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Broad-Based Teams Case Study #1 - Composite Crew Module (CCM) Project Management Challenge 2009 Daytona
Broad-Based Teams Case Study #1 - Composite Crew Module (CCM) Project Management Challenge 2009 Daytona

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

2009 Mike Kirsch, CCM Project Manager NASA Engineering and Safety Center Principal Engineer Engineering Excellence

Engineering Excellence

NESC Overview Engineering Excellence
NESC Overview Engineering Excellence

NESC Overview

NESC Overview Engineering Excellence

Engineering Excellence

NESC Overview • In 2003, the NASA Engineering & Safety Center (NESC) was formed as

NESC Overview

NESC Overview • In 2003, the NASA Engineering & Safety Center (NESC) was formed as a

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

for consideration of all points of view • Facilitating hands-on design and development experience Engineering Excellence
for consideration of all points of view • Facilitating hands-on design and development experience Engineering Excellence
for consideration of all points of view • Facilitating hands-on design and development experience Engineering Excellence
for consideration of all points of view • Facilitating hands-on design and development experience Engineering Excellence

Engineering Excellence

NESC Background NESC emphasis is to create broad-based teams to enable networks that discourage silos

NESC Background

NESC Background NESC emphasis is to create broad-based teams to enable networks that discourage silos •

NESC emphasis is to create broad-based teams to enable networks that discourage silos

Recruit team membership from a broad community

Increase inter-Center knowledge and information flow

• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage
• Increase inter-Center knowledge and information flow • Facilitate inter-Center collaboration • Encourage

Facilitate inter-Center collaboration

Encourage inter-Center relationships and communities of practice

inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence
inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence
inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence
inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence
inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence
inter-Center collaboration • Encourage inter-Center relationships and communities of practice Engineering Excellence

Engineering Excellence

NESC Composite Crew Module Engineering Excellence
NESC Composite Crew Module Engineering Excellence

NESC Composite Crew Module

NESC Composite Crew Module Engineering Excellence

Engineering Excellence

January 2007 NASA Administrator chartered the NESC to form an agency team to… • design
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
Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module =
Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module =

Composite Crew Module Overview

Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module = Upper
Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module = Upper
Composite Crew Module Overview Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module = Upper

Upper Pressure Shell

Splice Joint

Lower Pressure Shell

Upper Pressure Shell Splice Joint Lower Pressure Shell Pressure Module = Upper Pressure She ll +

Pressure Module = Upper Pressure Shell + Splice Joint + Lower Pressure Shell

Lower Pressure Shell Pressure Module = Upper Pressure She ll + Splice Joint + Lower Pressure

Engineering Excellence

System Dimensions Engineering Excellence

System Dimensions

System Dimensions Engineering Excellence
System Dimensions Engineering Excellence
System Dimensions Engineering Excellence
System Dimensions Engineering Excellence

Engineering Excellence

Project Attributes • Broad NASA Center representation • ARC, DFRC, GRC, GSFC, JPL, JSC, KSC,

Project Attributes

Broad NASA Center representation

Project Attributes • Broad NASA Center representation • ARC, DFRC, GRC, GSFC, JPL, JSC, KSC, LaRC,

• 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)

scale hardware • Production slow down May 2008 – S eptember 2008 (NESC Budget realignment) Engineering

Engineering Excellence

Project Management Project Manager Mike Kirsch LARC Deputy Project Mgr--Technical Integration Jeff Stewart

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)

Administrative Assistant Terri Derby ATK (Swales) Resource Analyst Pro-E & IT Admin Program Support
Resource Analyst Pro-E & IT Admin Program Support Support Pamela Throckmorton Mike Mongilio Steve Summit
Resource Analyst
Pro-E & IT Admin
Program Support
Support
Pamela Throckmorton
Mike Mongilio
Steve Summit
LARC
ATK (Swales)
ATK (Iuka)
Advisors Advisor Damodar Ambur LARC Advisor Tom Modlin JSC Advisor Joe Pellicciotti GSFC Advisor Tod
Advisors
Advisor
Damodar Ambur
LARC
Advisor
Tom Modlin
JSC
Advisor
Joe Pellicciotti
GSFC
Advisor
Tod Palm
NGC
 

Testing

 

Materials

Analysis

 

Design Engineering

 

Manufacturing

 

NDE

 

Lead

 

Lead

 

Lead Jim Jeans

   

Lead

   

Lead

 

Lead

Sotiris

Kellas

Dan Polis

Jeff Stewart

 

Larry Pelham

     

Ken Hodges

LARC

GSFC

Genesis Engineering

GSFC

 

MSFC

JSC

Chip McCann

 

Wade Jackson

David

Sleight

 

Ian Fernandez

Dawson

Vincent

Randy

Sparks

Tristan

Curry

 

JSC

LARC

LARC

 

Craig Collier Collier Research Corp

ARC

NGC (MSFC)

ATK (Clearfield)

 

UAH

John Thesken

 

Ben Rodini

 

Jonathan Bartley-Cho Northrop Grumman Corp

Phil Yarrington Collier Research Corp

Dave Paddock

Mike Western

Tom McCabe

 

Elliott Cramer

 

GRC

SGT

LARC

Janicki

ATK

(Iuka)

 

LARC

 

Donny

NGC

Wang

Ron Schmidt

LMC

 

Eric Schleicher

 

Steve Rickman

 

Jerry

Stuart

NGC

Eric Friesen

Chip Henderson

Brad Parker

 
   

ATK (Swales)

     

JSC

   

Janicki

 

ATK

(Iuka)

   

GSFC

                         
 

Marc Dinardo

     

Perry Wagner

   

Laurie Carrillo

 

Luis Santos

GSFC

Robert

Boscia

Fred Hall

 

Jeff Stone

 

LMC

 

ATK (Swales)

   

JSC

       

Alcore

 

ATK

(Iuka)

ATK (Iuka)

Wayne Sawyer

   

Charles Kaprielian

 

Angel Alvarez-

 

Dan Richardson

ATK (Swales)

Terry Graham

Touch (ATK)

Sam Russell

 
 

AS&M

 

ATK (Swales)

     

Hernandez

JSC

     

ATK (MSFC)

   

MSFC

Jared Schoenly

     

Brett Bednarcyk

 

ATK (Swales)

Bill Kelly

Stephen Williams

Rance Jones

James Walker

 
 

AMA

       

Mike

Abel

Cindy Sowards

   

MSFC

 

GRC

   

Ed Fasanella

   

Doug Lenhardt

ATK

Danny Lambert

   
 

LaRC

KSC

 

Andrew Johnson

Steven Johnson

 
 

Al Tabiei

 

Craig Bowser

 

Jerry Gray

Phil Thompson

 

ATK (Iuka)

MPSE

ATK Swales

Scott Ragasa

 
     

UAH

 
ATK (Iuka) MPSE ATK Swales Scott Ragasa         UAH   Engineering Excellence

Engineering Excellence

Virtual Engineering Enablers • Goal – Create a virtual environment that promotes communications as if

Virtual Engineering Enablers

Virtual Engineering Enablers • Goal – Create a virtual environment that promotes communications as if the

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

control • Instant Messaging (Chat) • Desktop sharing (2 clicks) • Smart Boards/tablets Engineering Excellence

Engineering Excellence

Co-location Floor Plan Engineering Excellence

Co-location Floor Plan

Co-location Floor Plan Engineering Excellence
Co-location Floor Plan Engineering Excellence
Co-location Floor Plan Engineering Excellence

Engineering Excellence

Materials Selection • Prepreg - IM7/977-2 tape and 4-harness satin fabric • High strength fiber

Materials Selection

Materials Selection • Prepreg - IM7/977-2 tape and 4-harness satin fabric • High strength fiber •

• 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

e - core splice adhesive • EY-3010/Lord 4688 - potting compound s - low density, low

Engineering Excellence

Lower Shell Loading • Backbone carries pressure load – no ring frame (~100 lbs savings)

Lower Shell Loading

Lower Shell Loading • Backbone carries pressure load – no ring frame (~100 lbs savings) •

• 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 sharing with Heat Shield (~1000 lbs heat shield savings)

sharing with Heat Shield (~1000 lbs heat shield savings) 50% load sharing on backbone Internal Pressure

50% load sharing on backbone

(~1000 lbs heat shield savings) 50% load sharing on backbone Internal Pressure Water Landing Engineering Excellence

Internal Pressure

(~1000 lbs heat shield savings) 50% load sharing on backbone Internal Pressure Water Landing Engineering Excellence

Water Landing

(~1000 lbs heat shield savings) 50% load sharing on backbone Internal Pressure Water Landing Engineering Excellence
(~1000 lbs heat shield savings) 50% load sharing on backbone Internal Pressure Water Landing Engineering Excellence

Engineering Excellence

New Technology - Cobonded Joints - Air Force CAI • Replaces bonde d or bolted

New Technology - Cobonded Joints - Air Force CAI

New Technology - Cobonded Joints - Air Force CAI • Replaces bonde d or bolted joints
New Technology - Cobonded Joints - Air Force CAI • Replaces bonde d or bolted joints

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

connections • Lobe core tapers out before Pi • Also used to bond Gussets to upper
connections • Lobe core tapers out before Pi • Also used to bond Gussets to upper

Engineering Excellence

Pi Preform Comparison Program HST's Super Lightweight Interchangeable Carrier NESC Composite Crew Module

Pi Preform Comparison

Pi Preform Comparison Program HST's Super Lightweight Interchangeable Carrier NESC Composite Crew Module

Program

HST's Super Lightweight Interchangeable Carrier

NESC Composite Crew Module

Joint type

traditional back-to-back L-clips

pi preform technology

Geometry

Geometry
Geometry

Pre-cured part count

5 pre-cured details:

2 pre-cured details:

web, skin, closeout, two L-clips

web and skin

Bonding process

2 step paste bond

1 step cobond

Tension

   

Capability

~900 lb/in

~2000 lb/in

paste bond 1 step cobond Tension     Capability ~900 lb/in ~2000 lb/in Engineering Excellence

Engineering Excellence

Upper Pressure Shell Tooling • Use Temperature: 400F • Use Pressure: 100psi • CTE: Chop

Upper Pressure Shell Tooling

Upper Pressure Shell Tooling • Use Temperature: 400F • Use Pressure: 100psi • CTE: Chop Carbon

• 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”

Critical Zones +/- .010” • Non-critical Zones +/- 030” • Durability: 30 cycles (300+ hours) •

• Durability: 30 cycles (300+ hours)

• Schedule: 12-16 weeks

• Cost: $375K

Tool nickname: “Big Plunger”

30 cycles (300+ hours) • Schedule: 12-16 weeks • Cost: $375K Tool nickname: “Big Plunger” Engineering

Engineering Excellence

Upper Pressure Shell Tool Engineering Excellence

Upper Pressure Shell Tool

Upper Pressure Shell Tool Engineering Excellence
Upper Pressure Shell Tool Engineering Excellence
Upper Pressure Shell Tool Engineering Excellence

Engineering Excellence

Upper IML Processing Autoclave cure Layup IML Bag Part Engineering Excellence

Upper IML Processing

Upper IML Processing Autoclave cure Layup IML Bag Part Engineering Excellence
Autoclave cure Layup IML Bag Part
Autoclave cure
Layup IML
Bag Part

Engineering Excellence

Shell Core Installation Film Adhesive Install Core Debagging Outer Skins Tacked Ceiling Core Engineering Excellence

Shell Core Installation

Shell Core Installation Film Adhesive Install Core Debagging Outer Skins Tacked Ceiling Core Engineering Excellence
Film Adhesive Install Core Debagging Outer Skins Tacked Ceiling Core
Film Adhesive
Install Core
Debagging
Outer Skins
Tacked Ceiling Core

Engineering Excellence

Automatic Ultrasonic Inspection Engineering Excellence

Automatic Ultrasonic Inspection

Automatic Ultrasonic Inspection Engineering Excellence
Automatic Ultrasonic Inspection Engineering Excellence
Automatic Ultrasonic Inspection Engineering Excellence

Engineering Excellence

Upper Manufacturing Demonstration Unit Complete! Engineering Excellence

Upper Manufacturing Demonstration Unit Complete!

Upper Manufacturing Demonstration Unit Complete! Engineering Excellence
Upper Manufacturing Demonstration Unit Complete! Engineering Excellence
Upper Manufacturing Demonstration Unit Complete! Engineering Excellence

Engineering Excellence

Lower Shell Engineering Excellence

Lower Shell

Lower Shell Engineering Excellence
Lower Shell Engineering Excellence

Engineering Excellence

Upper IML and OML Layup • Between 4 and 39 plies thick • Approximately 400

Upper IML and OML Layup

Upper IML and OML Layup • Between 4 and 39 plies thick • Approximately 400 ply

• 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

.75” – 1.25” • Manage material yield • Manage material “out time” < 30 days Engineering

Engineering Excellence

Upper IML Plies Engineering Excellence

Upper IML Plies

Upper IML Plies Engineering Excellence
Upper IML Plies Engineering Excellence

Engineering Excellence

1 IML Ply Segment Engineering Excellence

1 IML Ply Segment

1 IML Ply Segment Engineering Excellence
1 IML Ply Segment Engineering Excellence
1 IML Ply Segment Engineering Excellence

Engineering Excellence

1 ply segment Engineering Excellence

1 ply segment

1 ply segment Engineering Excellence
1 ply segment Engineering Excellence

Engineering Excellence

Flat Patterns • Integrated electronic process flow exists • Design, Manufacturing, and Inspection via •

Flat Patterns

Flat Patterns • Integrated electronic process flow exists • Design, Manufacturing, and Inspection via • CAD,
• Integrated electronic process flow exists
• Integrated electronic process flow exists

Design, Manufacturing, and Inspection via

• CAD, NASTRAN, FiberSIM, flat patterns, laser projection, layup, inspection

and Inspection via • CAD, NASTRAN, FiberSIM, flat patterns, laser projection, layup, inspection Engineering Excellence

Engineering Excellence

Civil Servant “Hands On” Experience Ian Fernandez, Design Engineer ARC Dave Sleight, Structural Analyst LaRC

Civil Servant “Hands On” Experience

Civil Servant “Hands On” Experience Ian Fernandez, Design Engineer ARC Dave Sleight, Structural Analyst LaRC
Ian Fernandez, Design Engineer ARC Dave Sleight, Structural Analyst LaRC Cecilia Larrosa, Aerospace engineering
Ian Fernandez,
Design Engineer
ARC
Dave Sleight,
Structural Analyst
LaRC
Cecilia Larrosa,
Aerospace engineering intern
ARC

Engineering Excellence

T&V Objectives • Show, through destructive testi ng, that allowable material properties are conservative •

T&V Objectives

T&V Objectives • Show, through destructive testi ng, that allowable material properties are conservative • For

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

with analysis models • Verify structural design robustness, and understand failure modes Engineering Excellence

Engineering Excellence

Critical Test Locations LIDS/Tunnel Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment

Critical Test Locations

LIDS/Tunnel

Critical Test Locations LIDS/Tunnel Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment
Critical Test Locations LIDS/Tunnel Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment
Critical Test Locations LIDS/Tunnel Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment

Main Parachute Attachment

Test Locations LIDS/Tunnel Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment

Drogue Parachute Attachment

Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment Crucifom Engineering Excellence
Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment Crucifom Engineering Excellence
Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment Crucifom Engineering Excellence

Splice

Backbone Attachment Crucifom
Backbone
Attachment
Crucifom
Main Parachute Attachment Drogue Parachute Attachment Splice Backbone Attachment Crucifom Engineering Excellence

Engineering Excellence

Building Block Approach Tests • Coupon • Sandwich flatwise tension - complete • Edgewise compression

Building Block Approach Tests

Building Block Approach Tests • Coupon • Sandwich flatwise tension - complete • Edgewise compression -

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

simplified interface (flat panel) • Non-potted core – complete • Potted core - complete Engineering Excellence

Engineering Excellence

Full Scale Testing: Loads “Freebody” Main Chute Load 64,400 lbs Drogue Load 34,200 lbs Maximum

Full Scale Testing: Loads “Freebody”

Full Scale Testing: Loads “Freebody” Main Chute Load 64,400 lbs Drogue Load 34,200 lbs Maximum Internal

Main Chute Load 64,400 lbs

Testing: Loads “Freebody” Main Chute Load 64,400 lbs Drogue Load 34,200 lbs Maximum Internal Pressure, 31.1

Drogue Load 34,200 lbs

Maximum Internal Pressure, 31.1 psi
Maximum Internal
Pressure, 31.1 psi
Drogue Load 34,200 lbs Maximum Internal Pressure, 31.1 psi Launch abort Load 134,000 lbs Service Module
Drogue Load 34,200 lbs Maximum Internal Pressure, 31.1 psi Launch abort Load 134,000 lbs Service Module
Drogue Load 34,200 lbs Maximum Internal Pressure, 31.1 psi Launch abort Load 134,000 lbs Service Module

Launch abort Load 134,000 lbs

Service Module Load 101,000 lbs

Maximum Delta Load 76,000 lbs

Launch abort Load 134,000 lbs Service Module Load 101,000 lbs Maximum Delta Load 76,000 lbs Engineering

Engineering Excellence

Combined Loads Test System (COLTS) NASA Langley Engineering Excellence
Combined Loads Test System (COLTS) NASA Langley Engineering Excellence

Combined Loads Test System (COLTS) NASA Langley

Combined Loads Test System (COLTS) NASA Langley Engineering Excellence
Combined Loads Test System (COLTS) NASA Langley Engineering Excellence

Engineering Excellence

Overall Project Status • 24 months into the project • Independent reviews conducted throughout project

Overall Project Status

Overall Project Status • 24 months into the project • Independent reviews conducted throughout project life

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

tests completion expected in July 09 • CCM Final Report completion expected in September 09 Engineering

Engineering Excellence

Composite Crew Module Engineering Excellence

Composite Crew Module

Composite Crew Module Engineering Excellence
Composite Crew Module Engineering Excellence
Composite Crew Module Engineering Excellence

Engineering Excellence