Experimental Auxiliary Rocket Engine, Part I Final Report
Design and development of rocket engine for spacecraft reaction control and maneuvering systems
REACTION CONTROL↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Effect of aerodynamic and angle-of-attack uncertainties on the May 1979 entry flight control system of the Space Shuttle from Mach 8 to 1.5
A six degree of freedom simulation analysis was performed for the space shuttle orbiter during entry from Mach 8 to Mach 1.5 with realistic off nominal conditions by using the flight control systems defined by the shuttle contractor. The off nominal conditions included aerodynamic uncertainties in extrapolating from wind tunnel derived characteristics to full scale flight characteristics, uncertainties in the estimates of the reaction control system interaction with the orbiter aerodynamics, an error in deriving the angle of attack from onboard instrumentation, the failure of two of the four reaction control system thrusters on each side, and a lateral center of gravity offset coupled with vehicle and flow asymmetries. With combinations of these off nominal conditions, the flight control system performed satisfactorily. At low hypersonic speeds, a few cases exhibited unacceptable performances when errors in deriving the angle of attack from the onboard instrumentation were modeled. The orbiter was unable to maintain lateral trim for some cases between Mach 5 and Mach 2 and exhibited limit cycle tendencies or residual roll oscillations between Mach 3 and Mach 1. Piloting techniques and changes in some gains and switching times in the flight control system are suggested to help alleviate these problems.
Stone, H. W.↗
Cassini Orbit Trim Maneuvers at Saturn - Overview of Attitude Control Flight Operations
The Cassini spacecraft has been in orbit around Saturn since July 1, 2004. To remain on the planned trajectory which maximizes science data return, Cassini must perform orbit trim maneuvers using either its main engine or its reaction control system thrusters. Over 200 maneuvers have been executed on the spacecraft since arrival at Saturn. To improve performance and maintain spacecraft health, changes have been made in maneuver design command placement, in accelerometer scale factor, and in the pre-aim vector used to align the engine gimbal actuator prior to main engine burn ignition. These and other changes have improved maneuver performance execution errors significantly since 2004. A strategy has been developed to decide whether a main engine maneuver should be performed, or whether the maneuver can be executed using the reaction control system.
spacecraft configuration↗
Comparison of thruster configurations in attitude control systems
Several aspects concerning reaction control jet systems as used to govern the attitude of a spacecraft were considered. A thruster configuration currently in use was compared to several new configurations developed in this study. The method of determining the error signals which control the firing of the thrusters was also investigated. The current error determination procedure is explained and a new method is presented. Both of these procedures are applied to each of the thruster configurations which are developed and comparisons of the two methods are made.
Boland, J. S., III↗
STS-78 Flight Day 17
On this seventeenth day of the STS-78 mission, the flight crew, Cmdr. Terence T. Henricks, Pilot Kevin R. Kregel, Payload Cmdr. Susan J. Helms, Mission Specialists Richard M. Linnehan, Charles E. Brady, Jr., and Payload Specialists Jean-Jacques Favier, Ph.D. and Robert B. Thirsk, M.D., are shown conducting routine firings of the orbiter's reaction control system jets and checking out its flight control systems and aero surfaces in anticipation of the planned landing at the Kennedy Space Center. Commander Tom Henricks and Pilot Kevin Kregel successfully fire Columbia's 44 reaction control system jets and then test the aero surfaces that will be used during Columbia's high speed re-entry. This firings procedure is part of a test to prove a concept that may be used on Space Shuttle Discovery's next mission -- STS-82 -- to service the Hubble Space Telescope. The vernier jet firings should raise the orbit without disturbing any payloads on board, or in the case of the Hubble Space Telescope, without placing any force on the telescope's fragile solar arrays.
Source record↗
In-Space Chemical Propulsion Systems Roadmap
In-space propulsion begins where the launch vehicle upper stage leaves off, performing the functions of primary propulsion, reaction control, station keeping, precision pointing, and orbital maneuvering. The main engines used in space provide the primary propulsive force for orbit transfer, planetary trajectories and extra planetary landing and ascent. The reaction control and orbital maneuvering systems provide the propulsive force for orbit maintenance, position control, station keeping, and spacecraft attitude control. Advanced in-space propulsion technologies will enable much more effective exploration of our Solar System and will permit mission designers to plan missions to "fly anytime, anywhere, and complete a host of science objectives at the destinations" with greater reliability and safety. With wide range of possible missions and candidate propulsion technologies, the question of which technologies are "best" for future missions is a difficult one. A portfolio of propulsion technologies should be developed to provide optimum solutions for a diverse set of missions and destinations. A large fraction of the rocket engines in use today are chemical rockets; that is, they obtain the energy needed to generate thrust by chemical reactions to create a hot gas that is expanded to produce thrust. A significant limitation of chemical propulsion is that it has a relatively low specific impulse (Is, or thrust per mass flow rate of propellant). A significant improvement (>30%) in Is can be obtained by using cryogenic propellants, such as liquid oxygen and liquid hydrogen, for example. Historically, these propellants have not been applied beyond upper stages.
Oxidizers↗
STOL capability impact on advanced tactical aircraft design
The design and technical issues affecting supersonic STOL development as an airbase attack fighter are discussed. An Air Force study has indicated that, from a weight and cost standpoint, the preferred directions will include two-dimensional nozzles with vectoring and thrust reversing capability. Take-off and landing requirements would determine other design features, and the use of a jump strut to enable landing maneuvers to be made at pitch angles which would normally drag the tail is detailed. The addition of a tip-mounted reaction control system is foreseen as necessary for roll control at the low aerodynamic speeds of STOL landing. A severe 700 ft landing distance design is outlined, and includes a lifting engine with bleed-air features to feed the reaction control system.
Krepski, R. E.↗
Attitude control study for a large flexible spacecraft using a Solar Electric Propulsion System (SEPS)
The attitude control performance of the solar electric propulsion system (SEPS) was evaluated. A thrust vector control system for powered flight control was examined along with a gas jet reaction control system, and a reaction wheel system, both of which have been proposed for nonpowered flight control. Comprehensive computer simulations of each control system were made and evaluated using a 30 mode spacecraft model. Results obtained indicate that thrust vector control and reaction wheel systems offer acceptable smooth proportional control. The gas jet control system is shown to be risky for a flexible structure such as SEPS, and is therefore, not recommended as a primary control method.
Tolivar, A. F.↗
Mechanistic Insights into Adsorptive and Catalytic Reactions from Controllable Distributions of Metal Cations (Pd, Pt, Ni, Cr, Cu) as [M‐OH] +1 /1Al or M +2 /2Al in Zeolites
Anchoring divalent metal ions in the same zeolite framework with similar Si/Al ratio selectively as zeolite-bound M +2 or [M +2 -OH] +1 cationic species enables critical comparison of the species’ intrinsic reactivity for industrially and fundamentally relevant reactions. H-BEA zeolites with similar Si/Al ratios but differing framework Al siting were used to anchored multiple divalent metal cations (Ni, Pd, Pt, Cr, Cu) in the zeolite micropores. State-of-the-art infrared (IR) spectroscopy, electron paramagnetic resonance (EPR) measurements, including two-dimensional pulsed HYSCORE EPR, extended X-ray absorption fine structure (EXAFS), and density functional theory (DFT) calculations together provide unambiguous evidence for the selective formation of divalent metal cations as M +2 /2Al species (for H-BEA prepared in the conventional hydroxide media), and [M +2 OH] +1 /1Al species for H-BEA prepared in HF. Solid-state proton-decoupled triple-quantum magic-angle spinning (3Q MAS) NMR measurements confirmed contrasting Al distributions in the two H-BEA zeolites, which led to a contrasting divalent cation speciation. The reactivities of the two cationic species were explored for catalytic and adsorptive applications in both organometallic homogeneous and heterogeneous catalysis. This work demonstrates their divergent reactivity in ethylene dimerization, ethylene oxidation (Wacker process), selective catalytic reduction (SCR) of NO, NO adsorption, and methane oxidation. Both M +2 /2Al and [M +2 OH] +1 /1Al cations are both active for ethylene dimerization, but [M +2 OH] +1 /1Al species show higher reaction rates for each Pd, Ni, Pt. [M +2 OH] +1 /1Al is active for acetaldehyde formation in Wacker ethylene oxidation. A new active site for ethylene oligomerization is proposed that possesses a terminal OH group (Cr-OH) in Phillips catalysts evident by a nearly inactive isolated Cr +2 /2Al species that contrast an active Cr─OH motif.
Divalent metal cations in a zeolite↗
Spatiotemporal Reaction Dynamics Control in Two‐Photon Polymerization for Enhancing Writing Characteristics
Since 2001, 3D microfabrication based on two‐photon polymerization (TPP) has drawn extensive attention and interest in biology, optics, photonics, material science, and high‐energy physics. The in‐volume fabrication capability due to the threshold behavior of two‐photon absorption enables TPP higher flexibility compared with other nanofabrication techniques. However, as determined by the in‐volume fabrication feature as well as various reaction dynamics, the writing characteristics of TPP, such as throughput, accuracy, surface quality, and fabrication capability, are still limited. Herein, a comprehensive study is performed on the spatiotemporal behavior of reaction dynamics during TPP fabrication, mainly focusing on spatiotemporal characteristics of radical diffusion, photothermal effect, microscale mechanics, and voxel stacking process. Based on the study, a nonsequential fabrication method is established to simultaneously improve key writing characteristics of TPP and realize sharp features, high speeds, large overhang structure, and smooth surfaces. The method established in this work can be applied to improve the performance of functional devices for various fields.
36 MATERIALS SCIENCE↗
Combustion performance and heat transfer characterization of LOX/hydrocarbon type propellants, volume 1
A program to evaluate liquid oxygen and various hydrocarbon fuel as low cost alternative propellants suitable for future space transportation system applications is discussed. The emphasis of the program is directed toward low earth orbit maneuvering engine and reaction control engine systems. The feasibility of regeneratively cooling an orbit maneuvering thruster was analytically determined over a range of operating conditions from 100 to 1000 psia chamber pressure and 1000 to 10,000-1bF thrust, and specific design points were analyzed in detail for propane, methane, RP-1, ammonia, and ethanol; similar design point studies were performed for a filmcooled reaction control thruster. Heat transfer characteristics of propate were experimentally evaluated in heated tube tests. Forced convection heat transfer coefficients were determined over the range of fluid conditions encompassed by 450 to 1800 psia, -250 to +250 F, and 50 to 150 ft/sec, with wall temperatures from ambient to 1200 F. Seventy-seven hot firing tests were conducted with LOX/propane and LOC/ethanol, for a total duration of nearly 1400 seconds, using both heat sink and water-cooled calorimetric chambers.
Michel, R. W.↗
Aerothermodynamic Environments Definition for the Mars Science Laboratory Entry Capsule
An overview of the aerothermodynamic environments definition status is presented for the Mars Science Laboratory entry vehicle. The environments are based on Navier-Stokes flowfield simulations on a candidate aeroshell geometry and worst-case entry heating trajectories. Uncertainties for the flowfield predictions are based primarily on available ground data since Mars flight data are scarce. The forebody aerothermodynamics analysis focuses on boundary layer transition and turbulent heating augmentation. Turbulent transition is expected prior to peak heating, a first for Mars entry, resulting in augmented heat flux and shear stress at the same heatshield location. Afterbody computations are also shown with and without interference effects of reaction control system thruster plumes. Including uncertainties, analysis predicts that the heatshield may experience peaks of 225 W/sq cm for turbulent heat flux, 0.32 atm for stagnation pressure, and 400 Pa for turbulent shear stress. The afterbody heat flux without thruster plume interference is predicted to be 7 W/sq cm on the backshell and 10 W/sq cm on the parachute cover. If the reaction control jets are fired near peak dynamic pressure, the heat flux at localized areas could reach as high as 76 W/sq cm on the backshell and 38 W/sq cm on the parachute cover, including uncertainties. The final flight environments used for hardware design will be updated for any changes in the aeroshell configuration, heating design trajectories, or uncertainties.
Edquist, Karl T.↗
Combustion performance and heat transfer characterization of LOX/hydrocarbon type propellants
An evaluation liquid oxygen (LOX) and various hydrocarbon fuels as low cost alternative propellants suitable for future space transportation system applications was done. The emphasis was directed toward low earth orbit maneuvering engine and reaction control engine systems. The feasibility of regeneratively cooling an orbit maneuvering thruster was analytically determined over a range of operating conditions from 100 to 1000 psia chamber pressure and 1000 to 10,000-1bF thrust, and specific design points were analyzed in detail for propane, methane, RP-1, ammonia, and ethanol; similar design point studies were performed for a film-cooled reaction control thruster. Heat transfer characteristics of propane were experimentally evaluated in heated tube tests. Forced convection heat transfer coefficients were determined. Seventy-seven hot firing tests were conducted with LOX/propane and LOX/ethanol, for a total duration of nearly 1400 seconds, using both heat sink and water-cooled calorimetric chambers. Combustion performance and stability and gas-side heat transfer characteristics were evaluated.
Michel, R. W.↗
Propulsion Risk Reduction Activities for Nontoxic Cryogenic Propulsion
The Propulsion and Cryogenics Advanced Development (PCAD) Project s primary objective is to develop propulsion system technologies for nontoxic or "green" propellants. The PCAD project focuses on the development of nontoxic propulsion technologies needed to provide necessary data and relevant experience to support informed decisions on implementation of nontoxic propellants for space missions. Implementation of nontoxic propellants in high performance propulsion systems offers NASA an opportunity to consider other options than current hypergolic propellants. The PCAD Project is emphasizing technology efforts in reaction control system (RCS) thruster designs, ascent main engines (AME), and descent main engines (DME). PCAD has a series of tasks and contracts to conduct risk reduction and/or retirement activities to demonstrate that nontoxic cryogenic propellants can be a feasible option for space missions. Work has focused on 1) reducing the risk of liquid oxygen/liquid methane ignition, demonstrating the key enabling technologies, and validating performance levels for reaction control engines for use on descent and ascent stages; 2) demonstrating the key enabling technologies and validating performance levels for liquid oxygen/liquid methane ascent engines; and 3) demonstrating the key enabling technologies and validating performance levels for deep throttling liquid oxygen/liquid hydrogen descent engines. The progress of these risk reduction and/or retirement activities will be presented.
Smith, Timothy D.↗
Propulsion Risk Reduction Activities for Non-Toxic Cryogenic Propulsion
The Propulsion and Cryogenics Advanced Development (PCAD) Project s primary objective is to develop propulsion system technologies for non-toxic or "green" propellants. The PCAD project focuses on the development of non-toxic propulsion technologies needed to provide necessary data and relevant experience to support informed decisions on implementation of non-toxic propellants for space missions. Implementation of non-toxic propellants in high performance propulsion systems offers NASA an opportunity to consider other options than current hypergolic propellants. The PCAD Project is emphasizing technology efforts in reaction control system (RCS) thruster designs, ascent main engines (AME), and descent main engines (DME). PCAD has a series of tasks and contracts to conduct risk reduction and/or retirement activities to demonstrate that non-toxic cryogenic propellants can be a feasible option for space missions. Work has focused on 1) reducing the risk of liquid oxygen/liquid methane ignition, demonstrating the key enabling technologies, and validating performance levels for reaction control engines for use on descent and ascent stages; 2) demonstrating the key enabling technologies and validating performance levels for liquid oxygen/liquid methane ascent engines; and 3) demonstrating the key enabling technologies and validating performance levels for deep throttling liquid oxygen/liquid hydrogen descent engines. The progress of these risk reduction and/or retirement activities will be presented.
Smith, Timothy D.↗
Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions
A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.
Morehead, Robert L.↗
Feasibility and Utility of a Cryogenic Integrated RCS
Traditional in-space propulsion systems use storable propellants, such as MMH/NTO, for applications beyond Low Earth Orbit (LEO). Modern advancements in Cryogenic Fluid Management (CFM) technologies opens the door for use of more efficient cryogenic propellants, such as LOX/LCH4 or LOX/LH2, in these long-duration missions beyond LEO. As these Main Propulsion Systems (MPS) transition to cryogenic propellants, a cryogenic solution for Reaction Control Systems (RCS) becomes attractive for several reasons. A mixed-fluid vehicle solution with cryogenic (cool) MPS and storable (warm) RCS complicates thermal management. Additionally, a vehicle with common cryogenic propellant across the MPS and RCS could take advantage of shared hardware such as tanks, thermal management equipment, and pressurization system, reducing mass and development time. The fluid system design proposed in this presentation features shared hardware, leading to the designation of Cryogenic Integrated Reaction Control System (iRCS). The iRCS design stores cryogenic propellant in the low-pressure (10’s psia) MPS tanks, creates steady high-pressure (100’s psia) flow through an electric pump (e-pump), feeds pulse-firing RCS thrusters, and returns any excess flow to the tank through a pressure control device on a recirculation line. This iRCS design is inspired by the automotive fuel-rail, where similar elevated-pressure and pulse-firing requirements are levied. This design has several inherent advantages. Because this design is pump-fed rather than pressure-fed, heavy, high-pressure propellant storage is not required. The RCS propellant can therefore be stored by increasing MPS tank volume. Furthermore, by increasing the pressure of the circulated fluid through an e-pump, the propellant quality moves further into the sub-cooled regime. Sub-cooled liquid is desirable for accurate pressure and flow control at the thruster inlet. Lastly, the iRCS allows the distribution system hardware to maintain cryogenic temperatures by slowly recirculating liquid in a low-energy “Idle Mode”. Altogether, the iRCS concept enables a more efficient cryogenic vehicle design.
Integrated↗
A study of the durability of beryllium rocket engines
An experimental test program was performed to demonstrate the durability of a beryllium INTEREGEN rocket engine when operating under conditions simulating the space shuttle reaction control system. A vibration simulator was exposed to the equivalent of 100 missions of X, Y, and Z axes random vibration to demonstrate the integrity of the recently developed injector-to-chamber braze joint. An off-limits engine was hot fired under extreme conditions of mixture ratio, chamber pressure, and orifice plugging. A durability engine was exposed to six environmental cycles interspersed with hot-fire tests without intermediate cleaning, service, or maintenance. Results from this program indicate the ability of the beryllium INTEREGEN engine concept to meet the operational requirements of the space shuttle reaction control system.
Paster, R. D.↗