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Propellant management for low thrust chemical propulsion systems

Low-thrust chemical propulsion systems (LTPS) will be required for orbital transfer of large space systems (LSS). The work reported in this paper was conducted to determine the propellant requirements, preferred propellant management technique, and propulsion system sizes for the LTPS. Propellants were liquid oxygen (LO2) combined with liquid hydrogen (LH2), liquid methane or kerosene. Thrust levels of 100, 500, and 1000 lbf were combined with 1, 4, and 8 perigee burns for transfer from low earth orbit to geosynchronous earth orbit. This matrix of systems was evaluated with a multilayer insulation (MLI) or a spray-on-foam insulation. Vehicle sizing results indicate that a toroidal tank configuration is needed for the LO2/LH2 system. Multiple perigee burns and MLI allow far superior LSS payload capability. Propellant settling, combined with a single screen device, was found to be the lightest and least complex propellant management technique.

Hamlyn, K. M.↗

Spacecraft Chemical Propulsion Systems at NASA's Marshall Space Flight Center: Heritage and Capabilities

NASA Marshall Space Flight Center (MSFC) is well known for its contributions to large ascent propulsion systems such as the Saturn V and the Space Shuttle. This paper highlights a lesser known but equally rich side of MSFC - its heritage in spacecraft chemical propulsion systems and its current capabilities for in-space propulsion system development and chemical propulsion research. The historical narrative describes the efforts associated with developing upper-stage main propulsion systems such as the Saturn S-IVB as well as orbital maneuvering and reaction control systems such as the S-IVB auxiliary propulsion system, the Skylab thruster attitude control system, and many more recent activities such as Chandra, the Demonstration of Automated Rendezvous Technology, X-37, the X-38 de-orbit propulsion system, the Interim Control Module, the US Propulsion Module, and several technology development activities. Also discussed are MSFC chemical propulsion research capabilities, along with near- and long-term technology challenges to which MSFC research and system development competencies are relevant.

McRight, Patrick S.↗

INSPACE CHEMICAL PROPULSION SYSTEMS AT NASA's MARSHALL SPACE FLIGHT CENTER: HERITAGE AND CAPABILITIES

NASA s Marshall Space Flight Center (MSFC) is well known for its contributions to large ascent propulsion systems such as the Saturn V rocket and the Space Shuttle external tank, solid rocket boosters, and main engines. This paper highlights a lesser known but very rich side of MSFC-its heritage in the development of in-space chemical propulsion systems and its current capabilities for spacecraft propulsion system development and chemical propulsion research. The historical narrative describes the flight development activities associated with upper stage main propulsion systems such as the Saturn S-IVB as well as orbital maneuvering and reaction control systems such as the S-IVB auxiliary propulsion system, the Skylab thruster attitude control system, and many more recent activities such as Chandra, the Demonstration of Automated Rendezvous Technology (DART), X-37, the X-38 de-orbit propulsion system, the Interim Control Module, the US Propulsion Module, and multiple technology development activities. This paper also highlights MSFC s advanced chemical propulsion research capabilities, including an overview of the center s Propulsion Systems Department and ongoing activities. The authors highlight near-term and long-term technology challenges to which MSFC research and system development competencies are relevant. This paper concludes by assessing the value of the full range of aforementioned activities, strengths, and capabilities in light of NASA s exploration missions.

McRight, P. S.↗

Modeling of Spacecraft Advanced Chemical Propulsion Systems

This paper outlines the development of the Advanced Chemical Propulsion System (ACPS) model for Earth and Space Storable propellants. This model was developed by the System Technology Operation of SAIC-Huntsville for the NASA MSFC In-Space Propulsion Project Office. Each subsystem of the model is described. Selected model results will also be shown to demonstrate the model's ability to evaluate technology changes in chemical propulsion systems.

Benfield, Michael P. J.↗

Modeling of Spacecraft Advanced Chemical Propulsion Systems

This paper outlines the development of the Advanced Chemical Propulsion System (ACPS) model for Earth and Space Storable propellants. This model was developed by the System Technology Operation of SAIC-Huntsville for the NASA MSFC In-Space Propulsion Project Office. Each subsystem of the model is described. Selected model results will also be shown to demonstrate the model's ability to evaluate technology changes in chemical propulsion systems.

Benfield, Michael P. J.↗

Solar Electric and Chemical Propulsion Technology Applications to a Titan Orbiter/Lander Mission

Several advanced propulsion technology options were assessed for a conceptual Titan Orbiter/Lander mission. For convenience of presentation, the mission was broken into two phases: interplanetary and Titan capture. The interplanetary phase of the mission was evaluated for an advanced Solar Electric Propulsion System (SEPS), while the Titan capture phase was evaluated for state-of-art chemical propulsion (NTO/Hydrazine), three advanced chemical propulsion options (LOX/Hydrazine, Fluorine/Hydrazine, high Isp mono-propellant), and advanced tank technologies. Hence, this study was referred to as a SEPS/Chemical based option. The SEPS/Chemical study results were briefly compared to a 2002 NASA study that included two general propulsion options for the same conceptual mission: an all propulsive based mission and a SEPS/Aerocapture based mission. The SEP/Chemical study assumed identical science payload as the 2002 NASA study science payload. The SEPS/Chemical study results indicated that the Titan mission was feasible for a medium launch vehicle, an interplanetary transfer time of approximately 8 years, an advanced SEPS (30 kW), and current chemical engine technology (yet with advanced tanks) for the Titan capture. The 2002 NASA study showed the feasibility of the mission based on a somewhat smaller medium launch vehicle, an interplanetary transfer time of approximately 5.9 years, an advanced SEPS (24 kW), and advanced Aerocapture based propulsion technology for the Titan capture. Further comparisons and study results were presented for the advanced chemical and advanced tank technologies.

Cupples, Michael↗

A Combined Solar Electric and Storable Chemical Propulsion Vehicle for Piloted Mars Missions

The Mars Design Reference Architecture (DRA) 5.0 explored a piloted Mars mission in the 2030 timeframe, focusing on architecture and technology choices. The DRA 5.0 focused on nuclear thermal and cryogenic chemical propulsion system options for the mission. Follow-on work explored both nuclear and solar electric options. One enticing option that was found in a NASA Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) design study used a combination of a 1-MW-class solar electric propulsion (SEP) system combined with storable chemical systems derived from the planned Orion crew vehicle. It was found that by using each propulsion system at the appropriate phase of the mission, the entire SEP stage and habitat could be placed into orbit with just two planned Space Launch System (SLS) heavy lift launch vehicles assuming the crew would meet up at the Earth-Moon (E-M) L2 point on a separate heavy-lift launch. These appropriate phases use high-thrust chemical propulsion only in gravity wells when the vehicle is piloted and solar electric propulsion for every other phase. Thus the SEP system performs the spiral of the unmanned vehicle from low Earth orbit (LEO) to E-M L2 where the vehicle meets up with the multi-purpose crew vehicle. From here SEP is used to place the vehicle on a trajectory to Mars. With SEP providing a large portion of the required capture and departure changes in velocity (delta V) at Mars, the delta V provided by the chemical propulsion is reduced by a factor of five from what would be needed with chemical propulsion alone at Mars. This trajectory also allows the SEP and habitat vehicle to arrive in the highly elliptic 1-sol parking orbit compatible with envisioned Mars landing concepts. This paper explores mission options using between SEP and chemical propulsion, the design of the SEP system including the solar array and electric propulsion systems, and packaging in the SLS shroud. Design trades of stay time, power level, specific impulse and propellant type are discussed.

Mercer, Carolyn R.↗

A Combined Solar Electric and Storable Chemical Propulsion Vehicle for Piloted Mars Missions

The Mars Design Reference Architecture (DRA) 5.0 explored a piloted Mars mission in the 2030 timeframe, focusing on architecture and technology choices. The DRA 5.0 focused on nuclear thermal and cryogenic chemical propulsion system options for the mission. Follow-on work explored both nuclear and solar electric options. One enticing option that was found in a NASA Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) design study used a combination of a 1-MW-class solar electric propulsion (SEP) system combined with storable chemical systems derived from the planned Orion crew vehicle. It was found that by using each propulsion system at the appropriate phase of the mission, the entire SEP stage and habitat could be placed into orbit with just two planned Space Launch System (SLS) heavy lift launch vehicles assuming the crew would meet up at the Earth-Moon (E-M) L2 point on a separate heavy-lift launch. These appropriate phases use high-thrust chemical propulsion only in gravity wells when the vehicle is piloted and solar electric propulsion for every other phase. Thus the SEP system performs the spiral of the unmanned vehicle from low Earth orbit (LEO) to E-M L2 where the vehicle meets up with the multi-purpose crew vehicle. From here SEP is used to place the vehicle on a trajectory to Mars. With SEP providing a large portion of the required capture and departure changes in velocity (delta V) at Mars, the delta V provided by the chemical propulsion is reduced by a factor of five from what would be needed with chemical propulsion alone at Mars. This trajectory also allows the SEP and habitat vehicle to arrive in the highly elliptic 1-sol parking orbit compatible with envisioned Mars landing concepts. This paper explores mission options using between SEP and chemical propulsion, the design of the SEP system including the solar array and electric propulsion systems, and packaging in the SLS shroud. Design trades of stay time, power level, specific impulse and propellant type are discussed.

Mercer, Carolyn R.↗

Combining Solar Electric and Chemical Propulsion for Crewed Missions to Mars

This paper documents the results of an investigation of human Mars mission architectures that leverage near-term technology investments and infrastructures resulting from the planned Asteroid Redirect Mission, including high-power Solar Electric Propulsion (SEP) and a human presence in Lunar Distant Retrograde Orbit (LDRO). The architectures investigated use a combination of SEP and chemical propulsion elements. Through this combination of propulsion technologies, these architectures take advantage of the high efficiency SEP propulsion system to deliver cargo, while maintaining the faster trip times afforded by chemical propulsion for crew transport. Evolved configurations of the Asteroid Redirect Vehicle (ARV) are considered for cargo delivery. Sensitivities to SEP system design parameters, including power level and propellant quantity, are presented. For the crew delivery, liquid oxygen and methane stages were designed using engines common to future human Mars landers. Impacts of various Earth departure orbits, Mars loiter orbits, and Earth return strategies are presented. The use of the Space Launch System for delivery of the various architecture elements was also investigated and launch vehicle manifesting, launch scheduling and mission timelines are also discussed. The study results show that viable Mars architecture can be constructed using LDRO and SEP in order to take advantage of investments made in the ARM mission.

Percy, Tom↗

Advanced Chemical Propulsion

Design, propellant selection, and launch assistance for advanced chemical propulsion system is discussed. Topics discussed include: rocket design, advance fuel and high energy density materials, launch assist, and criteria for fuel selection.

Bai, S. Don↗

Chemical propulsion technology

An overview of NASA's low thrust liquid chemical propulsion program is presented with particular emphasis on thrust system technology in the ten to one thousand pound thrust range. Key technology issues include high performance of cooled low thrust engines; small cryogenic pumps; multiple starts-shutdowns (10) with slow ramps (approximately 10 seconds); thrust variation - 4/1 in flight and 20/1 between flights; long life (100 hours); improved system weight and size; and propellant selection.

Priem, R. J.↗

Manufacturing waste disposal practices of the chemical propulsion industry

The waste production, mitigation and disposal practices of the United States chemical propulsion industry have been investigated, delineated, and comparatively assessed to the U.S. industrial base. Special emphasis has been placed on examination of ozone depleting chemicals (ODC's). The research examines present and anticipated future practices and problems encountered in the manufacture of solid and liquid propulsion systems. Information collected includes current environmental laws and regulations that guide the industry practices, processes in which ODC's are or have been used, quantities of waste produced, funding required to maintain environmentally compliant practices, and preventive efforts.

Goldberg, Benjamin E.↗

On-Board Chemical Propulsion

NASA Lewis Research Center's On-Board Propulsion program (OBP) is developing low-thrust chemical propulsion technologies for both satellite and vehicle reaction control applications. There is a vigorous international competition to develop new, highperformance bipropellant engines. High-leverage bipropellant systems are critical to both commercial competitiveness in the international communications market and to cost-effective mission design in government sectors. To significantly improve bipropellant engine performance, we must increase the thermal margin of the chamber materials. Iridium-coated rhenium (Ir/Re) engines, developed and demonstrated under OBP programs, can operate at temperatures well above the constraints of state-of-practice systems, providing a sufficient margin to maximize performance with the hypergolic propellants used in most satellite propulsion systems.

Schneider, Steven J.↗

A High Power Solar Electric Propulsion - Chemical Mission for Human Exploration of Mars

Recently Solar Electric Propulsion (SEP) as a main propulsion system has been investigated as an option to support manned space missions to near-Earth destinations for the NASA Gateway spacecraft. High efficiency SEP systems are able to reduce the amount of propellant long duration chemical missions require, ultimately reducing the required mass delivered to Low Earth Orbit (LEO) by a launch vehicle. However, for long duration interplanetary Mars missions, using SEP as the sole propulsion source alone may not be feasible due to the long trip times to reach and insert into the destination orbit. By combining an SEP propulsion system with a chemical propulsion system the mission is able to utilize the high-efficiency SEP for sustained vehicle acceleration and deceleration in heliocentric space and the chemical system for orbit insertion maneuvers and trans-earth injection, eliminating the need for long duration spirals. By capturing chemically instead of with low-thrust SEP, Mars stay time increases by nearly 200 days. Additionally, the size the of chemical propulsion system can be significantly reduced from that of a standard Mars mission because the SEP system greatly decreases the Mars arrival and departure hyperbolic excess velocities (V(sub infinity)).

Solar Electric Propulsion↗

A comparison of chemical propulsion, nuclear thermal propulsion, and multimegawatt electric propulsion for Mars missions

Various propulsion systems are considered for a split-mission piloted exploration of Mars in terms of reducing total initial mass in low earth orbit (IMLEO) as well as trip time. Aerobraked nuclear thermal propulsion (NTP), multimegawatt (MMW) nuclear electric propulsion (NEP), and MMW solar electric propulsion (SEP) are discussed and compared to a baseline aerobraked chemical propulsion system. NTP offers low IMLEO, MMW NEP allows both low IMLEO and a short trip time, and both nuclear systems offer better mission characteristics than the chemical system. The MMW SEP is concluded to be less efficient in spite of a lower IMLEO because of the system's higher specific mass and nonconstant power production. It is recommended that MMW NEP and SEP systems be considered for application to Mars cargo missions. The NEP system is concluded to be the most effective propulsion configuration for piloted Mars missions and lunar base missions.

Frisbee, Robert H.↗

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↗

LEO-to-GEO low thrust chemical propulsion

One approach being considered for transporting large space structures from low Earth orbit (LEO) to geosynchronous equatorial orbit (GEO) is the use of low thrust chemical propulsion systems. A variety of chemical rocket engine cycles evaluated for this application for oxygen/hydrogen and oxygen/hydrocarbon propellants (oxygen/methane and oxygen/RF-1) are discussed. These cycles include conventional propellant turbine drives, turboalternator/electric motor pump drive, and fuel cell/electric motor pump drive as well as pressure fed engines. Thrust chamber cooling analysis results are presented for regenerative/radiation and film/radiation cooling.

Shoji, J. M.↗

High Temperature Materials for Chemical Propulsion Applications

Radiation or passively cooled thrust chambers are used for a variety of chemical propulsion functions including apogee insertion, reaction control for launch vehicles, and primary propulsion for planetary spacecraft. The performance of these thrust chambers is limited by the operating temperature of available materials. Improved oxidation resistance and increased operating temperatures can be achieved with the use of thermal barrier coatings such as zirconium oxide (ZrO2) and hafnium oxide (HfO2). However, previous attempts to include these materials showed cracking and spalling of the oxide layer due to poor bonding. Current research at NASA's Marshall Space Flight Center (MSFC) has generated unique, high temperature material options for in-space thruster designs that are capable of up to 2500 C operating temperatures. The research is focused on fabrication technologies to form low cost Iridium,qF_.henium (Ir/Re) components with a ceramic hot wall created as an integral, functionally graded material (FGM). The goal of this effort is to further de?celop proven technologies for embedding a protective ceramic coating within the Ir/Re liner to form a robust functional gradient material. Current work includes the fabrication and testing of subscale samples to evaluate tensile, creep, thermal cyclic/oxidation, and thermophysical material properties. Larger test articles have also being fabricated and hot-fire tested to demonstrate the materials in prototype thrusters at 1O0 lbf thrust levels.

Elam, Sandra↗