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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Developing the World's Most Powerful Solid Booster

NASA's Journey to Mars has begun. Indicative of that challenge, this will be a multi-decadal effort requiring the development of technology, operational capability, and experience. The first steps are underway with more than 15 years of continuous human operations aboard the International Space Station (ISS) and development of commercial cargo and crew transportation capabilities. NASA is making progress on the transportation required for deep space exploration - the Orion crew spacecraft and the Space Launch System (SLS) heavy-lift rocket that will launch Orion and large components such as in-space stages, habitat modules, landers, and other hardware necessary for deep-space operations. SLS is a key enabling capability and is designed to evolve with mission requirements. The initial configuration of SLS - Block 1 - will be capable of launching more than 70 metric tons (t) of payload into low Earth orbit, greater mass than any other launch vehicle in existence. By enhancing the propulsion elements and larger payload fairings, future SLS variants will launch 130 t into space, an unprecedented capability that simplifies hardware design and in-space operations, reduces travel times, and enhances two solid propellant five-segment boosters, both based on space shuttle technologies. This paper will focus on development of the booster, which will provide more than 75 percent of total vehicle thrust at liftoff. Each booster is more than 17 stories tall, 3.6 meters (m) in diameter and weighs 725,000 kilograms (kg). While the SLS booster appears similar to the shuttle booster, it incorporates several changes. The additional propellant segment provides additional booster performance. Parachutes and other hardware associated with recovery operations have been deleted and the booster designated as expendable for affordability reasons. The new motor incorporates new avionics, new propellant grain, asbestos-free case insulation, a redesigned nozzle, streamlined manufacturing processes, and new inspection techniques. New materials and processes provide improved performance, safety, and affordability but also have led to challenges for the government/industry development team. The team completed its first full-size qualification motor test firing in early 2015. The second is scheduled for mid-2016. This paper will discuss booster accomplishments to date, as well as challenges and milestones ahead.

Priskos, Alex S.↗
NASA NTRS2016

NASA's Space Launch System: Developing the World's Most Powerful Solid Booster

NASA's Journey to Mars has begun. Indicative of that challenge, this will be a multi-decadal effort requiring the development of technology, operational capability, and experience. The first steps are under way with more than 15 years of continuous human operations aboard the International Space Station (ISS) and development of commercial cargo and crew transportation capabilities. NASA is making progress on the transportation required for deep space exploration - the Orion crew spacecraft and the Space Launch System (SLS) heavy-lift rocket that will launch Orion and large components such as in-space stages, habitat modules, landers, and other hardware necessary for deep-space operations. SLS is a key enabling capability and is designed to evolve with mission requirements. The initial configuration of SLS - Block 1 - will be capable of launching more than 70 metric tons (t) of payload into low Earth orbit, greater mass than any other launch vehicle in existence. By enhancing the propulsion elements and larger payload fairings, future SLS variants will launch 130 t into space, an unprecedented capability that simplifies hardware design and in-space operations, reduces travel times, and enhances the odds of mission success. SLS will be powered by four liquid fuel RS-25 engines and two solid propellant five-segment boosters, both based on space shuttle technologies. This paper will focus on development of the booster, which will provide more than 75 percent of total vehicle thrust at liftoff. Each booster is more than 17 stories tall, 3.6 meters (m) in diameter and weighs 725,000 kilograms (kg). While the SLS booster appears similar to the shuttle booster, it incorporates several changes. The additional propellant segment provides additional booster performance. Parachutes and other hardware associated with recovery operations have been deleted and the booster designated as expendable for affordability reasons. The new motor incorporates new avionics, new propellant grain, asbestos-free case insulation, a redesigned nozzle, streamlined manufacturing processes, and new inspection techniques. New materials and processes provide improved performance, safety, and affordability but also have led to challenges for the government/industry development team. The team completed its first full-size qualification motor test firing in early 2015. The second is scheduled for mid-2016. This paper will discuss booster accomplishments to date, as well as challenges and milestones ahead.

Priskos, Alex↗
NASA NTRS1983

Feasibility demonstration of booster cross-over system for 3 1/2 inch SRB/MLP frangible nut system

Recent testing of the SRB/MLP Frangible Nut System (SOS Part Number 114850-9/Boosters P/N 114848-3) at NASA indicated a need to reduce the function time between boosters (2) within a single frangible nut. These boosters are initiated separately by electrical impulse(s). Coupling the output of each detonator with an explosive cross-over would reduce the function time between boosters (independent of electrical impulse) while providing additional redundancy to the system. The objectives of this program were to: provide an explosive cross-over between boosters, reduce function time between boosters to less than one (1) millisecond within a given nut, reduce cost of boosters, be compatible with the existing frangible nut system, and meet requirements of USBI Spec's (nut 10SPC-0030, booster 10SPC-0031).

Source record↗
NASA NTRS1991

Space shuttle with common fuel tank for liquid rocket booster and main engines (supertanker space shuttle)

An operation and schedule enhancement is shown that replaces the four-body cluster (Space Shuttle Orbiter (SSO), external tank, and two solid rocket boosters) with a simpler two-body cluster (SSO and liquid rocket booster/external tank). At staging velocity, the booster unit (liquid-fueled booster engines and vehicle support structure) is jettisoned while the remaining SSO and supertank continues on to orbit. The simpler two-bodied cluster reduces the processing and stack time until SSO mate from 57 days (for the solid rocket booster) to 20 days (for the liquid rocket booster). The areas in which liquid booster systems are superior to solid rocket boosters are discussed. Alternative and future generation vehicles are reviewed to reveal greater performance and operations enhancements with more modifications to the current methods of propulsion design philosophy, e.g., combined cycle engines, and concentric propellant tanks.

Thorpe, Douglas G.↗
NASA NTRS1959

An Investigation of a 0.05-Scale Model of the XSM-64A Navaho Missile and Booster: Force Study at Mach Numbers from 1.77 to 3.51 - Part 1

An investigation has been conducted in the Langley Unitary Plan wind tunnel to determine the aerodynamic loads and the static longitudinal and lateral stability of a 0.05-scale model of the XSM-64A Navaho missile and booster and its various components. Tests were conducted through a Mach number range of 1.77 to 3.51 with a corresponding Reynolds number range of 2.4 x 10(exp 6) to 2.9 x 10(exp 6). Results are presented for an angle-of-attack range of -8 deg to 4 deg for the missile-booster combination and -10 deg to 10 deg for the missile-alone configuration. Tests for both configurations were conducted through an angle-of-sideslip range of -8 deg to 8 deg. Also presented are some effects on the model characteristics of the deflection of various components including canard, tip aileron, vertical stabilizer, speed brakes, and booster pitch and yaw thrust chambers. The various components on which loads were measured include the wing, tip aileron, rudder, booster, booster separating surface, booster fin, and booster yaw and pitch thrust chambers. These data are presented without analysis.

Church, James D.↗
NASA NTRS2015

Pressure-Equalizing Cradle for Booster Rocket Mounting

A launch system and method improve the launch efficiency of a booster rocket and payload. A launch aircraft atop which the booster rocket is mounted in a cradle, is flown or towed to an elevation at which the booster rocket is released. The cradle provides for reduced structural requirements for the booster rocket by including a compressible layer, that may be provided by a plurality of gas or liquid-filled flexible chambers. The compressible layer contacts the booster rocket along most of the length of the booster rocket to distribute applied pressure, nearly eliminating bending loads. Distributing the pressure eliminates point loading conditions and bending moments that would otherwise be generated in the booster rocket structure during carrying. The chambers may be balloons distributed in rows and columns within the cradle or cylindrical chambers extending along a length of the cradle. The cradle may include a manifold communicating gas between chambers.

Rutan, Elbert L.↗
NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗
NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

Goals of NASA's Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to: (1) Reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS. (2) Enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. SLS Block 1 vehicle is being designed to carry 70 mT to LEO: (1) Uses two five-segment solid rocket boosters (SRBs) similar to the boosters that helped power the space shuttle to orbit. Evolved 130 mT payload class rocket requires an advanced booster with more thrust than any existing U.S. liquid-or solid-fueled boosters

Crocker, Andy↗
DOE OSTI2016

Design of the transfer line from booster to storage ring at 3 GeV

The Synchrotron Booster Ring accelerates the e-beam up to 3 GeV and particles are transported from booster to storage ring by transfer line. In this study, two options are considered, the first one is a long booster which shares the same tunnel with storage ring and the second one is a compact booster. As a result, two transfer line are designed based on booster options. The optical design is constrained by the e-beam Twiss parameters entering and leaving the transfer line. Twiss parameters in the extraction point of booster are used for the entrance of transfer line and are matched in the exit of transfer line to the injection point of the storage ring.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Design of 3 GeV booster ring lattice

The aim of this study is to design of a 3 GeV booster ring for the 3 GeV storage ring. Electrons are needed to be accelerated to 3.0 GeV from 0.15 GeV energy. In this frame, we studied on two options for booster ring; a compact booster and the booster that shares the same tunnel with the storage ring. The lattice type has been chosen FODO for both options, lattice parameters are calculated, sextupole magnets are used to decrease dynamic aperture problem and dynamic aperture calculations are also made with considering of the necessary conditions. After designing and calculating of the parameters, these designs have been compared with each other. In addition to this comparison, these booster design parameters have been compared with some world centers design parameters and the reliability of the booster design is seen. Beam optics, OPA and Elegant simulation programs have been used in the study calculations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2015

Output-Based Adaptive Meshing Applied to Space Launch System Booster Separation Analysis

This paper presents details of Computational Fluid Dynamic (CFD) simulations of the Space Launch System during solid-rocket booster separation using the Cart3D inviscid code with comparisons to Overflow viscous CFD results and a wind tunnel test performed at NASA Langley Research Center's Unitary PlanWind Tunnel. The Space Launch System (SLS) launch vehicle includes two solid-rocket boosters that burn out before the primary core stage and thus must be discarded during the ascent trajectory. The main challenges for creating an aerodynamic database for this separation event are the large number of basis variables (including orientation of the core, relative position and orientation of the boosters, and rocket thrust levels) and the complex flow caused by the booster separation motors. The solid-rocket boosters are modified from their form when used with the Space Shuttle Launch Vehicle, which has a rich flight history. However, the differences between the SLS core and the Space Shuttle External Tank result in the boosters separating with much narrower clearances, and so reducing aerodynamic uncertainty is necessary to clear the integrated system for flight. This paper discusses an approach that has been developed to analyze about 6000 wind tunnel simulations and 5000 flight vehicle simulations using Cart3D in adaptive-meshing mode. In addition, a discussion is presented of Overflow viscous CFD runs used for uncertainty quantification. Finally, the article presents lessons learned and improvements that will be implemented in future separation databases.

Booster↗
DOE OSTI2015

Early Beam Injection Scheme for the Fermilab Booster: A Path for Intensity Upgrade

Over the past decade, Fermilab has focused efforts on the intensity frontier physics and is committed to increase the average beam power delivered to the neutrino and muon programs substantially. Many upgrades to the existing injector accelerators, namely, the current 400 MeV LINAC and the Booster, are in progress under the Proton Improvement Plan (PIP). Proton Improvement Plan-II (PIP-II) proposes to replace the existing 400 MeV LINAC by a new 800 MeV LINAC, as an injector to the Booster which will increase Booster output power by nearly a factor of two from the PIP design value by the end of its completion. In any case, the Fermilab Booster is going to play a very significant role for nearly next two decades. In this context, I have developed and investigated a new beam injection scheme called "early injection scheme" (EIS) for the Booster with the goal to significantly increase the beam intensity output from the Booster thereby increasing the beam power to the HEP experiments even before PIP-II era. The scheme, if implemented, will also help improve the slip-stacking efficiency in the MI/RR. Here I present results from recent simulations, beam studies, current status and future plans for the new scheme.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

An increased extraction energy booster complex for the Jefferson Lab electron ion collider

The proposed Jefferson Lab Electron Ion Collider (JLE-IC) envisions an ion complex composed of an ion linac, two booster synchrotrons and a collider ring. The evolv-ing design of the JLEIC booster required an increase in the extraction energy of the booster from 8 to 12.1 GeV kinetic energy, necessitating two machines instead of one. The decision was also made to switch to warm magnets, thus increasing the total radius of the 8 GeV booster. With the second booster being the same size as the collider rings. In this work we present the new designs for JLE-IC?s Low Energy Booster (LEB) and High Energy Boost-er (HEB).

Nissen, Edith↗
DOE OSTI2025

Beam results for the new super-conducting booster at Jefferson Lab

The performance results of a new super-conducting booster for the CEBAF injector at Jefferson Lab, could be of interest for other similar electron injectors. A recent addition of this new booster has provided us the ability to achieve a more adiabatic acceleration and therefore an improvement to the beam dynamics and beam brightness. It has also simplified the design and operation of the section of the injector responsible for accelerating the electron beam from a few hundred keV to several MeV (typically 6.7 MeV). The addition of the new booster was part of an upgrade to the CEBAF injector to improve the beam quality for future physics experiments with high sensitivity to beam quality. The booster consists of two cavities: a 2-cell cavity followed by a 7-cell cavity. This combination allows for a wide range of input electron beam energies, from 130 keV to more than 300 keV. In fact, during the last year, the booster was successfully operated with 140,180, and 200 keV input beam energies as the electron gun was being upgraded. This paper describes the new booster, presents beam optics data results from different beam studies, commissioning, and the physics quality beam operation.

Accelerator Physics↗
DOE OSTI2016

Run 16 Tandem gold performance in the injectors and possible improvement with AGS type 6:3:1 bunch merge in the Booster

During Run 16 the Tandem was used as the Gold pre-injector for a brief time so that RHIC could continue running while EBIS was down for repairs. Given the time constraints, the setup was largely derived from the EBIS Au setup. The EBIS Au setup used a 4:2:1 bunch merge in the Booster and a 12:6:2 bunch merge in the AGS.1 This note will describe the Tandem Au setup and compare it to that used for EBIS Au. The bunch merge in the Booster for Tandem Au did not work well, and it seems likely that the performance would’ve been significantly better if it did. An AGS type 6:3:1 merge in the Booster is described which might improve matters.2 Somewhat speculative estimates for the AGS bunch intensity and emittance, if that merge were successful in reducing the Booster extraction emittance to EBIS Au levels, are also given for several potential setups. Using 6 Booster loads from the Tandem, the AGS bunch intensity at extraction reached about 2.5e9 ions with a longitudinal emittance (ε) of about 0.59 eV·s/n.3 Using 12 Booster loads from EBIS, the peak bunch intensity and ε was about 3.1e9 ions and 0.75 eV·s/n, respectively. A 6.4 sec supercycle was used for both at the time, but the Tandem Au supercycle (barring any potential issues with Tandem) could probably have been reduced to about 4.6 sec.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

Operation of the NSLS-II Injector with a Lower Booster Injection Energy

The NSLS-II injector consists of a 200 MeV linac and a 3 GeV full-energy booster synchrotron. The linac contains five traveling-wave S-band accelerating structures driven by two high-power klystrons. Optimization of the NSLS-II injector has continued since user operation started in October 2014. Beam losses have been minimized by the injector tuning and stabilization, and high level software has been developed to characterize the booster and injection parameters. However, due to the recently increased frequency of klystrons arcing which shortens the lifetime of the klystron, operation of the linac with lowered klystron output power would allow injection to be maintained with fewer trips and extended lifetime of klystrons. Apart from the energy difference, the low energy klystron operation is quite similar to the nominal 200 MeV operation. Injection trials were carried out with scaled magnet settings of the linac, linac-to- booster (LtB) transport line, and the booster. The beam was successfully injected into the booster on May 31, 2017 at the low energy mode of the 170 MeV LtB injection. Overall transfer efficiency from the linac to the storage ring is identical to the standard 200 MeV operation. The 170 MeV injection mode has been adopted in NSLS-II user operation ever since the beam study. In the most recent injector studies on June 28 and July 3, 2017, the booster injection energy was further decremented to the final target value of 100 MeV via applying the same method established in the 170 MeV operation. The ultimate value of 100 MeV is determined by the special requirement of operating the injector at single klystron while repairing the other klystron or with two klystrons with significantly reduced outputs for the purpose of maximizing klystron lifetimes.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Contextual modeling and Bayesian Optimization for Improved Injection at the Fermilab Booster

The Fermilab accelerator complex delivers high-intensity proton beams to serve the lab’s neutrino, muon, and fixed-target programs. A normal-conducting Linac accelerates H− beam to 400 MeV and injects into the Booster rapid cycling synchrotron via charge exchange, which accelerates protons to 8 GeV. Injection from the Linac into the Booster is a critical area for high-power performance of the Fermilab proton complex. The Booster is a high-intensity proton ring with extreme space-charge forces which necessitates precise control over the beam losses through the acceleration cycle. The main challenge for the reliability of Booster performance is compensating for drifting conditions in the beam from the Linac, which can drift daily in energy by up to O(1) MeV w.r.t. design. Drifts in Linac orbit and energy must be corrected to match the Booster, while simultaneously accommodating interdependent drifts in transverse and longitudinal beam quality. Operationally, compensation for these changes is addressed by manual tuning of the Linac output energy and/or Booster acceptance, which can be inefficient and time-consuming. This works describes contextual Bayesian Optimization for injection tuning that takes into account the state of Linac beam via information from instrumentation in the injection line (Beam position monitors (BPMs), beam loss monitors (BLMs), wire scanners for transverse profiles (WSs)), as well as RF cavity setting parameters from the Linac.

Sharankova, R. [Fermilab] (ORCID:000000027014593X)↗
NASA NTRS1974

A study of two statistical methods as applied to shuttle solid rocket booster expenditures

The state probability technique and the Monte Carlo technique are applied to finding shuttle solid rocket booster expenditure statistics. For a given attrition rate per launch, the probable number of boosters needed for a given mission of 440 launches is calculated. Several cases are considered, including the elimination of the booster after a maximum of 20 consecutive launches. Also considered is the case where the booster is composed of replaceable components with independent attrition rates. A simple cost analysis is carried out to indicate the number of boosters to build initially, depending on booster costs. Two statistical methods were applied in the analysis: (1) state probability method which consists of defining an appropriate state space for the outcome of the random trials, and (2) model simulation method or the Monte Carlo technique. It was found that the model simulation method was easier to formulate while the state probability method required less computing time and was more accurate.

Perlmutter, M.↗