Engineering topics
Kynard, Mike
Publications and source records attributed to Kynard, Mike.
From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration
In 2006, NASA selected an evolved variant of the proven Saturn/Apollo J-2 upper stage engine to power the Ares I crew launch vehicle upper stage and the Ares V cargo launch vehicle Earth departure stage (EDS) for the Constellation Program. Any design changes needed by the new engine would be based where possible on proven hardware from the Space Shuttle, commercial launchers, and other programs. In addition to the thrust and efficiency requirements needed for the Constellation reference missions, it would be an order of magnitude safer than past engines. It required the J-2X government/industry team to develop the highest performance engine of its type in history and develop it for use in two vehicles for two different missions. In the attempt to achieve these goals in the past five years, the Upper Stage Engine team has made significant progress, successfully passing System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of spring 2010, more than 100,000 experimental and development engine parts have been completed or are in various stages of manufacture. Approximately 1,300 of more than 1,600 engine drawings have been released for manufacturing. This progress has been due to a combination of factors: the heritage hardware starting point, advanced computer analysis, and early heritage and development component testing to understand performance, validate computer modeling, and inform design trades. This work will increase the odds of success as engine team prepares for powerpack and development engine hot fire testing in calendar 2011. This paper will provide an overview of the engine development program and progress to date.
From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration
The NASA/industry team responsible for developing the J-2X Upper Stage Engine for the Constellation Program's Ares I and Ares V launch vehicles has made significant progress toward moving the design from paper to production during the past year. The J-2X exemplifies the Constellation goal of using proven technology and experience from more than 50 years of United States spaceflight experience and seeking where possible to employ common hardware in the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The J-2X will power the Ares I upper stage to place the Orion crew vehicle in orbit. For the Ares V, the J-2X will place the Earth departure stage (EDS) and lunar lander in orbit and later re-start to send the Orion and lander to the Moon. Pratt & Whitney Rocketdyne (PWR) is under contract to develop and produce the engine, leveraging its flight-proven LH2/LOX, gas generator cycle J-2 and RS-68 engine capabilities, recent experience with the X-33 aerospike XRS-2200 engine, and development knowledge of the J-2S tap-off cycle engine. The J-2X employs a gas generator operating cycle designed to produce 294,000 pounds of thrust in primary operating mode for the Ares I and Ares V ascent phases. It also has a secondary mode, during which it operates at 80 percent thrust by altering its mixture ratio to perform the TLI burn for the Ares V lunar sortie and lunar cargo missions. The J-2X development philosophy is based on proven hardware, an aggressive development schedule, and early risk reduction. NASA Marshall Space Flight Center (MSFC) and PWR began development of the J-2X in June 2006. The government/industry team of more than 600 people within NASA and PWR successfully completed the Critical Design Review (CDR) in November 2008, following extensive risk mitigation testing. The team is working toward a first flight of the J-2X on the Orion 1 mission in 2014. This paper will discuss the J-2X development background and provide top-level information on design and testing to date. Details will be provided on overcoming challenges such as gas generator instability, turbine blade life, and nozzle extension selection and materials.
Development Status of the J-2X
In June 2006, the NASA Marshall Space Flight Center (MSFC) and Pratt & Whitney Rocketdyne began development of an engine for use on the Ares I crew launch vehicle and the Ares V cargo launch vehicle. The development program will be completed in December 2012 at the end of a Design Certification Review and after certification testing of two flight configuration engines. A team of over 600 people within NASA and Pratt & Whitney Rocketdyne are currently working to prepare for the fall 2008 Critical Design Review (CDR), along with supporting an extensive risk mitigation test program. The J-2X will power the Ares I upper stage and the Ares V earth departure stage (EDS). The initial use will be in the Ares I, used to launch the Orion crew exploration vehicle. In this application, it will power the upper stage after being sent aloft on a Space Shuttle-derived. 5-segment solid rocket booster first stage. In this mission. the engine will ignite at altitude and provide the necessary acceleration force to allow the Orion to achieve orbital velocity. The Ares I upper stage, along with the J-2X. will then be expended. On the Ares V. first stage propulsion is provided by five RS-68B engines and two 5-segment boosters similar to the Ares I configuration. In the Ares V mission. the J-2X is first started to power the EDS and its payload. the Altair lunar lander. into earth orbit, then shut-down and get prepared for its next start. The EDS/Altair will remain in a parking orbit, awaiting rendezvous and docking with Orion. Once the two spacecraft are mated, the J-2X will be restarted to achieve earth departure velocity. After powering the Orion and Altair, the EDS will be expended. By using the J-2X Engine in both applications, a significant infrastructure cost savings is realized. Only one engine development is required, and the sustaining engineering and flight support infrastructures can be combined. There is also flexibility for changing, the production and flight manifest because a single production line can support both missions with minimal differences between each engine configuration kit.
SSME testing technology at the John C. Stennis Space Center
An effective capability for testing the Space Shuttle Main Engine is described. The test complex utilizes a number of sophisticated test stands, test support facilities, and control centers to conduct development testing and flight acceptance testing at both nominal and off-nominal conditions.