Propulsion — Page 60 | Engineering Papers

NASA NTRS2010

CECE: Expanding the Envelope of Deep Throttling Technology in Liquid Oxygen/Liquid Hydrogen Rocket Engines for NASA Exploration Missions

As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in high-energy, cryogenic, in-space propulsion. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Four series of demonstrator engine tests have been successfully completed between April 2006 and April 2010, accumulating 7,436 seconds of hot fire time over 47 separate tests. While the first two test series explored low power combustion (chug) and system instabilities, the third test series investigated and was ultimately successful in demonstrating several mitigating technologies for these instabilities and achieved a stable throttling ratio of 13:1. The fourth test series significantly expanded the engine s operability envelope by successfully demonstrating a closed-loop control system and extensive transient modeling to enable lower power engine starting, faster throttle ramp rates, and mission-specific ignition testing. The final hot fire test demonstrated a chug-free, minimum power level of 5.9%, corresponding to an overall 17.6:1 throttling ratio achieved. In total, these tests have provided an early technology demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future lander descent main engines.

Giuliano, Victor J.↗

NASA NTRS2010

CECE: Expanding the Envelope of Deep Throttling in Liquid Oxygen/Liquid Hydrogen Rocket Engines For NASA Exploration Missions

As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop technology and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy cryogenic engine. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Three series of demonstrator engine tests, the first in April-May 2006, the second in March-April 2007 and the third in November-December 2008, have demonstrated up to 13:1 throttling (104% to 8% thrust range) of the hydrogen/oxygen expander cycle engine. The first two test series explored a propellant feed system instability ("chug") environment at low throttled power levels. Lessons learned from these two tests were successfully applied to the third test series, resulting in stable operation throughout the 13:1 throttling range. The first three tests have provided an early demonstration of an enabling cryogenic propulsion concept, accumulating over 5,000 seconds of hot fire time over 27 hot fire tests, and have provided invaluable system-level technology data toward design and development risk mitigation for the NASA Altair and future lander propulsion system applications. This paper describes the results obtained from the highly successful third test series as well as the test objectives and early results obtained from a fourth test series conducted over March-May 2010

Giuliano, Victor J.↗

NASA NTRS2003

Investigation of a Light Gas Helicon Plasma Source for the VASIMR Space Propulsion System

An efficient plasma source producing a high-density (approx.10(exp 19/cu m) light gas (e.g. H, D, or He) flowing plasma with a high degree of ionization is a critical component of the Variable Specific Impulse Magnetoplasma Rocket (VASIMR) concept. We are developing an antenna to apply ICRF power near the fundamental ion cyclotron resonance to further accelerate the plasma ions to velocities appropriate for space propulsion applications. The high degree of ionization and a low vacuum background pressure are important to eliminate the problem of radial losses due to charge exchange. We have performed parametric (e.g. gas flow, power (0.5 - 3 kW), magnetic field , frequency (25 and 50 MHz)) studies of a helicon operating with gas (H2 D2, He, N2 and Ar) injected at one end with a high magnetic mirror downstream of the antenna. We have explored operation with a cusp and a mirror field upstream. Plasma flows into a low background vacuum (<10(exp -4) torr) at velocities higher than the ion sound speed. High densities (approx. 10(exp 19/cu m) have been achieved at the location where ICRF will be applied, just downstream of the magnetic mirror.

Squire, J. P.↗

NASA NTRS2003

A Collimated Retarding Potential Analyzer for the Study of Magnetoplasma Rocket Plumes

A gridded retarding potential analyzer (RPA) has been developed to characterize the magnetized plasma exhaust of the 10 kW Variable Specific Impulse Magnetoplasma Rocket (VX-10) experiment at NASA's Advanced Space Propulsion Laboratory. In this system, plasma is energized through coupling of radio frequency waves at the ion cyclotron resonance (ICR). The particles are subsequently accelerated in a magnetic nozzle to provide thrust. Downstream of the nozzle, the RPA's mounting assembly enables the detector to make complete axial and radial scans of the plasma. A multichannel collimator can be inserted into the RPA to remove ions with pitch angles greater than approximately 1 deg. A calculation of the general collimator transmission as a function over velocity space is presented, which shows the instrument's sensitivity in detecting changes in both the parallel and perpendicular components of the ion energy. Data from initial VX-10 ICRH experiments show evidence of ion heating.

Glover, T. W.↗

NASA NTRS2011

Space Shuttle Propulsion Materials, Manufacturing, and Operational Challenges

Presentations in this session include: (1) External Tank (ET) Materials, Manufacturing, and Operational Challenges; (2) Space Shuttle Main Engine (SSME) Materials, Manufacturing, and Operational Challenges,(3) Reusable Solid Rocket Motor (RSRM) Materials, Manufacturing, and Operational Challenges and (4) Solid Rocket Booster (SRB) Materials, Manufacturing, and Operational Challenges.

Owen, James↗

NASA NTRS2011

Space Shuttle Propulsion System Reliability

This session includes the following sessions: (1) External Tank (ET) System Reliability and Lessons, (2) Space Shuttle Main Engine (SSME), Reliability Validated by a Million Seconds of Testing, (3) Reusable Solid Rocket Motor (RSRM) Reliability via Process Control, and (4) Solid Rocket Booster (SRB) Reliability via Acceptance and Testing.

Welzyn, Ken↗

NASA NTRS2003

Software Estimates Costs of Testing Rocket Engines

Simulation-Based Cost Model (SiCM), a discrete event simulation developed in Extend , simulates pertinent aspects of the testing of rocket propulsion test articles for the purpose of estimating the costs of such testing during time intervals specified by its users. A user enters input data for control of simulations; information on the nature of, and activity in, a given testing project; and information on resources. Simulation objects are created on the basis of this input. Costs of the engineering-design, construction, and testing phases of a given project are estimated from numbers and labor rates of engineers and technicians employed in each phase, the duration of each phase; costs of materials used in each phase; and, for the testing phase, the rate of maintenance of the testing facility. The three main outputs of SiCM are (1) a curve, updated at each iteration of the simulation, that shows overall expenditures vs. time during the interval specified by the user; (2) a histogram of the total costs from all iterations of the simulation; and (3) table displaying means and variances of cumulative costs for each phase from all iterations. Other outputs include spending curves for each phase.

Smith, C. L.↗

NASA NTRS2011

Solid Propulsion Systems, Subsystems, and Components Service Life Extension

The service life extension of solid propulsion systems, subsystems, and components will be discussed based on the service life extension of the Space Transportation System Reusable Solid Rocket Motor (RSRM) and Booster Separation Motors (BSM). The RSRM is certified for an age life of five years. In the aftermath of the Columbia accident there were a number of motors that were approaching the end of their five year service life certification. The RSRM Project initiated an assessment to determine if the service life of these motors could be extended. With the advent of the Constellation Program, a flight test was proposed that would utilize one of the RSRMs which had been returned from the launch site due to the expiration of its five year service life certification and twelve surplus Chemical Systems Division BSMs which had exceeded their eight year service life. The RSRM age life tracking philosophy which establishes when the clock starts for age life tracking will be described. The role of the following activities in service life extension will be discussed: subscale testing, accelerated aging, dissecting full scale aged hardware, static testing full scale aged motors, data mining industry data, and using the fleet leader approach. The service life certification and extension of the BSMs will also be presented.

Hundley, Nedra H.↗

NASA NTRS2012

Nuclear Cryogenic Propulsion Stage Fuel Design and Fabrication

Nuclear Cryogenic Propulsion Stage (NCPS) is a game changing technology for space exploration. Goal of assessing the affordability and viability of an NCPS includes thses overall tasks: (1) Pre-conceptual design of the NCPS and architecture integration (2) NCPS Fuel Design and Testing (3) Nuclear Thermal Rocket Element Environmental Simulator (NTREES) (4) Affordable NCPS Development and Qualification Strategy (5) Second Generation NCPS Concepts. There is a critical need for fuels development. Fuel task objectives are to demonstrate capabilities and critical technologies using full scale element fabrication and testing.

Hickman, Robert↗

NASA NTRS2012

Nuclear Cryogenic Propulsion Stage Fuel Design and Fabrication

Nuclear Cryogenic Propulsion Stage (NCPS) is a game changing technology for space exploration. Goal of assessing the affordability and viability of an NCPS includes these overall tasks: (1) Pre-conceptual design of the NCPS and architecture integration (2) NCPS Fuel Design and Testing (3) Nuclear Thermal Rocket Element Environmental Simulator (NTREES) (4) Affordable NCPS Development and Qualification Strategy (5) Second Generation NCPS Concepts. There is a critical need for fuels development. Fuel task objectives are to demonstrate capabilities and critical technologies using full scale element fabrication and testing.

Hickman, Robert↗

NASA NTRS2012

Technology Area Roadmap for In-Space Propulsion Technologies

The exponential increase of launch system size.and cost.with delta-V makes missions that require large total impulse cost prohibitive. Led by NASA fs Marshall Space Flight Center, a team from government, industry, and academia has developed a flight demonstration mission concept of an integrated electrodynamic (ED) tethered satellite system called PROPEL: \Propulsion using Electrodynamics.. The PROPEL Mission is focused on demonstrating a versatile configuration of an ED tether to overcome the limitations of the rocket equation, enable new classes of missions currently unaffordable or infeasible, and significantly advance the Technology Readiness Level (TRL) to an operational level. We are also focused on establishing a far deeper understanding of critical processes and technologies to be able to scale and improve tether systems in the future. Here, we provide an overview of the proposed PROPEL mission. One of the critical processes for efficient ED tether operation is the ability to inject current to and collect current from the ionosphere. Because the PROPEL mission is planned to have both boost and deboost capability using a single tether, the tether current must be capable of flowing in both directions and at levels well over 1 A. Given the greater mobility of electrons over that of ions, this generally requires that both ends of the ED tether system can both collect and emit electrons. For example, hollow cathode plasma contactors (HCPCs) generally are viewed as state-of-the-art and high TRL devices; however, for ED tether applications important questions remain of how efficiently they can operate as both electron collectors and emitters. Other technologies will be highlighted that are being investigated as possible alternatives to the HCPC such as Solex that generates a plasma cloud from a solid material (Teflon) and electron emission (only) technologies such as cold-cathode electron field emission or photo-electron beam generation (PEBG) techniques

Johnson, Les↗

NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗

NASA NTRS2013

Integrated Design and Engineering Analysis (IDEA) Environment - Propulsion Related Module Development and Vehicle Integration

This report documents the work performed during the period from May 2011 - October 2012 on the Integrated Design and Engineering Analysis (IDEA) environment. IDEA is a collaborative environment based on an object-oriented, multidisciplinary, distributed framework using the Adaptive Modeling Language (AML). This report will focus on describing the work done in the areas of: (1) Integrating propulsion data (turbines, rockets, and scramjets) in the system, and using the data to perform trajectory analysis; (2) Developing a parametric packaging strategy for a hypersonic air breathing vehicles allowing for tank resizing when multiple fuels and/or oxidizer are part of the configuration; and (3) Vehicle scaling and closure strategies.

Kamhawi, Hilmi N.↗

NASA NTRS2014

Development of Modeling Approaches for Nuclear Thermal Propulsion Test Facilities

High efficiency of rocket propul-sion systems is essential for humanity to venture be-yond the moon. Nuclear Thermal Propulsion (NTP) is a promising alternative to conventional chemical rock-ets with relatively high thrust and twice the efficiency of the Space Shuttle Main Engine. NASA is in the pro-cess of developing a new NTP engine, and is evaluat-ing ground test facility concepts that allow for the thor-ough testing of NTP devices. NTP engine exhaust, hot gaseous hydrogen, is nominally expected to be free of radioactive byproducts from the nuclear reactor; how-ever, it has the potential to be contaminated due to off-nominal engine reactor performance. Several options are being investigated to mitigate this hazard potential with one option in particular that completely contains the engine exhaust during engine test operations. The exhaust products are subsequently disposed of between engine tests. For this concept (see Figure 1), oxygen is injected into the high-temperature hydrogen exhaust that reacts to produce steam, excess oxygen and any trace amounts of radioactive noble gases released by off-nominal NTP engine reactor performance. Water is injected to condense the potentially contaminated steam into water. This water and the gaseous oxygen (GO2) are subsequently passed to a containment area where the water and GO2 are separated into separate containment tanks.

Jones, Daniel R.↗

NASA NTRS2013

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.

Emrich, William↗

NASA NTRS2013

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

NASA NTRS2014

Space Launch System Base Heating Test: Sub-Scale Rocket Engine/Motor Design, Development & Performance Analysis

ATA-002 Technical Team has successfully designed, developed, tested and assessed the SLS Pathfinder propulsion systems for the Main Base Heating Test Program. Major Outcomes of the Pathfinder Test Program: Reach 90% of full-scale chamber pressure Achieved all engine/motor design parameter requirements Reach steady plume flow behavior in less than 35 msec Steady chamber pressure for 60 to 100 msec during engine/motor operation Similar model engine/motor performance to full-scale SLS system Mitigated nozzle throat and combustor thermal erosion Test data shows good agreement with numerical prediction codes Next phase of the ATA-002 Test Program Design & development of the SLS OML for the Main Base Heating Test Tweak BSRM design to optimize performance Tweak CS-REM design to increase robustness MSFC Aerosciences and CUBRC have the capability to develop sub-scale propulsion systems to meet desired performance requirements for short-duration testing.

Mehta, Manish↗