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Explore propulsion reports from NASA NTRS and DOE OSTI. Search rocket engines, electric propulsion and thrusters; verify designs and performance in the source documents.

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NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗
NASA NTRS1958

The Explorer Rocket Research Program

Since September of 1956, nine Jupiter-C missiles have been launched from the firing pad at Cape Canaveral. The first Jupiter-C firing tested the propulsion system, air frame, and guidance components of the missile, and the second and third firings tested a model of the Jupiter nose cone under realistic re-entry conditions. The remaining six Jupiter-C missiles were used as the launching vehicles for EXPLORER satellites I through VI (Fig. 1). Of the six satellite firings, EXPLORERs I, III, and IV achieved satisfactory orbits. The Jupiter-C missile was designed and developed as a joint program under the technical direction of the Jet Propulsion Laboratory and the Army Ballistic Missile Agency. The Jet Propulsion Laboratory developed the three high-speed stages, and the Army Ballistic Missile Agency handled the development, construction, and operation of the first-stage booster rocket and the guidance system. Many other organizations have contributed to the success of the EXPLORER satellite program, most notably the State University of Iowa, the Air Force Cambridge Research Center, and the satellite tracking teams of the Vanguard organization.

Robillard, G.↗
NASA NTRS1972

Nuclear propulsion in the United States.

The achievements of the Nuclear Propulsion Program over the past 15 years are reviewed. It is shown that the effort in basic and applied research and technological development resulted in a state of technology of nuclear rocket engines based on solid core reactors, which is suitable for the development of a space propulsion system. Current efforts aimed at achieving specific impulses on the order of 975 sec (3400 K) are noted. The characteristics of SNRE (Small Nuclear Rocket Engine), the ALPHA, BETA, and GAMMA engines are discussed. Attention is given to the design and principles of operation of the Rotating Fluidized Dust Bed Reactor.

Gabriel, D. S.↗
NASA NTRS1977

Comparative analysis of the designs and implementation of vehicles based on reactive propulsion proposed during the nineteenth and beginning of the twentieth centuries

Examination of the presently known historical scientific literature related to the problem of reactive flight indicates that considerable attention had already been given to the idea of reactive propulsion in the nineteenth century; about thirty designs for reaction flying vehicles were proposed during this period. However, the authors of a majority of the designs limited themselves only to a presentation of a diagram of the engine or an account of the principle of its operation, giving neither plans for its structural development nor precise calculations of the amount of energy required for accomplishing reaction flight. None of these authors considered the reaction flying vehicle as an object of variable mass, their choice of energy sources was extremely random, and the theory of the flight of reaction flying vehicles remained completely undeveloped. Early rocket designs of Nezhdanovsky, Ganswindt, Goddard, Tsiolkovsky, and others are examined and the evolution of liquid-propellant rocket engines, solid-propellant rocket engines, and jet aircraft engines is reviewed.

Sokolskiy, V. N.↗
NASA NTRS1979

Laser rocket system analysis

The laser rocket systems investigated in this study were for orbital transportation using space-based, ground-based and airborne laser transmitters. The propulsion unit of these systems utilizes a continuous wave (CW) laser beam focused into a thrust chamber which initiates a plasma in the hydrogen propellant, thus heating the propellant and providing thrust through a suitably designed nozzle and expansion skirt. The specific impulse is limited only by the ability to adequately cool the thruster and the amount of laser energy entering the engine. The results of the study showed that, with advanced technology, laser rocket systems with either a space- or ground-based laser transmitter could reduce the national budget allocated to space transportation by 10 to 345 billion dollars over a 10-year life cycle when compared to advanced chemical propulsion systems (LO2-LH2) of equal capability. The variation in savings depends upon the projected mission model.

Jones, W. S.↗
NASA NTRS1986

Advances in high chamber pressure propulsion

NASA has been involved in the development of improved high thrust booster rocket engines to meet the propulsion requirements of launch vehicles such as the Space Shuttle. Solutions that NASA/Marshall Space Flight Center pursued to accomplish the high performance, long life goals set for SSME are discussed. In addition, currently projected requirements for liquid rocket engines have identified liquid oxygen/hydrocarbon-fueled engines for booster application in the near future. These advanced hydrocarbon-fueled engines will require improvements in performance and life to be suitable for their projected missions. Raising chamber pressure to increase performance and reduce engine envelope are the key objectives in hydrocarbon-fueled engine technology. This paper traces the history of advances in high pressure rocket engine systems and the challenges it presents.

Mccool, A. A.↗
NASA NTRS1988

Evaluation of innovative rocket engines for single-stage earth-to-orbit vehicles

Computer models of rocket engines and single-stage-to-orbit vehicles that were developed by the authors at DFVLR and NASA have been combined. The resulting code consists of engine mass, performance, trajectory and vehicle sizing models. The engine mass model includes equations for each subsystem and describes their dependences on various propulsion parameters. The engine performance model consists of multidimensional sets of theoretical propulsion properties and a complete thermodynamic analysis of the engine cycle. The vehicle analyses include an optimized trajectory analysis, mass estimation, and vehicle sizing. A vertical-takeoff, horizontal-landing, single-stage, winged, manned, fully reusable vehicle with a payload capability of 13.6 Mg (30,000 lb) to low earth orbit was selected. Hydrogen, methane, propane, and dual-fuel engines were studied with staged-combustion, gas-generator, dual bell, and the dual-expander cycles. Mixture ratio, chamber pressure, nozzle exit pressure liftoff acceleration, and dual fuel propulsive parameters were optimized.

Manski, Detlef↗
NASA NTRS1991

In-situ propellant rocket engines for Mars mission ascent vehicle

When comtemplating the human exploration of Mars, many scenarios using various propulsion systems have been considered. One propulsion option among them is a vehicle stage with multiple, pump fed rocket engines capable of operating on propellants available on Mars. This reduces the Earth launch mass requirements, resulting in economic and payload benefits. No plentiful sources of hydrogen on Mars have been identified on the surface of Mars, so most commonly used high performance liquid fuels, such as hydrogen and hydrocarbons, can be eliminated as possible in-situ propellants. But 95 pct. of the Martian atmosphere consists of carbon dioxide, which can be converted into carbon monoxide and oxygen. The carbon monoxide oxygen propellant conbination is a candidate for a Martian in-situ propellant rocket engine. The feasibility is analyzed of a pump fed engine cycle using the propellant combination of carbon monoxide and oxygen.

Roncace, Elizabeth A.↗
NASA NTRS1991

Development of an electrostatic propulsion engine using sub-micron powders as the reaction mass

Asteroid sample return missions would benefit from development of an improved rocket engine. Chemical rockets achieve their large thrust with high mass consumption rate (dm/dt) but low exhaust velocity; therefore, a large fraction of their total mass is fuel. Present day ion thrusters are characterized by high exhaust velocity, but low dm/dt; thus, they are inherently low thrust devices. However, their high exhausy velocity is poorly matched to typical mission requirements and therefore, wastes energy. A better match would be intermediate between the two forms of propulsion. This could be achieved by electrostatically accelerating solid powder grains, raising the possibility that interplanetary material could be processed to use as reaction mass. An experiment to study the charging properties of sub-micron sized powder grains is described. If a suitable material can be identified, then it could be used as the reaction mass in an electrostatic propulsion engine. The experiment employs a time of flight measurement to determine the exhaust velocity (v) of various negatively charged powder grains that were charged and accelerated in a simple device. The purpose is to determine the charge to mass ratio that can be sustained for various substances. In order to be competitive with present day ion thrusters, a specific impulse (v/g) of 3000 to 5000 seconds is required. Preliminary results are presented. More speculatively, there are some mission profiles that would benefit from collection of reaction mass at the remote asteroid site. Experiments that examine the generation of sub-micron clusters by electrostatic self-disruption of geologically derived material are planned.

Herbert, F.↗
NASA NTRS1991

Space shuttle propulsion systems

This is a presentation of view graphs. The design parameters are given for the redesigned solid rocket motor (RSRM), the Advanced Solid Rocket Motor (ASRM), Space Shuttle Main Engine (SSME), Solid Rocket Booster (SRB) separation motor, Orbit Maneuvering System (OMS), and the Reaction Control System (RCS) primary and Vernier thrusters. Space shuttle propulsion issues are outlined along with ASA program definition, ASA program selection methodology, its priorities, candidates, and categories.

Bardos, Russell↗
NASA NTRS1991

In-situ propellant rocket engines for Mars missions ascent vehicle

When contemplating the human exploration of Mars, many scenarios using various propulsion systems have been considered. One propulsion option among them is a vehicle stage with multiple, pump fed rocket engines capable of operating on propellants available on Mars. This reduces the earth launch mass requirements, resulting in economic and payload benefits. No plentiful sources of hydrogen on Mars have been identified on the surface of Mars, so most commonly used high performance liquid fuels, such as hydrogen and hydrocarbons, can be eliminated as possible in situ propellants. But 95 pct of the Martian atmosphere consists of carbon dioxide, which can be converted into carbon monoxide and oxygen. The carbon monoxide oxygen propellant combination is a candidate for a Martian in situ propellant rocket engine. The feasibility is analyzed of a pump fed engine cycle using the propellant combination of carbon monoxide and oxygen.

Roncace, Elizabeth A.↗
NASA NTRS1991

Analytical study of nozzle performance for nuclear thermal rockets

Nuclear propulsion has been identified as one of the key technologies needed for human exploration of the Moon and Mars. The Nuclear Thermal Rocket (NTR) uses a nuclear reactor to heat hydrogen to a high temperature followed by expansion through a conventional convergent-divergent nozzle. A parametric study of NTR nozzles was performed using the Rocket Engine Design Expert System (REDES) at the NASA Lewis Research Center. The REDES used the JANNAF standard rigorous methodology to determine nozzle performance over a range of chamber temperatures, chamber pressures, thrust levels, and different nozzle configurations. A design condition was set by fixing the propulsion system exit radius at five meters and throat radius was varied to achieve a target thrust level. An adiabatic wall was assumed for the nozzle, and its length was assumed to be 80 percent of a 15 degree cone. The results conclude that although the performance of the NTR, based on infinite reaction rates, looks promising at low chamber pressures, finite rate chemical reactions will cause the actual performance to be considerably lower. Parameters which have a major influence on the delivered specific impulse value include the chamber temperature and the chamber pressures in the high thrust domain. Other parameters, such as 2-D and boundary layer effects, kinetic rates, and number of nozzles, affect the deliverable performance of an NTR nozzle to a lesser degree. For a single nozzle, maximum performance of 930 seconds and 1030 seconds occur at chamber temperatures of 2700 and 3100 K, respectively.

Davidian, Kenneth O.↗
NASA NTRS1992

Nuclear thermal propulsion transportation systems for lunar/Mars exploration

Nuclear thermal propulsion technology development is underway at NASA and DoE for Space Exploration Initiative (SEI) missions to Mars, with initial near-earth flights to validate flight readiness. Several reactor concepts are being considered for these missions, and important selection criteria will be evaluated before final selection of a system. These criteria include: safety and reliability, technical risk, cost, and performance, in that order. Of the concepts evaluated to date, the Nuclear Engine for Rocket Vehicle Applications (NERVA) derivative (NDR) is the only concept that has demonstrated full power, life, and performance in actual reactor tests. Other concepts will require significant design work and must demonstrate proof-of-concept. Technical risk, and hence, development cost should therefore be lowest for the concept, and the NDR concept is currently being considered for the initial SEI missions. As lighter weight, higher performance systems are developed and validated, including appropriate safety and astronaut-rating requirements, they will be considered to support future SEI application. A space transportation system using a modular nuclear thermal rocket (NTR) system for lunar and Mars missions is expected to result in significant life cycle cost savings. Finally, several key issues remain for NTR's, including public acceptance and operational issues. Nonetheless, NTR's are believed to be the 'next generation' of space propulsion systems - the key to space exploration.

Clark, John S.↗
NASA NTRS1993

Prospects for utilization of air liquefaction and enrichment system (ALES) propulsion in fully reusable launch vehicles

A concept is shown for a fully reusable, earth to orbit launch vehicle with horizontal takeoff and landing, employing an air-turborocket for low speed and a rocket for high speed acceleration, both using LH2 fuel. The turborocket employs a modified liquid air cycle to supply the oxidizer. The rocket uses 90 percent pure LOX that is collected from the atmosphere, separated, and stored during operation of the turborocket from about Mach 2 to Mach 5 or 6. The takeoff weight and the thrust required at takeoff are markedly reduced by collecting the rocket oxidizer in-flight. The paper shows an approach and the corresponding technology needs for using ALES propulsion in a SSTO vehicle. Reducing the trajectory altitude at the end of collection reduces the wing area and increases payload. The use of state-of-the-art materials, such as graphite polyimide, is critical to meet the structure weight objective for SSTO. Configurations that utilize 'waverider' aerodynamics show great promise to reduce the vehicle weight.

Bond, W. H.↗
NASA NTRS1987

Low Thrust Space Propulsion

An overview of low rocket engine propulsion concepts for space missions is presented. Chemical and electrical rocket engines are shown. Animation illustrates propulsion applications.

Source record↗
NASA NTRS1990

Low Thrust Propulsion

This video presents an overview of low thrust rocket engine propulsion concepts for space missions. Chemical and electrical rocket engines are shown. Animation illustrates various propulsion applications.

Source record↗
NASA NTRS1995

Progress in incompressible Navier-Stokes computations for propulsion flows and its dual-use applications

Development of an incompressible Navier-Stokes solution procedure was performed for the analysis of a liquid rocket engine pump components and for the mechanical heart assist devices. The solution procedure for the propulsion systems is applicable to incompressible Navier-Stokes flows in a steadily rotating frame of reference for any general complex configurations. The computer codes were tested on different complex configurations such as liquid rocket engine inducer and impellers. As a spin-off technology from the turbopump component simulations, the flow analysis for an axial heart pump was conducted. The baseline Left Ventricular Assist Device (LVAD) design was improved by adding an inducer geometry by adapting from the liquid rocket engine pump. The time-accurate mode of the incompressible Navier-Stokes code was validated with flapping foil experiment by using different domain decomposition methods. In the flapping foil experiment, two upstream NACA 0025 foils perform high-frequency synchronized motion and generate unsteady flow conditions for a downstream larger stationary foil. Fairly good agreement was obtained between unsteady experimental data and numerical results from two different moving boundary procedures. Incompressible Navier-Stokes code (INS3D) has been extended for heat transfer applications. The temperature equation was written for both forced and natural convection phenomena. Flow in a square duct case was used for the validation of the code in both natural and forced convection.

Kiris, Cetin↗