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Space Shuttle launch pad rescue plan

The final preparation of the Space Shuttle Orbiter for flight involves the loading of large quantities of hazardous propellants. Additionally, many pyrotechnially operated mechanical joints are armed and ready for flight. The personnel manning at the pad is minimized during these operations to reduce the risk. Upon completion of propellant loading, the flight crew must be boarded onto the vehicle which at this point has tremendous potential energy. Plans have been made to safely and quickly evacuate the crew should some unforeseen contigency occur. Both aided and unaided egress scenarios have been planned. Personnel protective equipment is an important consideration to assure the highest chance for survival. Rapid movement of personnel is enhanced by the use of the slidewire system and specially prepared armored personnel carriers. The end result is a system that provides a reasonable chance of survival should an emergency occur during late countdown at the pad.

Doerr, Donald F.

NASA Team Develops a Test Article to Demonstrate “Zero Boil-Off” Storage of Liquid Hydrogen via Cryocoolers and a Two-Stage Cooling Approach

Funded by NASA’s Technology Demonstration Mission Program and managed by the Cryogenic Fluid Management Portfolio Project, a NASA team is developing a test article to demonstrate the “zero boil-off” storage of liquid hydrogen using active cooling (cryocoolers) and a two-stage cooling approach. The current state of the art for storage of liquid hydrogen on-orbit is on the order of hours while future missions may require storage for months or even years. To enable such extended storage durations, “near zero” propellant loss, or “zero boil-off”, must be achieved. This may be accomplished with the implementation of “near zero” leakage components, a high performing suite of passive technologies to minimize the environmental heat loads, and active cooling via cryocoolers to intercept and remove heat from the propellant tanks and associated structure. Of course, with any cryogenic vehicle and mission, a mass and power trade should be conducted to determine if it is indeed feasible to carry the additional dry mass associated with active cooling, or if one could simply carry additional propellants to accommodate propellant loss which is typically not an option for a long duration mission.

Hydrogen Storage

Development and Testing of a Green-Propellant Micro-Hybrid Thruster with Electrostatic Ignition

As early as 1937 German scientists at Peenemunde experimented with highly unstable fuel blends of nitrous oxide (N2O) and ethanol. These early tests mostly resulted in explosions and destroyed rocket engines. More recently several companies have developed experimental nitrous oxide fuel blends (NOFB) with Isp exceeding 300 sec. Although NOFBx has recently been cleared for tests on the International Space Station, this propellant remains highly experimental and has not been cleared for commercial transport by the US DOT. Recent work by Karabeyoglu et al. has raised concerns about the safety risks of mixing hydrocarbons with N2O. Liquid oxidizer/fuel blends are highly explosive and require extreme care in transport and servicing. By adding small amounts of a liquid organic fuel such as alcohol or a hydrocarbon, the odds of an explosive decomposition event are significantly increased.iv The proposed solution mitigates the explosion hazards of NOFB by separating the oxidizer from the hydrocarbon fuel formed as of a small cylindrical section of ABS thermoplastic. As N2O vapor flows across the grain segment, current enters a 1000 VDC high-tension lead in the ABS fuel grain and produces an inductive spark that vaporizes a small amount of the material. The ablated fuel vapor plus residual energy from the spark seed a localized exothermic N2O dissociation that produces sufficient heat to initiate combustion. The process is also effective when gaseous oxygen is used. A low TRL (2-3) prototype demonstrating the feasibility of controlled hydrocarbon-seeding was recently tested at Utah State University.v The unit features a miniature 2.5 cm ABS fuel grain fabricated using a Stratasys Dimension 3-D printer. The 9-N thruster was pulse-fired up to 27 consecutive times on a single ABS grain segment. Ignition was achieved by as little as 12-15 Joules energy input. This value is contrasted with the typical 30-minute pre-heat requirement for the ECAPS LMP-103S ADN-based monopropellant, requiring an energy input of 14,850 Joules for catalytic dissociation. The hydrocarbon-seeded micro-hybrid was also adapted as a non-pyrotechnic ignitor for a 900 N (200-lbf) thrust hybrid motor. The motor was successfully ignited 4 consecutive times with no hardware swaps or propellant additions. The amount of ABS seed material that can be fit into the injector cap is the only limit to the number of available repeat firings. This series of tests marks the first time a hybrid motor was ever ignited by other than a solid-propellant pyrotechnic charge or bi-propellant flame ignitor. Nitrous oxide hybrid motors are typically difficult to ignite and usually require multiple solid-propellant charges to initiate combustion, so this nonpyrotechnic ignition is a significant accomplishment. The controlled hydrocarbon-seeding approach is fundamentally different from all other green propellant solutions offered by the aerospace industry. Although the proposed system is more correctly a hybrid technology; the system retains all the simple features of a monopropellant design. To date no optimization study has been performed to identify the best grain geometry for electrostatic ignition. Fortunately, because the grain segments are fabricated using rapid-prototyping technology, changing the grain geometry is as simple as modifying the 3-D printer CAD-file. Vacuum Isp exceeding 270 seconds has been demonstrated (Ref v), a value significantly higher than those offered by competing green monopropellant options. The propellants of choice, N2O/GOX and ABS are 100% non-toxic, non-explosive, and environmentally benign. Because the inert oxidizer and fuel components are mixed only within the combustion chamber, the system retains the inherent safety of a hybrid rocket and can be piggy-backed as a secondary payload with no overall mission risk increase to the primary payload, an excellent characteristic for secondary launch systems.

Whitmore, Stephen A.

SAFER Inspection of Space Shuttle Thermal Protection System

In the aftermath of the space shuttle Columbia accident, it quickly became clear that new methods would need to be developed that would provide the capability to inspect and repair the shuttle's thermal protection system (TPS). A boom extension to the Remote Manipulator System (RMS) with a laser topography sensor package was identified as the primary means for measuring the damage depth in acreage tile as well as scanning Reinforced Carbon- Carbon (RCC) surfaces. However, concern over the system's fault tolerance made it prudent to investigate alternate means of acquiring close range photographs and contour depth measurements in the event of a failure. One method that was identified early was to use the Simplified Aid For EVA Rescue (SAFER) propulsion system to allow EVA access to damaged areas of concern. Several issues were identified as potential hazards to SAFER use for this operation. First, the ability of an astronaut to maintain controlled flight depends upon efficient technique and hardware reliability. If either of these is insufficient during flight operations, a safety tether must be used to rescue the crewmember. This operation can jeopardize the integrity of the Extra-vehicular Mobility Unit (EMU) or delicate TPS materials. Controls were developed to prevent the likelihood of requiring a tether rescue, and procedures were written to maximize the chances for success if it cannot be avoided. Crewmember ability to manage tether cable tension during nominal flight also had to be evaluated to ensure it would not negatively affect propellant consumption. Second, although propellant consumption, flight control, orbital dynamics, and flight complexity can all be accurately evaluated in Virtual Reality (VR) Laboratory at Johnson Space Center, there are some shortcomings. As a crewmember's hand is extended to simulate measurement of tile damage, it will pass through the vehicle without resistance. In reality, this force will push the crewmember away from the vehicle, and could induce a moment which, if strong enough, could saturate the attitude control system in SAFER. This raises the concern that additional propellant will be consumed to maintain controlled flight. To account for this, the fidelity of the Virtual Reality simulation was improved to include the effect of crewmember contact with the vehicle during SAFER flight. In addition, while participating in VR simulations, the subject is in shirt sleeves and sits in a chair. This does not provide a flight-like representation of body position awareness. To prevent inadvertent contact with tile or RCC, other facilities were utilized to establish crew preferences for body attitude and tool configuration. Finally, a study was performed to determine if attitude constraints are needed for the Space shuttle and International Space Station to reduce SAFER flight difficulty.

Scoville, Zebulon C.

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius

Status of NASA's Space Launch System

NASA's Space Launch System (SLS) continued to make significant progress in 2015, completing hardware and testing that brings NASA closer to a new era of deep space exploration. The most significant program milestone of the year was completion of Critical Design Review (CDR). A team of independent reviewers concluded that the vehicle design is technically and programmatically ready to move to Design Certification Review (DCR) and launch readiness in 2018. Just four years after program start, every major element has amassed development and flight hardware and completed key tests that will set the stage for a growing schedule of manufacturing and testing in 2016. Key to SLS' rapid progress has been the use of existing technologies adapted to the new launch vehicle. The space shuttle-heritage RS-25 engine is undergoing adaptation tests to prove it can meet SLS requirements and environments with minimal change. The four-segment shuttle-era booster has been modified and updated with an additional propellant segment, new insulation, and new avionics. The Interim Cryogenic Upper Stage is a modified version of an existing upper stage. The first Block I SLS configuration will launch a minimum of 70 metric tons (t) of payload to low Earth orbit (LEO). The vehicle architecture has a clear evolutionary path to more than 100t and, ultimately, to 130t. Among the program's major accomplishments in 2015 were the first booster qualification hotfire test, a series of seven RS-25 adaptation hotfire tests, manufacturing of most of the major components for both core stage test articles and first flight tank, delivery of the Pegasus core stage barge, and the upper stage simulator. Renovations to the B-2 test stand for stage green run testing was completed at NASA Stennis Space Center. This year will see the second booster qualification motor hotfire, flight and additional development RS-25 engine tests, and completion of core stage test articles and test stands and several flight article sections. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Lyles, Garry

Status of NASA's Space Launch System

NASA's Space Launch System (SLS) continued to make significant progress in 2015, completing hardware and testing that brings NASA closer to a new era of deep space exploration. The most significant program milestone of the year was completion of Critical Design Review (CDR). A team of independent reviewers concluded that the vehicle design is technically and programmatically ready to move to Design Certification Review (DCR) and launch readiness in 2018. Just four years after program start, every major element has amassed development and flight hardware and completed key tests that will set the stage for a growing schedule of manufacturing and testing in 2016. Key to SLS' rapid progress has been the use of existing technologies adapted to the new launch vehicle. The space shuttle-heritage RS-25 engine is undergoing adaptation tests to prove it can meet SLS requirements and environments with minimal change. The four-segment shuttle-era booster has been modified and updated with an additional propellant segment, new insulation, and new avionics. The Interim Cryogenic Upper Stage is a modified version of an existing upper stage. The first Block I SLS configuration will launch a minimum of 70 metric tons of payload to low Earth orbit (LEO). The vehicle architecture has a clear evolutionary path to more than 100 metric tons and, ultimately, to 130 metric tons. Among the program's major accomplishments in 2015 were the first booster qualification hotfire test, a series of seven RS-25 adaptation hotfire tests, manufacturing of most of the major components for both core stage test articles and first flight tank, delivery of the Pegasus core stage barge, and the upper stage simulator. Renovations to the B-2 test stand for stage green run testing was completed at NASA Stennis Space Center. This year will see the second booster qualification motor hotfire, flight and additional development RS-25 engine tests, and completion of core stage test articles and test stands and several flight article sections. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Honeycutt, John

Laser velocimeter measurements of the flow fields around single- and counter-rotation propeller models

A two-component LV system was used to make detailed measurements of the flow field around both a single-rotation and a counter-rotation propeller/nacelle. The conditions measured for the single-rotation tractor configuration include two different blade angles and two propeller advance ratios, and for the counter-rotation propeller configuration include both pusher and tractor mounts. The measurements show the increasing slipstream velocities and contraction with increasing blade angle and with decreasing advance ratios. Data for the counter-rotation system show that the aft propeller turns the flow in the opposite direction from the front propeller. Additionally, the LV system was used as a diagnostic tool to provide data to explain the large side force measured on the propeller/nacelle at angle-of-attack.

Dunham, D. M.

The NASA-Lewis program on fusion energy for space power and propulsion, 1958-1978

An historical synopsis is provided of the NASA-Lewis research program on fusion energy for space power and propulsion systems. It was initiated to explore the potential applications of fusion energy to space power and propulsion systems. Some fusion related accomplishments and program areas covered include: basic research on the Electric Field Bumpy Torus (EFBT) magnetoelectric fusion containment concept, including identification of its radial transport mechanism and confinement time scaling; operation of the Pilot Rig mirror machine, the first superconducting magnet facility to be used in plasma physics or fusion research; operation of the Superconducting Bumpy Torus magnet facility, first used to generate a toroidal magnetic field; steady state production of neutrons from DD reactions; studies of the direct conversion of plasma enthalpy to thrust by a direct fusion rocket via propellant addition and magnetic nozzles; power and propulsion system studies, including D(3)He power balance, neutron shielding, and refrigeration requirements; and development of large volume, high field superconducting and cryogenic magnet technology.

Schulze, Norman R.

Ares I-X Test Flight Reference Trajectory Development

Ares I-X was the first test flight of NASA's Constellation Program's Ares I crew launch vehicle. Ares I is a two stage to orbit launch vehicle that provides crew access to low Earth orbit for NASA's future manned exploration missions. The Ares I first stage consists of a Shuttle solid rocket motor (SRM) modified to include an additional propellant segment and a liquid propellant upper stage with an Apollo J2X engine modified to increase its thrust capability. The modified propulsion systems were not available for the first test flight, thus the test had to be conducted with an existing Shuttle 4 segment reusable solid rocket motor (RSRM) and an inert Upper Stage. The test flight's primary objective was to demonstrate controllability of an Ares I vehicle during first stage boost and the ability to perform a successful separation. In order to demonstrate controllability, the Ares I-X ascent control algorithms had to maintain stable flight throughout a flight environment equivalent to Ares I. The goal of the test flight reference trajectory development was to design a boost trajectory using the existing RSRM that results in a flight environment equivalent to Ares I. A trajectory similarity metric was defined as the integrated difference between the Ares I and Ares I-X Mach versus dynamic pressure relationships. Optimization analyses were performed that minimized the metric by adjusting the inert upper stage weight and the ascent steering profile. The sensitivity of the optimal upper stage weight and steering profile to launch month was also investigated. A response surface approach was used to verify the optimization results. The analyses successfully defined monthly ascent trajectories that matched the Ares I reference trajectory dynamic pressure versus Mach number relationship to within 10% through Mach 3.5. The upper stage weight required to achieve the match was found to be feasible and varied less than 5% throughout the year. The paper will discuss the flight test requirements, provide Ares I-X vehicle background, discuss the optimization analyses used to meet the requirements, present analysis results, and compare the reference trajectory to the reconstructed flight trajectory.

Starr, Brett R.

Missed Thrust Analysis and Design for Low Thrust Cislunar Transfers

This paper details the analysis of the missed thrust problem for low thrust cislunar transfers. Missed thrust analysis is completed for a reference NRHO to DRO transfer that is designed to maximize the final mass without consideration of robustness to unexpected loss of thrust. A new missed thrust design method is presented to include the robustness of the transfer as part of the optimization problem by including a minimal number of branching trajectories tied to the start of thrust arcs in the reference transfer and optimizing them all simultaneously. Results from variations of this approach are presented for and compared to the reference transfer designed without consideration for missed thrust. The results show that this new method can reduce the additional propellant required for recovery from an unexpected 7-day outage by up to 90% without significant increase to the propellant required to complete the reference transfer.

Grebow, Daniel J.

The Atmosphere-Space Transition Region Explorer (ASTRE) – A Low Perigee Satellite to Investigate the Coupling of the Earth’s Upper Atmosphere and Magnetosphere

The Atmosphere-Space Transition Region Explorer (ASTRE) is a mission concept designed to carry out an unprecedented study of the interaction between the Earth’s atmosphere and the ionized gases of space within the atmosphere-space transition region. By gathering direct measurements of the coupling of ion and neutral gases in this region, ASTRE provides the critical missing link in our knowledge of the transfer, dissipation, and regulation of energy and momentum between the sun and the upper atmosphere. ASTRE provides the first detailed, systematic investigation of this important unexplored region, vastly improves and constrains models of the upper atmosphere, and fills a critical gap in our understanding of how the coupled lower ionosphere/upper atmosphere “works” as a system. To achieve its science objectives, ASTRE gathers accurate measurements of plasma and neutral gases, electric and magnetic fields, and energetic particles using well-proven, in situ instruments with excellent flight heritage. Furthermore, as described herein, all the instruments have been designed to perform well in the low perigee environment, including altitudes of 150 km and lower. ASTRE utilizes a three-axis stabilized satellite that uses on-board propulsion to carry out systematic, low perigee measurements at high latitudes. The satellite design incorporates a “form follows function” approach with a cylindrical shape and conductive body-mounted solar arrays to minimize drag and perturbations to the space environment. Atomic-oxygen resistant materials are utilized and a passive thermal design with heat pipes and radiator panels minimizes the impact of aero-heating. ASTRE launches into a 250 km × 1500 km elliptical insertion orbit with an inclination of 83°. Perigee precesses from its highest northern latitude to its highest southern latitude every ~60 days. Hydrazine propulsion provides over 2000 orbits with perigee below 200 km, with a significant fraction as low as 150 km, during high latitude, two-week campaigns when perigee precesses to either the northern or southern high latitude region. At mid and low latitudes, the perigee is near 225 km. Because very conservative assumptions were made with respect to the orbital analysis and drag, including continuous 3-sigma “worst-case” solar flux and atmospheric density, when additional propellant is included (accommodated in the current design) and some of the stringent assumptions are relaxed, the ASTRE mission described herein may be expected to include repeated excursions to altitudes of ~130 km or even lower. This paper presents an overview of the ASTRE mission, its science motivation, and objectives. It includes a discussion of the science-driven requirements and traceability, followed by a “proof-of concept” implementation that includes notional instruments and a straightforward spacecraft design. Three key points are demonstrated: 1) There is a critical knowledge gap in the high latitude, atmosphere-space transition region below 250 km; 2) The instrument and measurement techniques needed to obtain the ASTRE measurements are well-proven and function well in the low-altitude environment; and 3) A mature spacecraft design, flight dynamics analysis, and concept of operations have been developed that demonstrate that the ASTRE mission can be achieved in a straightforward manner using current technologies.

Ionosphere

Aerocapture as an Enabling Technology for Planetary Missions

Aerocapture is an atmospheric maneuver where aerodynamic forces are used to transfer a spacecraft from a hypersonic orbit to a targeted capture orbit. Aerocapture provides large mass benefits over all-propulsive maneuvers that are typically used to enter capture orbits, as the aerodynamic forces of the vehicle in an atmosphere slow down the vehicle rather than using propellant. Additionally, aerocapture is a quick maneuver where the spacecraft enters the target orbit after a short transit through the atmosphere versus similar aero-assist maneuvers like aerobraking, where the vehicle enters the desired orbit incrementally from a highly elliptical orbit and usually takes a time period of the order of months.

Soumyo Dutta

Silicone containing solid propellant

The addition of a small amount, for example 1% by weight, of a liquid silicone oil to a metal containing solid rocket propellant provides a significant reduction in heat transfer to the inert nozzle walls. Metal oxide slag collection and blockage of the nozzle are eliminated and the burning rate is increased by about 5% to 10% thus improving ballistic performance.

Ramohalli, K. N. R.

Advanced launch vehicle upper stages using liquid propulsion and metallized propellants

Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel or oxidizer. Typically, aluminum particles are the metal additives. These propellants provide increase in the density and/or the specific impulse of the propulsion system. Using metallized propellants for volume- and mass-constrained upper stages can deliver modest increases in performance for Low Earth Orbit to Geosynchronous Earth Orbit and other Earth orbital transfer missions. Metallized propellants, however, can enable very fast planetary missions with a single-stage upper stage system. Trade studies comparing metallized propellant stage performance with non-metallized upper stages and the Inertial Upper Stage are presented. These upper stages are both one- and two-stage vehicles that provide the added energy to send payloads to altitudes and onto trajectories that are unattainable with only the launch vehicle. The stage designs are controlled by the volume and the mass constraints of the Space Transportation System and Space Transportation System-Cargo launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.

Palaszewski, B. A.

Advanced Launch Vehicle Upper Stages Using Liquid Propulsion and Metallized Propellants

Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel or oxidizer. Typically, aluminum (Al) particles are the metal additive. These propellants provide increase in the density and/or the specific impulse of the propulsion system. Using metallized propellant for volume-and mass-constrained upper stages can deliver modest increases in performance for low earth orbit to geosynchronous earth orbit (LEO-GEO) and other earth orbital transfer missions. Metallized propellants, however, can enable very fast planetary missions with a single-stage upper stage system. Trade studies comparing metallized propellant stage performance with non-metallized upper stages and the Inertial Upper Stage (IUS) are presented. These upper stages are both one- and two-stage vehicles that provide the added energy to send payloads to altitudes and onto trajectories that are unattainable with only the launch vehicle. The stage designs are controlled by the volume and the mass constraints of the Space Transportation System (STS) and Space Transportation System-Cargo (STS-C) launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.

Palaszewski, Bryan A.

Upper stages using liquid propulsion and metallized propellants

Metallized propellants are liquid propellants with a metal additive suspended in a gelled fuel. Typically, aluminum particles are the metal additive. These propellants increase the density and/or the specific impulse of the propulsion system. Using metallized propellants for volume- and mass-constrained upper stages can deliver modest increases in performance for low Earth orbit to geosynchronous Earth orbit (LEO-GEO) and other Earth-orbital transfer missions. However, using metallized propellants for planetary missions can deliver great reductions in flight time with a single-stage, upper-stage system. Tradeoff studies comparing metallized propellant stage performance with nonmetallized upper stages and the Inertial Upper Stage (IUS) are presented. These upper stages, launched from the STS and STS-C, are both one- and two-stage vehicles that provide the added energy to send payloads to high altitude orbits and onto interplanetary trajectories that are unattainable with only the Space Transportation System (STS) and the Space Transportation System-Cargo (STS-C). The stage designs are controlled by the volume and the mass constraints of the STS and STS-C launch vehicles. The influences of the density and specific impulse increases enabled by metallized propellants are examined for a variety of different stage and propellant combinations.

Palaszewski, Bryan A.