Next-Generation RS-25 Engines for the NASA Space Launch System
No abstract available
Ballard, Richard O.↗
Engineering topics
Ballard, Richard O.
Publications and source records attributed to Ballard, Richard O..
Next-Generation RS-25 Engines for the NASA Space Launch System
The utilization of heritage RS-25 engines, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over 1 million seconds total accumulated hot-fire time. In addition, there were also 16 flight engines and 2 development engines remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway to improve system affordability and eliminate obsolescence concerns. These key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.
Ballard, Richard O.↗
Next-Generation RS-25 Engines for the NASA Space Launch System
The utilization of heritage RS-25 engine, also known as the Space Shuttle Main Engine (SSME), has enabled rapid progress in the development and certification of the NASA Space Launch System (SLS) toward operational flight status. The RS-25 brings design maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. Beyond these initial SLS flights, NASA must have a renewed supply of RS-25 engines that must reflect program affordability imperatives as well as technical requirements imposed by the SLS Block-1B vehicle (i.e., 111% RPL power level, reduced service life). Recognizing the long lead times needed for the fabrication, assembly and acceptance testing of flight engines, design activities are underway at NASA and the RS-25 engine provider, Aerojet Rocketdyne, to improve system affordability and eliminate obsolescence concerns. This paper describes how the achievement of these key objectives are enabled largely by utilizing modern materials and fabrication technologies, but also by innovations in systems engineering and integration (SE&I) practices.
Ballard, Richard O.↗
SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture
Following the cancellation of the Constellation program and retirement of the Space Shuttle, NASA initiated the Space Launch System (SLS) program to provide next-generation heavy lift cargo and crew access to space. A key constituent of the SLS architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). The RS-25 was selected to serve as the main propulsion system for the SLS core stage in conjunction with the solid rocket boosters. This selection was largely based on the maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle boat-tail and installing it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration details involving changes to significant areas such as the environments, interface conditions, technical performance requirements, operational constraints and so on, there were other challenges to be overcome in the area of replacing the obsolete engine control system (ECS). While the magnitude of accomplishing this effort was less than that needed to develop and field a new clean-sheet engine system, the path to the first flight of SLS has not been without unexpected challenges.
Ballard, Richard O.↗
SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture
A key constituent of the NASA Space Launch System (SLS) architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). This engine was selected largely due to the maturity and extensive experience gained through 30-plus years of service. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle and mounting it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration and operational details, there were also hardware upgrades needed. While the magnitude of effort is less than that needed to develop a new clean-sheet engine system, this paper describes some of the expected and unexpected challenges encountered to date on the path to the first flight of SLS.
Ballard, Richard O.↗
SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture
No abstract available
Ballard, Richard O.↗
System Engineering and Technical Challenges Overcome in the J-2X Rocket Engine Development Project
Beginning in 2006, NASA initiated the J-2X engine development effort to develop an upper stage propulsion system to enable the achievement of the primary objectives of the Constellation program (CxP): provide continued access to the International Space Station following the retirement of the Space Station and return humans to the moon. The J-2X system requirements identified to accomplish this were very challenging and the time expended over the five years following the beginning of the J- 2X effort have been noteworthy in the development of innovations in both the fields for liquid rocket propulsion and system engineering.
Ballard, Richard O.↗
Overview of Liquid Propellant Rocket Engine Systems and the J-2X
No abstract available
Ballard, Richard O.↗
Future NTP Development Synergy Leveraged from Current J-2X Engine Development
This paper is a discussion of how the many long-lead development elements required for the realization of a future nuclear thermal propulsion (NTP) system can be effectively leveraged from the ongoing work being conducted on the J-2X engine program for the Constellation Program. Development studies conducted to date for NTP forward planning have identified a number of technical areas that will require advancement to acceptable technology readiness levels (TRLs) before they can be utilized in NTP system development. These include high-temperature, high-area ratio nozzle extension; long-life, low-NPSP. turbomachinery; and low-boiloff propellant management; and a qualified nuclear fuel element. The current J-2X program is working many of these areas that can be leveraged to support NTP development in a highly compatible and synergistic fashion. In addition to supporting technical development, there are other programmatic issues being worked in the J-2X program that can be leveraged by a future NTP development program. These include compliance with recently-evolved space system requirements such as human-rating, fault tolerance and fracture control. These and other similar mandatory system requirements have been adopted by NASA and can result in a significant technical impact beyond elevation of the root technologies required by NTP. Finally, the exploitation of experience, methodologies, and procedures developed by the J-2X program in the areas of verification, qualification, certification, altitude simulation testing, and facility definition will be especially applicable to a future NTP system. The similarities in system mission (in-space propulsion) and operational environment (vacuum, zero-gee) between J-2X and NTP make this highly synergistic. Thus, it can be $hown that the collective benefit of leveraging experience and technologies developed during the J-2X program can result in significant savings in development cost and schedule for NTP.
Ballard, Richard O.↗
Nuclear Thermal Propulsion (NTP) Development Activities at the NASA Marshall Space Flight Center - 2006 Accomplishments
In 2005-06, the Prometheus program funded a number of tasks at the NASA-Marshall Space Flight Center (MSFC) to support development of a Nuclear Thermal Propulsion (NTP) system for future manned exploration missions. These tasks include the following: 1. NTP Design Develop Test & Evaluate (DDT&E) Planning 2. NTP Mission & Systems Analysis / Stage Concepts & Engine Requirements 3. NTP Engine System Trade Space Analysis and Studies 4. NTP Engine Ground Test Facility Assessment 5. Non-Nuclear Environmental Simulator (NTREES) 6. Non-Nuclear Materials Fabrication & Evaluation 7. Multi-Physics TCA Modeling. This presentation is a overview of these tasks and their accomplishments
Ballard, Richard O.↗
REIMR: A Process for Utilizing Propulsion-Oriented 'Lessons-Learned' to Mitigate Development Risk
This paper is a summary overview of a study conducted a t the NASA Marshall Space Flight Center (MSFC) during the initial phases of the Space Launch Initiative (SLI) program to evaluate a large number of technical problems associated with the design, development, test, evaluation and operation of several major liquid propellant rocket engine systems (i.e., SSME, Fastrac, J-2, F-1). The results of this study was the identification of the "Fundamental Root Causes" that enabled the technical problems to manifest, and practices that can be implemented to prevent them from recurring in future engine development efforts. This paper will discus the Fundamental Root Causes, cite some examples of how the technical problems arose from them, and provide a discussion of how they can be mitigated or avoided.
Ballard, Richard O.↗
Operational Issues in the Development of a Cost-Effective Reusable LOX/LH2 Engine
Contents include the following: SLI initiated under NASA Research Announcement (NRA) 8-30. Strategic Objectives. Make spaceflight safer (1 in 10000 mission LOV). Make spaceflight cheaper ($1000/lb payload). Two prototype LOX/LH2 engine systems funded under Cycle-1 of NRA8-30. COBRA (Pratt & Whitney / Aerojet). RS-83 (Rocketdyne).
Ballard, Richard O.↗
Operational Issues in the Development of a Cost-Effective Reusable LOX/LH2 Engine
The NASA Space Launch Initiative (SLI) was initiated in early 2001 to conduct technology development and to reduce the business and technical risk associated with developing the next-generation reusable launch system. In the field of main propulsion, two LOXLH2 rocket engine systems, the Pratt & Whitney / Aerojet Joint Venture (JV) COBRA and the Rocketdyne RS-83, were funded to develop a safe, economical, and reusable propulsion system. Given that a large-thrust reusable rocket engine program had not been started in the U.S. since 1971, with the Space Shuttle Main Engine (SSME), this provided an opportunity to build on the experience developed on the SSME system, while exploiting advances in technology that had occurred in the intervening 30 years. One facet of engine development that was identified as being especially vital in order to produce an optimal system was in the areas of operability and maintainability. In order to achieve the high levels of performance required by the Space Shuttle, the SSME system is highly complex with very tight tolerances and detailed requirements. Over the lifetime of the SSME program, the engine has required a high level of manpower to support the performance of inspections, maintenance (scheduled and unscheduled) and operations (prelaunch and post-flight). As a consequence, the labor- intensive needs of the SSME provide a significant impact to the overall cost efficiency of the Space Transportation System (STS). One of the strategic goals of the SLI is to reduce cost by requiring the engine(s) to be easier (Le. less expensive) to operate and maintain. The most effective means of accomplishing this goal is to infuse the operability and maintainability features into the engine design from the start. This paper discusses some of the operational issues relevant to a reusable LOx/LH2 main engine, and the means by which their impact is mitigated in the design phase.
Ballard, Richard O.↗
COBRA System Engineering Processes to Achieve SLI Strategic Goals
The COBRA Prototype Main Engine Development Project was an endeavor conducted as a joint venture between Pratt & Whitney and Aerojet to conduct risk reduction in LOX/LH2 main engine technology for the NASA Space Launch Initiative (SLI). During the seventeen months of the project (April 2001 to September 2002), approximately seventy reviews were conducted, beginning with the Engine Systems Requirements Review (SRR) and ending with the Engine Systems Interim Design Review (IDR). This paper discusses some of the system engineering practices used to support the reviews and the overall engine development effort.
Ballard, Richard O.↗
Development Status of the NASA MC-1 (Fastrac) Engine
The MC-1 (formerly known as the Fastrac 60K) Engine is being developed for the X-34 technology demonstrator vehicle. It is a pump-fed liquid rocket engine with fixed thrust operating at one rated power level of 60,000 lbf vacuum thrust using a 15:1 area ratio nozzle (slightly higher for the 30:1 flight nozzle). Engine system development testing of the MC-1 has been ongoing since 24 Oct 1998. To date, 48 tests have been conducted on three engines using three separate test stands. This paper will provide some details of the engine, the tests conducted, and the lessons learned to date.
Ballard, Richard O.↗
Development Status of the NASA MC-1 (Fastrac) Engine
This paper presents viewgraphs on the Development Status of the NASA MC-1 (Fastrac) Engine. The topics include: 1) MC-1 Engine; 2) MC-1 Engine Views; 3) MC-1 Engine Schematic; 4) Development Test Summary; 5) Hotfire Test Summary; 6) Lessons Learned During Testing; 7) MFV Cycling Anomaly; 8) MFV Seal Failure; 9) GGFV Seal Failure; and 10) H4-3 Pop Anomaly.
Ballard, Richard O.↗
Cargo transfer vehicle RCS propellant contamination issues
The purpose of this report is to address Cargo Transfer Vehicle (CTV) RCS contamination issues and contribute to the resources necessary to optimize the vehicle and propulsion systems required in the CTV of the National Launch System (NLS) Heavy Lift Launch Vehicle (HLLV). This study reviews the thruster-induced contaminants; their transportation from the thrust chamber to the vehicle, payload, and SSF; and the mechanism by which damage is inflicted on their components. The effect of both monopropellant and bipropellant RCS rocket exhaust plumes on a spacecraft and related functional surfaces has been the subject of considerable study over the years. It is recognized that the RCS rocket produces contaminants which can significantly degrade the performance of optical windows, solar cells, thermal-protective coatings, and other external vehicle components. This is particularly true when the rocket is operating in the pulse mode. The exhaust plume impingement pressure and heat-transfer phenomena also complicate the environment to which the vehicle and its functional surfaces are exposed, but are not addressed in this study. Bipropellant contamination presented several modes of damage to incident surfaces, which can pose a long-term deleterious consequence to CTV payloads and the Space Station Freedom (SSF). Monopropellant contamination did not pose any significant long-term issues other than the possibility of aniline deposition. The use of either bipropellant and monopropellant propulsion systems can have a design impact on the CTV propulsion system with respect to maneuvering operations in the proximity of SSF.
Ballard, Richard O.↗