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NASA’s uncrewed Artemis I mission launched from KSC on November 16, 2022. After a successful mission that included orbiting the Moon, the Orion spacecraft returned to Earth splashing down in the Pacific Ocean on December 11, 2022. While the spacecraft made a safe return to Earth, postflight inspection of Orion’s thermal protection indicated that the base heatshield did not perform as expected. The heatshield is composed of Avcoat, an ablative material designed to protect the crew module during the nearly 5000ºF temperatures experienced during atmospheric entry upon return from the Moon. Specifically, inspection revealed more than 100 locations where the charred Avcoat material chipped away from the heatshield.

The NESC formed a team of subject matter experts from across and outside of the Agency to assist the Orion Program team in the overall investigation. NESC team members are supporting or leading efforts in multi-physics analysis, material testing, fault tree and root cause analysis, aeroscience review, analysis peer review, nondestructive evaluation (NDE), as well as investigation of alternative heatshield concepts.

 The NESC works closely with the Artemis I Char Loss Team to ensure the observed material loss is thoroughly understood so that decisions may be made regarding use for upcoming crewed missions. To date, NESC contributions have included pathfinding NDE techniques for postflight heatshield inspection, investigation of key Avcoat material properties and behavior, and providing key inputs to the fault tree development and disposition to guide a thorough investigation of possible causes.

screenshot-2024-12-26-at-9-34-31 am.png?
View from Artemis I crew cabin window showing material loss during entry (foreground).
An artist's illustration of Orion crew module entering the Earth's atmosphere.
An artist’s illustration of Orion crew module entering the Earth’s atmosphere.

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W.; Punch, E.; Twombly, E.; and Wallace, J: Estimation Scheme for Weld Residual Stress Effect on Crack Opening Displacements. ASME Pressure Vessels and Piping Conference, Paper PVP2023-107396, Atlanta, GA, July 2023.  Cardona, A.; Jegley, D.; and Lovejoy, A.: Manufacturing Trials of Integrally Stiffened Panels for Flight Applications. AIAA-2023-0781, SciTech 2023, National Harbor, MD, January 2023.  Cline, J.; Dorsey, J.; Kang, D.; Doggett, W.; and Allen, D.: Ideas For Infusing In-Space Servicing, Assembly and Manufacturing Concepts into Nuclear Electric Propulsion Architectures. Joint Army-Navy-NASA- Air Force (JANNAF) 12th Spacecraft Propulsion Joint Subcommittee Meeting, Huntsville, AL, December 2022.  Doggett, W.; Heppler, J.; Mahlin, M.; Pappa, R.; Teter, J.; Song, K.; White, B.; Wong, I.; and Mikulas, M.: Towers: Critical Initial Infrastructure for the Moon. AIAA-2023-0383, SciTech 2023, National Harbor, MD, January 2023.  Fleishel, R.; Ferrell, W.; and TerMaath, S.: Fatigue-Damage Initiation at Process Introduced Internal Defects in Electron-Beam-Melted Ti- 6Al-4V. 2023. Metals 13:2, 350. Special Issue: Deformation, Fracture and Microstructure of Metallic Materials, https://doi.org/10.3390/ met13020350.  Fleishel, R. and TerMaath, S.: Modeling fatigue overload behavior in microstructurally short cracks: connecting initiation and long crack behavior. ASCE Engineering Mechanics Institute, Georgia Tech, Atlanta, GA, June 6-9, 2023.  Goyal, V.; Tuck-Lee, J.; Babuska, P.; and Zeitunian, E.: Lessons Learned in the Buckling Assessments of Space Structures. AIAA Scitech 2023, National Harbor, MD, January 23-27, 2023.  Goyal, V.; Sagrillo, C.; Fannon, J.; Forth, S.; and Kezirian, M.: Space Systems Technical Guide for Composite Overwrapped Pressure Vessels. AIAA Scitech 2023, National Harbor, MD, January 23-27, 2023.  Hart, D.; Balsara, Martinez, and TerMaath, S.: Multi-Scale Multi- Physics Bondline Strength Prediction Research. NATO Science & Technology Organization, Applied Vehicle Technology Panel (AVT-361) Research Workshop on Certification of Bonded Repair on Composite Aircraft Structures, Amsterdam, Netherlands, Oct 18-20, 2022.  Kaleel, I., Ricks, T.M., Gustafson, P.A., Pineda, E.J., Bednarcyk, B.A., and Arnold, S.M. (2023) “Massively Multiscale Modeling using NASA Multiscale Analysis Tool through Partitioned Task-Parallel Approach” 2023 AIAA SciTech Forum, 23-27 January 2023, National Harbor, MD.  Lin, L.: Correlation Study of SWOT Payload Acoustic Prediction and Test. AIAA SciTech, January 2023.  Ma, X. and TerMaath, S.: Microstructural Analysis of Intergranular Stress Corrosion Cracking in 5xxx Series Aluminum Reinforced with a Composite Patch. 2023. Advances in the Analysis and Design of Marine Structures. Ringsberg & Guedes Soares (Eds), CRC Press. ISBN 978-1-032-50636-4.  Pak, C.: Linear and Geometrically Nonlinear Structural Shape Sensing from Strain Data. AIAA Journal, Vol. 61, No. 2, 2023, pp. 907-922.  Pak, C.: Finite Element Model Tuning Using Analytical Sensitivity Values. Journal of Aircraft, Articles in Advance (Vol. 60, No. 2 or 3), 2023.  Panda, J.; Nguyen, M.P.; Keil. D.R.; and Hamm, K.R.: A Microphone Phased Array for Launch Acoustics Application. AIAA SciTech Conference, National Harbor, MD, (2023), AIAA Paper 2023-0790.  Qu, X.; Shimizu, L.; Rome J.; Nordendale, N.; and Goyal, V.: Reliability- based Damage Tolerance Analysis for Additive Manufacturing Part. NAFEMS World Congress 2023, Tampa, FL, May 2023.  Ricks, T. M.; Pineda, E. J.; Bednarcyk, B. A.; McCorkle, L. S.; Miller, S. G.; Murthy, P. L.; and Segal, K. N.: Multiscale Progressive Failure Analysis of 3D Woven Composites. 2022, Polymers, 14(20), 4340.  Rome, J. and Goyal, V.: Moving Towards a Print Then Use Framework for Additive Manufacturing. ASME SSDM 2023, June 2023, SSDM2023-111806, Accepted.  Rudd, M.T.; Eberlein, D.J.; Waters, W.A.; Gardner, N.W.; Schultz, M.R.; and Bisagni, C.: Analysis and Validation of a Scaled, Launch- Vehicle-Like Composite Cylinder under Axial Compression. Composite Structures, Volume 304, Part 1, January 2023.  Rudd, M.T.; Schultz, M.R.; Gardner, N.W.; and Bisagni, C.: Test and Analysis of a Composite Conical-Cylindrical Shell. AIAA SciTech 2023 Forum, AIAA paper no. AIAA 2023-1525, National Harbor, MD, January 2023.  Soltz, B.; Goyal, V.; Rome, J.; and Qu, X.: Structural Requirements, Process Simulation, and Residual Stress Characterization for Additively Manufactured Spaceflight Parts. AIAA 2023-2078, https:// doi.org/10.2514/6.2023-2078, AIAA Scitech 2023, National Harbor, MD, January 23-27, 2023.  Soltz, B.; Sivess, A.; Hickman, M.; Ghazari, A. and Shimizu, L.: Static Load Testing and Analysis Recommendations For Space Vehicles. OTR 2023-00653, 33rd Aerospace Testing Seminar, The Aerospace Corporation, May 16, 2023.  Song, K.; Mikulas, M.; Mahlin, M.; and Cassady, J.: Sizing and Design Tool for Tall Lunar Tower. AIAA-2023-0382, SciTech 2023, National Harbor, MD, January 2023.  Hammel, J.: Utilizing 3D-DIC on the Mars 2020 Rover Wheel Assembly: Test-Analysis Correlation. IEEE, March 2023.  Song, K.; Stark, A.; Amundsen, R.; Mikulas, M.; Mahlin, M.; and Cassady, J.: Sizing, Buckling, and Thermal-Structural Analysis of Tall Lunar Tower. 2023 AIAA ASCEND, Las Vegas, NV, October 2023.  TerMaath, S.: Multi-scale Computational Structural Mechanics. Turing- Oden Workshop on Data Science and Machine Learning. Alan Turing Institute, London, January 25-27, 2023.  TerMaath, S.; Crusenberry, C.; and Arndt, C.: Reduced Order Modeling of Progressive Failure in Composite/Metal Structure. 6th International Conference on Protective Structures, Auburn University, May 14-17, 2023.  TerMaath, S.: Probabilistic multi-scale characterization and prediction of bimaterial bondline structural reliability. Canadian National Research Council, Ottawa, June 1, 2023.  TerMaath, S.; Ingling, B.; Noland, J.; and Hart, D.: Evaluation of low-velocity impact damage in metal/composite layered structure. 8th International Symposium on Life-Cycle Civil Engineering (IALCCE). Milano, Italy, July 2-6, 2023.  Twombly, E.; Hill, L.; Wilkowski, G.; Brust, B.; Lin, B.; and Tregoning, R.: Evaluation of the Inherent LBB Behavior of Small-Diameter Class 1 and 2 Nuclear Piping Systems. ASME Pressure Vessels and Piping Conference, Paper PVP2023-107685, Atlanta, GA, July 2023.  Ytuarte, E.; Ragheb, H.; Sobey, A.; and TerMaath, S.: Peridynamics with stochastic bond strengths for determination of final failure in composite laminates. ASCE Engineering Mechanics Institute, Georgia Tech, Atlanta, GA, June 6-9, 2023.2022, Park City, UT. Systems Engineering
      Driscoll, A. and Vining, G.: Debunking Stress Rupture Theories Using Weibull Regression Plots. Fall Technical Conference, October 12-14, 2022, Park City, UT  Driscoll, A.: Advances in Stress Rupture Modeling: A Case Study for Predicting COPV Reliability. Joint Statistical Meetings, August 5-10, 2023, Toronto, Canada.  Huang, Z. C.: Toward Closed Form Formulas for System Reliability and Confidence Quantification. 2023 Annual Reliability and Maintainability Symposium (RAMS), January 23-26, 2023, DOI: 10.1109/RAMS51473.2023.10088214.  Parker, P. and Wilson, S.: Motivating Statistical Research for NASA Applications. Joint Statistical Meetings, August 5-10, 2023, Toronto, Canada.  Thermal Control and Protection 
      Rickman, S.: Re-Architecting the NASA Wire Derating Approach, Phase II, Wire and Wire Bundle Ampacity Testing and Analysis. Aerospace Electrical Interconnect Symposium, October 2022, Houston, TX.  Rickman, S.: Space Mission Thermal Control and Protection Challenges – Past, Present, and Future. The Intersociety Conference on Thermal and Thermomechanical Phenomena in Electronic Systems (ITherm), June 2023, Orlando, FL.  Rickman, S.: Introduction to Orbits. Rice/Envision Aerospace and Aviation Academy, June 2023, Houston, TX.  Rickman, S.: Development and Application of a Novel Calorimetry Technique for the Study of Lithium-Ion Cell Thermal Runaway., International Conference on Environmental Systems (ICES), July 2023, Calgary, Canada.  Rickman, S.: Introduction to On-Orbit Thermal Environments. Thermal and Fluids Analysis Workshop (TFAWS), August 2023, College Park, MD.  Shafirovich, E. and Rickman, S.: A Warm Garage for a Lunar Rover, Commercial Lunar Payload Services. Survive the Night Technology Workshop, December 2022, Cleveland, OH.  View the full article
    • By NASA
      NESC Honor Awards are given each year to NASA employees, industry representatives, and other stakeholders for their efforts and achievements in engineering, leadership, teamwork, and communication. These awards formally recognize those who have made outstanding contributions to the NESC mission, demonstrate engineering and technical excellence, and foster an open environment. 
      2022 Honorees from left to right: (Front Row) Tim Wilson (NESC Director); Yuan Chen (LaRC), Elspeth Peterson (KSC), Grace Belancik (ARC), Jing Pei (LaRC), Mark Vande Hei (NESC Chief Astronaut); (Second row) James Walker (MSFC), Carlton Faller (JSC), Jason Vaughn (MSFC), Shane Cravens (Syncom Space Services, SSC), Shawn Brechbill (MSFC), Kevin Dickens (GRC); (Third row) Christopher Johnston (LaRC).   NESC Director’s Award 
      Honors individuals for defending a technical position that conflicts with a program or organization’s initial or prevailing engineering perspectives and for taking personal initiative to foster clear and open communication and resolve controversial issues. 
      DANIEL L. DIETRICH – In recognition of the development and advocacy of the technical rationale to assess the safety and effectiveness of breathing systems for pilots of tactical aircraft. 

      NESC Leadership Award 
      Honors individuals for sustained leadership excellence demonstrated by establishing a vision, developing and managing a plan, and building consensus to proactively resolve conflicts and achieve results. 
      YUAN CHEN – In recognition of outstanding leadership in  the electrical, electronic, electromechanical parts’ community and the development of recommendations on the use of commercial parts in NASA missions. 
      NIKOLAUS GRAVENSTEIN – In recognition of outstanding technical leadership in support of Verification of Testing Standard for Carbon Dioxide (CO2) Partial Pressure in Extravehicular Activity Suits. 
      ELSPETH M. PETERSEN – In recognition of outstanding leadership to the Spacesuit Water Membrane Evaporator Assessment Team in negotiating creative solutions and facility challenges. 
      PATRICK A. SIMPKINS – In recognition of outstanding technical leadership in support of numerous NESC assessments to reduce risk to NASA’s most critical human and robotic spaceflight programs. 

      NESC Engineering Excellence Award 
      Honors individuals for making significant engineering contributions, developing innovative approaches, and ensuring appropriate levels of engineering rigor are applied to the resolution of technical issues in support of the NESC mission. 
      KEVIN W. DICKENS – In recognition of engineering excellence and sustained commitment to the NESC Propulsion Technical Discipline Team and NASA missions. 
      View the full article
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