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At least 361 records · Page 20

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↗

Demonstration of Multilayer Insulation, Vapor Cooling of Structure, and Mass Gauging for Large Scale Upper Stages: Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) Final Report

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The hardware consists of a 4 meter diameter stainless steel tank, structural skirts supporting the tank in the aft direction, and an aluminum forward skirt with vapor cooling channels bolted to it. The initial testing of the SHIIVER hardware was with liquid hydrogen and liquid nitrogen (as a substitute fluid for liquid oxygen and liquid methane) and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full with no MLI on the domes. It reduced the heat load to the tank by approximately 10%, but the boil-off was essentially unchanged at 50% full whether or not vapor cooling was operational with MLI on the domes. The MLI reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment and profile envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed as a result of acoustic testing. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads.

SHIIVER↗

Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems

In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.

Kurt A Polzin↗

Results from the Radio Frequency Mass Gauge Technology Demonstration on the Intuitive Machines Nova-C Lunar Lander

A cryogenic propellant mass gauge known as the Radio Frequency Mass Gauge (RFMG) was integrated into the Intuitive Machines (IM) Nova-C lunar lander and provided an estimate of the liquid oxygen and liquid methane mass in the lander propellant tanks throughout the IM-1 mission, including during microgravity coast phases. An RFMG electronics controller was used to measure and record the spectrum of the RF signal reflected from an antenna sensor in each tank over the frequency range 100 to 1,300 MHz. The RF spectrum of each of the tanks is unique and is sensitive to the index of refraction of the propellants and the spatial distribution of the liquid within the tanks. Electromagnetic simulation software was used to simulate the antenna response spectra for a given tank geometry, fluid properties, and liquid–vapor configurations within the tank. Over 10,000 antenna response simulations were completed for each propellant tank prior to the IM-1 mission and represented various volumetric fill levels and fluid configurations. The simulated spectra served as a database against which measured tank spectra were compared. For analysis, a spectral matching algorithm was used to find the best match between measured and simulated spectra, and the gauged mass was calculated from the most highly correlated fluid mass simulations. RFMG measurements were recorded during tank loading on the launch pad and during translunar coast, lunar orbit insertion, low lunar orbit, powered descent to the lunar surface, and postlanding on the Moon. This paper describes the RF and fluid simulations, the RFMG measurements and analysis of spectral data, the RFMG instrument, and the gauged results throughout all phases of the IM-1 mission.

lunar lander↗

Results from the Radio Frequency Mass Gauge Technology Demonstration on the Intuitive Machines Nova-C Lunar Lander

A cryogenic propellant mass gauge known as the Radio Frequency Mass Gauge (RFMG) was integrated into the Intuitive Machines (IM) Nova-C lunar lander and provided an estimate of the liquid oxygen and liquid methane mass in the lander propellant tanks throughout the IM-1 mission, including during microgravity coast phases. An RFMG electronics controller was used to measure and record the spectrum of the RF signal reflected from an antenna sensor in each tank over the frequency range 100 to 1,300 MHz. The RF spectrum of each of the tanks is unique and is sensitive to the index of refraction of the propellants and the spatial distribution of the liquid within the tanks. Electromagnetic simulation software was used to simulate the antenna response spectra for a given tank geometry, fluid properties, and liquid–vapor configurations within the tank. Over 10,000 antenna response simulations were completed for each propellant tank prior to the IM-1 mission and represented various volumetric fill levels and fluid configurations. The simulated spectra served as a database against which measured tank spectra were compared. For analysis, a spectral matching algorithm was used to find the best match between measured and simulated spectra, and the gauged mass was calculated from the most highly correlated fluid mass simulations. RFMG measurements were recorded during tank loading on the launch pad and during translunar coast, lunar orbit insertion, low lunar orbit, powered descent to the lunar surface, and postlanding on the Moon. This paper describes the RF and fluid simulations, the RFMG measurements and analysis of spectral data, the RFMG instrument, and the gauged results throughout all phases of the IM-1 mission.

lunar lander↗

Oxygen Compatibility Testing of Composite Materials

The development of polymer composite liquid oxygen LO2 tanks is a critical step in creating the next generation of launch vehicles. Future launch vehicles need to minimize the gross liftoff weight (GLOW), which is possible due to the 25%-40% reduction in weight that composite materials could provide over current aluminum technology. Although a composite LO2 tank makes these weight savings feasible, composite materials have not historically been viewed as "LO2 compatible." To be considered LO2 compatible, materials must be selected that will resist any type of detrimental, combustible reaction when exposed to usage environments. This is traditionally evaluated using a standard set of tests. However, materials that do not pass the standard tests can be shown to be safe for a particular application. This paper documents the approach and results of a joint NASA/Lockheed Martin program to select and verify LO2 compatible composite materials for liquid oxygen fuel tanks. The test approach developed included tests such as mechanical impact, particle impact, puncture, electrostatic discharge, friction, and pyrotechnic shock. These tests showed that composite liquid oxygen tanks are indeed feasible for future launch vehicles.

Graf, Neil A.↗

Demonstration of a pulsing liquid hydrogen/liquid oxygen thruster

The development of an injector/thruster concept capable of pulsing a liquid hydrogen/liquid oxygen attitude control propulsion system thruster over thrust and chamber-pressure ranges of 625 to 1250 lbF and 250 to 500 psia, respectively, is discussed. It is shown how continuing search for a simple light-weight, high-performance reaction control system concept led to successful operation tests at cryogenic propellant temperatures (150 and 45 degrees Rankine for oxygen and hydrogen, respectively). The analytical and experimental phases of the liquid/liquid thruster technology efforts are examined.

Herr, P. N.↗

Summary of LO2/Ethanol OMS/RCS Technology and Advanced Development 99-2744

NASA is pursuing non-toxic propellant technologies applicable to RLV and Space Shuttle orbital maneuvering system (OMS) and reaction control system (RCS). The primary objectives of making advancements in an OMS/RCS system are improved safety, reliability, and reduced operations and maintenance cost, while meeting basic operational and performance requirements. An OMS/RCS has a high degree of direct interaction with the vehicle and crew and requires subsystem and components that are compatible with integration into the vehicle with regard to external mold-line, power, and thermal control. In July 1997, a Phase I effort for the technology and advanced development of an upgrade of the space shuttle was conducted to define the system architecture, propellant tank, feed system, RCS thrusters, and OMS engine. Phase I of the project ran from July 1997 to October 1998. Phase II is currently being planned for the development and test of full-scale prototype of the system in 1999 and 2000. The choice of pressure-fed liquid oxygen (LO2) and ethanol is the result of numerous trade studies conducted from 1980 to 1996. Liquid oxygen and ethanol are clean burning, high-density propellants that provide a high degree of commonality with other spacecraft subsystems including life support, power, and thermal control, and with future human exploration and development of space missions. The key to this pressure-fed system is the use of subcooled liquid oxygen at 350 psia. In this approach, there is 80 degrees R of subcooling, which means that boil-off will not occur until the temperature has risen 80 R. The sub-cooling results naturally from loading propellants at 163 R, which is the saturation temperature at 14.7 psia, and then pressurizing to 350 psia on the launch pad. Thermal insulation and conditioning techniques are then used to limit the LO2 temperature to 185 R maximum, and maintain the sub-cooling. The other key is the wide temperature range of ethanol, -173 F to +300 F, which can provide heat to gasify liquid oxygen or provide a good coolant.

Curtis, Leslie A.↗

Small Launch Vehicle Concept Development for Affordable Multi-Stage Inline Configurations

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a study of two configurations of a three-stage, inline, liquid propellant small launch vehicle concept developed on the premise of maximizing affordability by targeting a specific payload capability range based on current industry demand. The initial configuration, NESC-1, employed liquid oxygen as the oxidizer and rocket propellant grade kerosene as the fuel in all three stages. The second and more heavily studied configuration, NESC-4, employed liquid oxygen and RP-1 on the first and second stages and liquid oxygen and liquid methane fuel on the third stage. On both vehicles, sensitivity studies were first conducted on specific impulse and stage propellant mass fraction in order to baseline gear ratios and drive the focus of concept development. Subsequent sensitivity and trade studies on the NESC-4 concept investigated potential impacts to affordability due to changes in gross liftoff weight and/or vehicle complexity. Results are discussed at a high level to understand the impact severity of certain sensitivities and how those trade studies conducted can either affect cost, performance, or both.

Beers, Benjamin R.↗

Small Launch Vehicle Concept Development for Affordable Multi-Stage Inline Configurations

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a study of two configurations of a three stage, inline, liquid propellant small launch vehicle concept developed on the premise of maximizing affordability by targeting a specific payload capability range based on current industry demand. The initial configuration, NESC-1, employed liquid oxygen as the oxidizer and rocket propellant grade kerosene as the fuel in all three stages. The second and more heavily studied configuration, NESC-4, employed liquid oxygen and rocket propellant grade kerosene on the first and second stages and liquid oxygen and liquid methane fuel on the third stage. On both vehicles, sensitivity studies were first conducted on specific impulse and stage propellant mass fraction in order to baseline gear ratios and drive the focus of concept development. Subsequent sensitivity and trade studies on the NESC-4 configuration investigated potential impacts to affordability due to changes in gross liftoff weight and/or vehicle complexity. Results are discussed at a high level to understand the severity of certain sensitivities and how those trade studies conducted can either affect cost, performance or both.

Beers, Benjamin R.↗

Small Launch Vehicle Concept Development for Affordable Multi-Stage Inline Configurations

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a study of two configurations of a three-stage, inline, liquid propellant small launch vehicle concept developed on the premise of maximizing affordability by targeting a specific payload capability range based on current and future industry demand. The initial configuration, NESC-1, employed liquid oxygen as the oxidizer and rocket propellant grade kerosene as the fuel in all three stages. The second and more heavily studied configuration, NESC-4, employed liquid oxygen and rocket propellant grade kerosene on the first and second stages and liquid oxygen and liquid methane fuel on the third stage. On both vehicles, sensitivity studies were first conducted on specific impulse and stage propellant mass fraction in order to baseline gear ratios and drive the focus of concept development. Subsequent sensitivity and trade studies on the NESC-4 concept investigated potential impacts to affordability due to changes in gross liftoff mass and/or vehicle complexity. Results are discussed at a high level to understand the impact severity of certain sensitivities and how those trade studies conducted can either affect cost, performance, or both.

Beers, Benjamin R.↗

Non-Toxic Reaction Control System for the Reusable First Stage Vehicle

This paper presents the Boeing Reusable Space Systems vision of a Reaction Control System (RCS) for the Reusable First Stage (RFS) being considered as a replacement for the Solid Rocket Booster for the Space Shuttle. The requirement is to,achieve reliable vehicle control during the upper atmospheric portion of the RFS trajectory while enabling more efficient ground operations, unhindered by constraints caused by operating with highly toxic RCS propellants. Boeing's objective for this effort is to develop a safer, more efficient and environmentally friendly RCS design approach that is suitable for the RFS concept of operations, including a low cost, efficient turnaround cycle. The Boeing RCS concept utilizes ethanol and liquid oxygen in place of the highly toxic, suspected carcinogen, ozone- depleting mono-methyl-hydrazine and highly toxic nitrogen tetroxide. The Space Shuttle Upgrade program, under the leadership of the NASA Johnson Space Flight Center, is currently developing liquid oxygen and ethanol (ethyl alcohol) technology for use as non-toxic orbital maneuvering system (OMS) and RCS. The development of this liquid oxygen and ethanol technology for the Space Shuffle offers a significant leverage to select much of the same technology for the RFS program. There are significant design and development issues involved with bringing this liquid oxygen and ethanol technology to a state of maturity suitable for an operational RCS, The risks associated with a new LOX and Ethanol RCS are mitigated by maintaining kerosene and hydrogen peroxide RCS technology as an alternative. These issues, presented within this paper, include managing the oxygen supply and achieving reliable ignition in the short pulse mode of engine operation. Performance, reliability and operations requirements are presented along with a specific RCS design concept to satisfying these requirements. The work reported in this paper was performed under NASA Marshall Space Flight Center Contract to define Reusable First Stage design concepts for the Space Shuttle.

Keith, E. L.↗

Large Eddy Simulation of Cryogenic Injection Processes at Supercritical Pressure

This paper highlights results from the first of a series of hierarchical simulations aimed at assessing the modeling requirements for application of the large eddy simulation technique to cryogenic injection and combustion processes in liquid rocket engines. The focus is on liquid-oxygen-hydrogen coaxial injectors at a condition where the liquid-oxygen is injected at a subcritical temperature into a supercritical environment. For this situation a diffusion dominated mode of combustion occurs in the presence of exceedingly large thermophysical property gradients. Though continuous, these gradients approach the behavior of a contact discontinuity. Significant real gas effects and transport anomalies coexist locally in colder regions of the flow, with ideal gas and transport characteristics occurring within the flame zone. The current focal point is on the interfacial region between the liquid-oxygen core and the coaxial hydrogen jet where the flame anchors itself.

Oefelein, Joseph C.↗

Large Eddy Simulation of Cryogenic Injection Processes at Supercritical Pressure

This paper highlights results from the first of a series of hierarchical simulations aimed at assessing the modeling requirements for application of the large eddy simulation technique to cryogenic injection and combustion processes in liquid rocket engines. The focus is on liquid-oxygen-hydrogen coaxial injectors at a condition where the liquid-oxygen is injected at a subcritical temperature into a supercritical environment. For this situation a diffusion dominated mode of combustion occurs in the presence of exceedingly large thermophysical property gradients. Though continuous, these gradients approach the behavior of a contact discontinuity. Significant real gas effects and transport anomalies coexist locally in colder regions of the flow, with ideal gas and transport characteristics occurring within the flame zone. The current focal point is on the interfacial region between the liquid-oxygen core and the coaxial hydrogen jet where the flame anchors itself.

Oefelein, Joseph C.↗

Non-Toxic Reaction Control System for the Reusable First Stage Vehicle

This paper presents the Boeing Reusable Space Systems vision of a Reaction Control System (RCS) for the Reusable First Stage (RFS) being considered as a replacement for the Solid Rocket Booster for the Space Shuttle. The requirement is to achieve reliable vehicle control during the upper atmospheric portion of the RFS trajectory while enabling more efficient ground operations, unhindered by constraints caused by operating with highly toxic RCS propellants. Boeing's objective for this effort is to develop a safer, more efficient and environmentally friendly RCS design approach that is suitable for the RFS concept of operations, including a low cost, efficient turnaround cycle. The Boeing RCS concept utilizes ethanol and liquid oxygen in place of the highly toxic, suspected carcinogen, ozone-depleting mono-methyl-hydrazine and highly toxic nitrogen tetroxide. The Space Shuttle Upgrade program, under the leadership of the NASA Johnson Space Flight Center, is currently developing liquid oxygen and ethanol (ethyl alcohol) technology for use as non-toxic orbital maneuvering system (OMS) and RCS. The development of this liquid oxygen and ethanol technology for the Space Shuttle offers a significant leverage to select much of the same technology for the RFS program. There are significant design and development issues involved with bringing this liquid oxygen and ethanol technology to a state of maturity suitable for an operational RCS. The risks associated with a new LOX and Ethanol RCS are mitigated by maintaining kerosene and hydrogen peroxide RCS technology as an alternative. These issues, presented within this paper, include managing the oxygen supply and achieving reliable ignition in the short pulse mode of engine operation. Performance, reliability and operations requirements are presented along with a specific RCS design concept to satisfying these requirements. The work reported in this paper was performed under NASA Marshall Space Flight Center Contract Number NAS8-97272 to define Reusable First Stage design concepts for the Space Shuttle.

Keith, E. L.↗

Cavitating Jet Method and System for Oxygenation of Liquids

Reclamation and re-use of water is critical for space-based life support systems. A number of functions must be performed by any such system including removal of various contaminants and oxygenation. For long-duration space missions, this must be done with a compact, reliable system that requires little or no use of expendables and minimal power. DynaJets cavitating jets can oxidize selected organic compounds with much greater energy efficiency than ultrasonic devices typically used in sonochemistry. The focus of this work was to develop cavitating jets to simultaneously accomplish the functions of oxygenation and removal of contaminants of importance to space-structured water reclamation systems. The innovation is a method to increase the concentration of dissolved oxygen or other gasses in a liquid. It utilizes a particular form of novel cavitating jet operating at low to moderate pressures to achieve a high-efficiency means of transporting and mixing the gas into the liquid. When such a jet is utilized to simultaneously oxygenate the liquid and to oxidize organic compounds within the liquid, such as those in waste water, the rates of contaminant removal are increased. The invention is directed toward an increase in the dissolved gas content of a liquid, in general, and the dissolved oxygen content of a liquid in particular.

Chahine, Georges L.↗