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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗
NASA NTRS1946

Flight Investigation of the Cooling Characteristics of a Two-row Radial Engine Installation III : Engine Temperature Distribution

The temperature distribution of a two-row radial engine in a twin-engine airplane has been investigated in a series of flight tests. The test engine was operated over a wide range of conditions at density altitudes of 5000 and 20,000 feet; quantitative results are presented showing the effects of flight and engine variables upon average engine temperature and over-all temperature spread. Discussions of the effect of the variables on the shape of the temperature patterns and on the temperature distribution of individual cylinders are also included. The results indicate that, for the tests conducted, the temperature distribution patterns were chiefly determined by the fuel-air ratio and cooling-air distributions. It was possible to calculate individual cylinder temperature, on the assumption of equal power distribution among cylinders, to within an average of plus or minus 14 degrees F. of the actual temperature. A considerable change occurred in either the spread or the thrust axis, the average engine fuel-air ratio, the engine speed, the power, or the blower ratio. Smaller effects on the temperature pattern were noticed with a change in cowl-flap opening and altitude. In most of the tests, a change in conditions affected the temperature of the barrels less than that of the heads. The variation of flight and engine variables had a negligible effect on the temperature distributions of the individual cylinders. (author)

Rennak, Robert M↗
NASA NTRS2011

Low Altitude Mapping Orbit Design and Maintenance for the Dawn Discovery Mission at Vesta

NASA's Dawn discovery mission will orbit the giant asteroid Vesta beginning in the summer of 2011. Four different near polar science orbits are planned. The lowest planned orbit at Vesta is called the Low Altitude Mapping Orbit or LAMO and is by far the most challenging to design and maintain due to the strong, nonspherical gravity expected there. This paper describes the orbit selection process. The true gravity field of Vesta remains highly uncertain. The proposed orbit selection process will be applied once sufficient gravity knowledge is obtained at higher orbits. The orbit selection process is applied here to a fictitious gravity field based on a Hubble space telescope shape model for Vesta assuming uniform density. The outcome of the process described here is a variety of stable orbits. However, Initially stable orbits at the LAMO altitude are not expected to remain stable operationally due to the unpredictable impulses resulting from the Dawn spacecraft thruster firings to de-saturate its momentum wheels. As a result, orbital maintenance maneuvers will be probably be necessary. This paper also briefly describes the statistical maneuver design process that resulted in the orbit maintenance plan.

orbit stability↗
NASA NTRS1988

Sampling the ancient volatile-rich areas of Mars

Viking images clearly show areas with a high density of fluidized craters that also display a significant number of wrinkle ridges. Fluidized crater ejecta morphology may indicate that the target material was rich in volatiles at the time of the impact. Therefore, these areas are of the utmost importance in deciphering both the Martian tectonic evolution and the amount of subsurface water, at times when more favorable conditions for life to evolve did exist on Mars. Although a large number of extensional features are associated with Tharsis and Elysium geologic activity, the planet-wide distribution of ridges suggests that Mars' tectonic history is far more complex than the Tharsis-dominated scenario indicates. Like on the Moon and Mercury, ridges on Mars were formed under compressive stresses, probably as a result of thrust-fault mechanism, although surface expressions and direct causes vary. Martian ridges are most easily seen on smooth plains of volcanic origin, but the majority of the 16,000 mapped and classified compressive features are located in the old terrains, far beyond Tharsis influence.

Chicarro, A. F.↗
NASA NTRS1983

CARS temperature measurements in the fuel preburner of the Space Shuttle main engine: A feasibility study

This report discusses the feasibility of making temperature profile measurements in the fuel preburner of the main engine of the space shuttle (SSME) using coherent anti-Stokes Raman spectroscopy (CARS). The principal thrust of the work is to identify problems associated with making CARS measurements in high temperature gas phase hydrogen at very high pressures (approx 400 atmospheres). To this end a theoretical study was made of the characteristics of the CAR spectra of H2 as a function of temperature and pressure and the accuracy with which temperatures can be extracted from this spectra. In addition the experimental problems associated with carrying out these measurements on a SSME at NSTL were identified. A conceptual design of a CARS system suitable for this work is included. Many of the results of the calculations made in this report are plotted as a function of temperature. In the course of presenting these results, it was necessary to decide whether the number of density or the pressure should be treated as a fixed parameter.

Beiting, E. J.↗
NASA NTRS2005

Vacuum Deployment and Testing of a 4-Quadrant Scalable Inflatable Solar Sail System

Solar sails reflect photons streaming from the sun and transfer momentum to the sail. The thrust, though small, is continuous and acts for the life of the mission without the need for propellant. Recent advances in materials and ultra-low mass gossamer structures have enabled a host of useful missions utilizing solar sail propulsion. The team of L'Garde, Jet Propulsion Laboratories, Ball Aerospace, and Langley Research Center, under the direction of the NASA In-Space Propulsion office, has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. The baseline design currently in development and testing was optimized around the 1 AU solar sentinel mission. Featuring inflatably deployed sub-T(sub g), rigidized beam components, the 10,000 sq m sail and support structure weighs only 47.5 kg, including margin, yielding an areal density of 4.8 g/sq m. Striped sail architecture, net/membrane sail design, and L'Garde's conical boom deployment technique allows scalability without high mass penalties. This same structural concept can be scaled to meet and exceed the requirements of a number of other useful NASA missions. This paper discusses the interim accomplishments of phase 3 of a 3-phase NASA program to advance the technology readiness level (TRL) of the solar sail system from 3 toward a technology readiness level of 6 in 2005. Under earlier phases of the program many test articles have been fabricated and tested successfully. Most notably an unprecedented 4-quadrant 10 m solar sail ground test article was fabricated, subjected to launch environment tests, and was successfully deployed under simulated space conditions at NASA Plum Brook s 30m vacuum facility. Phase 2 of the program has seen much development and testing of this design validating assumptions, mass estimates, and predicted mission scalability. Under Phase 3 a much larger 20 m square test article including subscale vane has been fabricated and tested. A 20 m system ambient deployment has been successfully conducted after enduring Delta-2 launch environment testing. The program will culminate in a vacuum deployment of a 20 m subscale test article at the NASA Glenn s Plum Brook 30 m vacuum test facility to bring the TRL level as close to 6 as possible in 1 g. This focused program will pave the way for a flight experiment of this highly efficient space propulsion technology.

Lichodziejewski, David↗
NASA NTRS1997

Enhancement of Mixing and Reaction in High-speed Combustor Flowfields

Research has been underway for a number of years, both in the United States and abroad, to develop advanced aerospace propulsion systems for use late in this century and beyond. One program is now underway at the NASA Langley Research Research has been underway for a number of years, both in the United States and abroad, to develop advanced aerospace propulsion systems for use late in this century and beyond. One program is now underway at the NASA Langley Research Center to develop a hydrogen-fueled supersonic combustion ramjet (scramjet) that is capable of propelling a vehicle at hypersonic speeds in the atmosphere. A part of that research has been directed toward the optimization of the scramjet combustor and, in particular, the efficiency of fuel-air mixing and reaction taking place in the engine. In the high-speed vehicle configurations currently being considered, achieving a high combustor efficiency becomes particularly difficult. With increasing combustor Mach number, the degree of fuel-air mixing that can be achieved through natural convective and diffusive processes is reduced leading to an overall decrease in combustion efficiency and thrust. Compressible shear layers and jets provide a good model for studying the physical processes occurring in high speed mixing and combustion in a scramjet. Mixing layers are characterized by large scale eddies that form due to the high shear that is present between the fuel and the air streams. These eddies entrain the fuel and air into the mixing region between the fluids leading to increased surface area and locally steep concentration gradients. Molecular diffusion then occurs across the strained interfaces. In an early study of high-speed mixing, Brown and Roshko show that the spreading rate of a supersonic mixing layer decreases with increasing Mach number, exhibiting a factor of three decrease in spread rate as compared with an incompressible mixing layer with the same density ratio. They conclude that the reduced spread rate is primarily due to compressibility. Papamoschou and Roshko also observe that the spreading rate of compressible mixing layers is significantly reduced over that of incompressible layers. To characterize the structure of the flow quantitatively, they define a convective Mach number. The reduction in mixing layer spreading rate is shown in these experiments to correlate well with increasing convective Mach number.

Drummond, J. Philip↗
NASA NTRS2016

Performance, Facility Pressure Effects, and Stability Characterization Tests of NASA's Hall Effect Rocket with Magnetic Shielding Thruster

NASAs Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5 kW Technology Demonstration Unit-1 (TDU-1) Hall thruster has been the subject of extensive technology maturation in preparation for flight system development. Part of the technology maturation effort included experimental evaluation of the TDU-1 thruster with conducting and dielectric front pole cover materials in two different electrical configurations. A graphite front pole cover thruster configuration with the thruster body electrically tied to cathode and an alumina front pole cover thruster configuration with the thruster body floating were evaluated. Both configurations were also evaluated at different facility background pressure conditions to evaluate background pressure effects on thruster operation. Performance characterization tests found that higher thruster performance was attained with the graphite front pole cover configuration with the thruster electrically tied to cathode. A total thrust efficiency of 68 and a total specific impulse of 2,820 s was demonstrated at a discharge voltage of 600 V and a discharge power of 12.5 kW. Thruster stability regimes were characterized with respect to the thruster discharge current oscillations and with maps of the current-voltage-magnetic field (IVB). Analysis of TDU-1 discharge current waveforms found that lower normalized discharge current peak-to-peak and root mean square magnitudes were attained when the thruster was electrically floated with alumina front pole covers. Background pressure effects characterization tests indicated that the thruster performance and stability was mostly invariant to changes in the facility background pressure for vacuum chamber pressure below 110-5 Torr-Xe (for thruster flow rate above 8 mgs). Power spectral density analysis of the discharge current waveform showed that increasing the vacuum chamber background pressure resulted in a higher discharge current dominant frequency. Finally the IVB maps of the TDU-1 thruster taken at elevated magnetic fields indicated that the discharge current became more oscillatory with increased facility background pressure at lower thruster mass flow rates, where thruster operation at higher flow rates resulted in less change to the thrusters IVB characteristics.

Hall Thrusters↗
DOE OSTI2023

Improving the representation of isopycnal mixing in E3SM (Final Report)

The DOE-supported Energy Exascale Earth System Model (E3SM) is a major attempt by the Department of Energy to develop a new Earth System Model using unstructured grids, which allow for the model to concentrate resolution where it is most needed and avoid numerical artifacts experienced by previous Earth System Models (ESMs) using regular grids in which the lateral resolution becomes extremely fine as the resolution shrinks at the poles. This effort required rewriting many of the algorithms previously developed for regular grids. One algorithm that was problematic in the first version of E3SM was the representation of mixing due to turbulent ocean eddies with scales smaller than the model grid. These mesoscale eddies are the primary way by which tracers are stirred along density surfaces in the ocean interior. In particular, the process of isopycnal mixing exchanges fresher, more oxygenated waters from polar regions with saltier, nutrient-rich and oxygen poor waters from tropical regions. Previous work in our group has shown that this mechanism is vitally important for bringing oxygen into poorly ventilated tropical regions (Gnanadesikan et al., 2012, 2013) and plays a significant role in determining the uptake of anthropogenic carbon dioxide (Gnanadesikan et al., 2015). However, in E3SMv1 this process was turned off, as turning it on caused the model to become unstable. Additionally, the rate of isopycnal mixing is directly proportional to a mixing coefficient $A_{Redi}$ whose value varies from less than 400 m 2 /s to 2000 m 2 /s across contemporary climate models. The main thrusts of this proposal therefore were to: 1.) Improve the numerics of isopycnal mixing in E3SM; 2.) Identify ways in which climate models are sensitive to the isopycnal mixing coefficient; and 3.) Develop better representations of the isopycnal mixing coefficient.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1985

MPD thruster performance - Propellant distribution and species effects

Previous research has shown that MPD thruster performance, as measured by thrust, specific impulse, and efficiency, is limited by a so-called 'onset' current level. Experimental results are presented which show that the onset current level varies with the radial position of mass injection. Specifically, mass injection into either of two zones results in drastically different performance for both argon and xenon propellants. This difference in performance is evidenced by the onset current levels, the onset V-J signatures, and the overall V-J characteristics. The behavior of the thruster with the total mass flow split between the two zones follows a transition between the zonal behavioral limits. The behavior of propellant mixtures also follows a transition between the behavior of the individual propellant species. The flow region between the two zones is characterized by a particle number density discontinuity, a large axial current density, and a large electron Hall parameter, suggesting a possible correlation between observed onset phenomena and a shear-flow discontinuity located in the region between the two zones.

Kelly, A. J.↗
NASA NTRS2011

Max Launch Abort System (MLAS) Pad Abort Test Vehicle (PATV) II Attitude Control System (ACS) Integration and Pressurization Subsystem Dynamic Random Vibration Analysis

In order to mitigate catastrophic failures on future generation space vehicles, engineers at the National Aeronautics and Space Administration have begun to integrate a novel crew abort systems that could pull a crew module away in case of an emergency at the launch pad or during ascent. The Max Launch Abort System (MLAS) is a recent test vehicle that was designed as an alternative to the baseline Orion Launch Abort System (LAS) to demonstrate the performance of a "tower-less" LAS configuration under abort conditions. The MLAS II test vehicle will execute a propulsive coast stabilization maneuver during abort to control the vehicles trajectory and thrust. To accomplish this, the spacecraft will integrate an Attitude Control System (ACS) with eight hypergolic monomethyl hydrazine liquid propulsion engines that are capable of operating in a quick pulsing mode. Two main elements of the ACS include a propellant distribution subsystem and a pressurization subsystem to regulate the flow of pressurized gas to the propellant tanks and the engines. The CAD assembly of the Attitude Control System (ACS) was configured and integrated into the Launch Abort Vehicle (LAV) design. A dynamic random vibration analysis was conducted on the Main Propulsion System (MPS) helium pressurization panels to assess the response of the panel and its components under increased gravitational acceleration loads during flight. The results indicated that the panels fundamental and natural frequencies were farther from the maximum Acceleration Spectral Density (ASD) vibrations which were in the range of 150-300 Hz. These values will direct how the components will be packaged in the vehicle to reduce the effects high gravitational loads.

Ekrami, Yasamin↗
NASA NTRS2016

Performance, Facility Pressure Effects, and Stability Characterization Tests of NASA's Hall Effect Rocket with Magnetic Shielding Thruster

NASA's Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5 kW Technology Demonstration Unit-1 (TDU-1) has been the subject of extensive technology maturation in preparation for flight system development. Part of the technology maturation effort included experimental evaluation of the TDU-1 thruster with conducting and dielectric front pole cover materials in two different electrical configurations. A graphite front magnetic pole cover thruster configuration with the thruster body electrically tied to cathode, and an alumina front pole cover thruster configuration with the thruster body floating were evaluated. Both configurations were also evaluated at different facility background pressure conditions to evaluate background pressure effects on thruster operation. Performance characterization tests found that higher thruster performance was attained with the graphite front pole cover configuration with the thruster electrically tied to cathode. A total thrust efficiency of 68% and a total specific impulse of 2,820 s was demonstrated at a discharge voltage of 600 V and a discharge power of 12.5 kW. Thruster stability regimes were characterized with respect to the thruster discharge current oscillations and with maps of the discharge current-voltage-magnetic field (IVB). Analysis of TDU-1 discharge current waveforms found that lower normalized discharge current peak-to-peak and root mean square magnitudes were attained when the thruster was electrically floated with alumina front pole covers. Background pressure effects characterization tests indicated that the thruster performance and stability were mostly invariant to changes in the facility background pressure for vacuum chamber pressure below 1×10-5 Torr-Xe (for thruster flow rates of 20.5 mg/s). Power spectral density analysis of the discharge current waveforms showed that increasing the vacuum chamber background pressure resulted in a higher discharge current dominant breathing mode frequency. Finally, IVB maps of the TDU-1 thruster indicated that the discharge current became more oscillatory with higher discharge current peak-to-peak and RMS values with increased facility background pressure at lower thruster mass flow rates; thruster operation at higher flow rates resulted in less change to the thruster's IVB characteristics with elevated background pressure.

Electric Propulsion↗
DOE OSTI2024

Design, Control and Application of Next Generation Qubits

Design, Control and Application of Next Generation Qubits Arun Bansil, Northeastern University (Principal Investigator) Claudio Chamon, Boston University (Co-Investigator) Adrian Feiguin, Northeastern University (Co-Investigator) Liang Fu, MIT (Co-Investigator) Eduardo Mucciolo, Univ. of Central Florida (Co-Investigator) Qimin Yan, Temple University (Co-Investigator) The quest for developing technologies for manipulating and storing information quantum mechanically is currently led by approaches that include Josephson-junctions, ion-traps, and qubits generated by defect spins in solids. Topological qubits, however, are inherently more robust to decoherence by environmental effects, and should be able to sprint ahead once practical barriers have been overcome. At the present stage of the development of the field, it is important to explore a variety of architectures and materials beyond the conventional paradigms in order to seed breakthroughs toward building a scalable quantum computer. Our comprehensive theoretical research program involved four interconnected thrusts as follows. • A materials discovery effort in two-dimensional compounds in search of materials to support Majorana zero modes and defect structures suitable as qubits. • Exploration of architectures for topological quantum computation by investigating both superconducting Majorana qubits, and robust platforms for braiding with new “meta-materials” built of arrays of Majorana qubits. • Investigation of properties of hybrid metal-organic qubits based on transition-metal centers in graphene, and molecular crystals of polyaromatic complexes with embedded transition-metal atoms. • Development of tensor-network and semiclassical approaches to study decoherence in the presence of random and dispersive spin baths, and NV centers in diamond. The full spectrum of theoretical and numerical approaches was used to address the goals of this project including first-principles, density-matrix-renormalization group, tensor networks, and data-driven high-throughput approaches using materials database and machine-learning.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Ascent performance issues of a vertical-takeoff rocket launch vehicle

Advanced manned launch systems studies under way at the NASA Langley Research Center are part of a broader effort that is examining options for the next manned space transportation system to be developed by the United States. One promising concept that uses near-term technologies is a fully reusable, two-stage vertical-takeoff rocket vehicle. This vehicle features parallel thrusting of the booster and orbiter with the booster cross-feeding the propellant to the orbiter until staging. In addition, after staging, the booster glides back unpowered to the launch site. This study concentrated on two issues that could affect the ascent performance of this vehicle. The first is the large gimbal angle range required for pitch trim until staging because of the propellant cross-feed. Results from this analysis show that if control is provided by gimballing of the rocket engines, they must gimbal greater than 20 deg, which is excessive when compared with current vehicles. However, this analysis also showed that this limit could be reduced to 10 deg if gimballing were augmented by throttling the booster engines. The second issue is the potential influence of off-nominal atmospheric conditions (density and winds) on the ascent performance. This study showed that a robust guidance algorithm could be developed that would insure accurate insertion, without prelaunch atmospheric knowledge.

Powell, Richard W.↗
NASA NTRS1999

Upper-Stage Flight Experiment

For propulsion applications that require that the propellants are storable for long periods, have a high density impulse, and are environmentally clean and non-toxic, the best choice is a combination of high-concentration hydrogen peroxide (High Test Peroxide, or HTP) and a liquid hydrocarbon (LHC) fuel. The HTP/LHC combination is suitable for low-cost launch vehicles, space taxi and space maneuvering vehicles, and kick stages. Orbital Sciences Corporation is under contract with the NASA Marshall Space Flight Center in cooperation with the Air Force Research Lab to design, develop and demonstrate a new low-cost liquid upper stage based on HTP and JP-8. The Upper Stage Flight Experiment (USFE) focuses on key technologies necessary to demonstrate the operation of an inherently simple propulsion system with an innovative, state-of-the-art structure. Two key low-cost vehicle elements will be demonstrated - a 10,000 lbf thrust engine and an integrated composite tank structure. The suborbital flight test of the USFE is scheduled for 2001. Preceding the flight tests are two major series of ground tests at NASA Stennis Space Center and a subscale tank development program to identify compatible composite materials and to verify their compatibility over long periods of time. The ground tests include a thrust chamber development test series and an integrated stage test. This paper summarizes the results from the first phase of the thrust chamber development tests and the results to date from the tank material compatibility tests. Engine and tank configurations that meet the goals of the program are described.

Anderson, W. E.↗
NASA NTRS2000

Gasdynamic Mirror Fusion Propulsion Experiment

A gasdynamic mirror (GDM) fusion propulsion experiment is currently being constructed at the NASA Marshall Space Flight Center (MSFC) to test the feasibility of this particular type of fusion device. Because of the open magnetic field line configuration of mirror fusion devices, they are particularly well suited for propulsion system applications since they allow for the easy ejection of thrust producing plasma. Currently, the MSFC GDM is constructed in three segments. The vacuum chamber mirror segment, the plasma injector mirror segment, and the main plasma chamber segment. Enough magnets are currently available to construct up to three main plasma chamber segments. The mirror segments are also segmented such that they can be expanded to accommodate new end plugging strategies with out requiring the disassembly of the entire mirror segment. The plasma for the experiment is generated in a microwave cavity located between the main magnets and the mirror magnets. Ion heating is accomplished through ambipolar diffusion. The objective of the experiment is to investigate the stability characteristics of the gasdynamic mirror and to map a region of parameter space within which the plasma can be confined in a stable steady state configuration. The mirror ratio, plasma density, and plasma "b" will be varied over a range of values and measurements subsequently taken to determine the degree of plasma stability.

Emrich, Bill↗
NASA NTRS2018

Instability and Target Design in a Z-Pinch Driven Pulsed Fission / Fusion Engine

Advanced forms of propulsion are required to drastically improve upon the limits of existing technology and enable deep space exploration. Nuclear reactors, both fission and fusion, have great potential as systems with high energy density for spacecraft propulsion. There are a variety of nuclear propulsion concepts that have been proposed over the last several decades. Some of these rely on the confinement of plasmas by both magnetic and inertial means. When discussing the plasma confinement one must consider the stability of the system. The conditions of the plasma dictate the burn rate of the nuclear fuel; therefore, the plasma must maintain a minimum set of conditions in order to achieve an adequate burn. Instabilities limit plasma confinement through growing fluctuations in density and pressure. This results in turbulent mixing and loss of confinement. Thus it is desirable to find ways of managing the impact of instabilities that arise in order for a sufficient burn of the fuel such that surplus energy can be converted into a propulsive force. Note that the same instabilities plague the confinement of plasmas for terrestrial power generation. Over the last several years there has been research relating to the development of a Pulsed Fission-Fusion Engine (PuFF) conducted by the authors and others at their respective institutions. The propulsion system concept centers on the use of a z-pinch to compress a plasma in order to induce nuclear reactions. The plasma along with the additional energy released by the fission and fusion processes is expanded with a magnetic nozzle to produce thrust. The concept, if developed, is expected to have an improvement in specific impulse of several orders of magnitude in comparison with chemical propulsion systems. The z-pinch has been explored in the past as a method to confine a plasma via magnetic confinement fusion (MCF) for power generation. It suffers; however, from instabilities that so far have prevented break even conditions.

Taylor, Brian↗
NASA NTRS2018

Chapter 12: Materials for Liquid Propulsion Systems

Earth to orbit launch vehicles are propelled by rocket engines and motors, both liquid and solid. This chapter will discuss liquid engines. The heart of a launch vehicle is its engine. The remainder of the vehicle (with the notable exceptions of the payload and guidance system) is an aero structure to support the propellant tanks which provide the fuel and oxidizer to feed the engine or engines. The basic principle behind a rocket engine is straightforward. The engine is a means to convert potential thermochemical energy of one or more propellants into exhaust jet kinetic energy. Fuel and oxidizer are burned in a combustion chamber where they create hot gases under high pressure. These hot gases are allowed to expand through a nozzle. The molecules of hot gas are first constricted by the throat of the nozzle (de-Laval nozzle) which forces them to accelerate; then as the nozzle flares outwards, they expand and further accelerate. It is the mass of the combustion gases times their velocity, reacting against the walls of the combustion chamber and nozzle, which produce thrust according to Newton's third law: for every action there is an equal and opposite reaction. Solid rocket motors are cheaper to manufacture and offer good values for their cost. Liquid propellant engines offer higher performance, that is, they deliver greater thrust per unit weight of propellant burned. They also have a considerably higher thrust to weigh ratio. Since liquid rocket engines can be tested several times before flight, they have the capability to be more reliable, and their ability to shut down once started provides an extra margin of safety. Liquid propellant engines also can be designed with restart capability to provide orbital maneuvering capability. In some instances, liquid engines also can be designed to be reusable. On the solid side, hybrid solid motors also have been developed with the capability to stop and restart. Solid motors are covered in detail in chapter 11. Liquid rocket engine operational factors can be described in terms of extremes: temperatures ranging from that of liquid hydrogen (-423 F) to 6000 F hot gases; enormous thermal shock (7000 F/sec); large temperature differentials between contiguous components; reactive propellants; extreme acoustic environments; high rotational speeds for turbo machinery and extreme power densities. These factors place great demands on materials selection and each must be dealt with while maintaining an engine of the lightest possible weight. This chapter will describe the design considerations for the materials used in the various components of liquid rocket engines and provide examples of usage and experiences in each.

Halchak, John A.↗