 15. New Technology - Cobonded Joints - Air Force CAI • Replaces bonded or bolted joints • 3D-woven “Pi” shape preform • Cobonded Pi preforms comprise majority of connections • Lobe core tapers out before Pi • Also used to bond Gussets to upper shell Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 16. Pi Preform Comparison HST's Super Lightweight Interchangeable Program NESC Composite Crew Module Carrier Joint type traditional back-to-back L-clips pi preform technology Geometry Pre-cured part 5 pre-cured details: 2 pre-cured details: count web, skin, closeout, two L-clips web and skin Bonding process 2 step paste bond 1 step cobond Tension ~900 lb/in ~2000 lb/in Capability Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 17. Upper Pressure Shell Tooling • Use Temperature: 400F • Use Pressure: 100psi • CTE: Chop Carbon laminate • Slight elevation in CTE contributed to ease of part de-mold • Dimensional Accuracy: • Critical Zones +/- .010” • Non-critical Zones +/- 030” • Durability: 30 cycles (300+ hours) • Schedule: 12-16 weeks • Cost: $375K Tool nickname: “Big Plunger” Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 18. Upper Pressure Shell Tool Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 19. Upper IML Processing Autoclave cure Layup IML Bag Part Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 20. Shell Core Installation Film Adhesive Install Core Outer Skins Debagging Tacked Ceiling Core Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 21. Automatic Ultrasonic Inspection Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 22. Upper Manufacturing Demonstration Unit Complete! Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 23. Lower Shell Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 24. Upper IML and OML Layup • Between 4 and 39 plies thick • Approximately 400 ply segments per skin • Manage ply orientation, 0, 90, +45, -45 degrees • Manage wrinkles over complex curvature and core tapers • Manage ply segment overlaps .75” – 1.25” • Manage material yield • Manage material “out time” < 30 days Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 25. Upper IML Plies Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 26. 1 IML Ply Segment Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 27. 1 ply segment Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 28. Flat Patterns • Integrated electronic process flow exists • Design, Manufacturing, and Inspection via • CAD, NASTRAN, FiberSIM, flat patterns, laser projection, layup, inspection Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 29. Civil Servant “Hands On” Experience Ian Fernandez, Design Engineer ARC Dave Sleight, Structural Analyst LaRC Cecilia Larrosa, Aerospace engineering intern ARC Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 30. T&V Objectives • Show, through destructive testing, that allowable material properties are conservative • For given worst-case load environments, obtain structural test responses to correlate with analysis models • Verify structural design robustness, and understand failure modes Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 31. Critical Test Locations LIDS/Tunnel Main Parachute Drogue Parachute Attachment Attachment Splice Backbone Attachment Crucifom Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 32. Building Block Approach Tests • Coupon • Sandwich flatwise tension - complete • Edgewise compression - complete • Pi preform (1/8” clevis) • pull off - complete • shear - complete • Visual impact study tests – on hold • Permeability tests – before and after impact – in work • Element • LIDS/tunnel double lap joint - complete • Splice • Acreage - complete • Longeron – complete • Offset – ECD 12/08 • Backbone attachment pull-off • 0° - complete • 20°- complete • Backbone attachment shear ECD – 1/09 • Cruciform - complete • Component • SM/ALAS simplified interface (flat panel) • Non-potted core – complete • Potted core - complete Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 33. Full Scale Testing: Loads “Freebody” Main Chute Load Drogue Load 64,400 lbs 34,200 lbs Launch abort Load 134,000 lbs Maximum Internal Pressure, 31.1 psi Maximum Delta Load 76,000 lbs Service Module Load 101,000 lbs Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 34. Combined Loads Test System (COLTS) NASA Langley Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 35. Overall Project Status • 24 months into the project • Independent reviews conducted throughout project life cycle • Conceptual design - March 2007 • Preliminary design – June 2007 • Detailed design – December 2007 • Manufacturing plan – May 2008 • Test plan – TBD (March 2009) • Full scale tooling delivered January 2008 • Building block fabrication and testing ongoing • Full scale upper pressure shell manufacturing demonstration unit completed in December 2008 • Upper and lower full scale subassemblies started October 1, 2009 • Sandwich systems cured the week of December 15 • Post cure operations currently underway, with completion expected in March 09 • Full scale testing planned at LaRC using COLTS facility beginning in Spring 09 • Full scale static tests completion expected in July 09 • CCM Final Report completion expected in September 09 Engineering Excellence This briefing is for status only and may not represent complete engineering information
- 36. Composite Crew Module Engineering Excellence This briefing is for status only and may not represent complete engineering information