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NASA NTRS2006

Structural Requirements for the Space Propulsion Engine Systems

In January 2004, the National Aeronautics and Space Administration (NASA) was given a vision for Space Exploration by President Bush, setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. As NASA gets ready to meet the vision set by President Bush, failures are not an option. Reliability of the propulsion engine systems will play an important role in establishing an overall safe and reliable operation of these new space systems. A new standard, NASA-STD-5012, Strength and Life Assessment for Space Propulsion System Engines, has been developed to provide structural requirements for assessment of the propulsion systems engine. This standard is a complement to the current NASA-wide standard NASA-STD-5001, Structural Design and Test Factors of Safety for Spaceflight Hardware, which excluded the requirement for the engine systems (rotatory structures) along with pressure vessels. As developed, this document builds on the heritage of the multiple industrial standards related to strength and life assessment of the structures. For assuring a safe and reliable operation of a product and/or mission, establishing a set of structural assessment requirements is a key ingredient. Hence, a concentrated effort was made to improve the requirements where there are known lessons learned during the design, test, and operation phases of the Space Shuttle Main Engine (SSME) and other engine development programs. Requirements delineated in this standard are also applicable for the reusable and/or human missions. It shall be noted that "reliability of a system cannot be tested and inspected but can only be achieved if it is first designed into a system." Hence, these strength and life assessment requirements for the space propulsion system engines shall be used along with other good engineering practices, requirements, and policies.

Aggarwal, Pravin K.↗

NASA NTRS2001

Robust Strategy for Rocket Engine Health Monitoring

Monitoring the health of rocket engine systems is essentially a two-phase process. The acquisition phase involves sensing physical conditions at selected locations, converting physical inputs to electrical signals, conditioning the signals as appropriate to establish scale or filter interference, and recording results in a form that is easy to interpret. The inference phase involves analysis of results from the acquisition phase, comparison of analysis results to established health measures, and assessment of health indications. A variety of analytical tools may be employed in the inference phase of health monitoring. These tools can be separated into three broad categories: statistical, rule based, and model based. Statistical methods can provide excellent comparative measures of engine operating health. They require well-characterized data from an ensemble of "typical" engines, or "golden" data from a specific test assumed to define the operating norm in order to establish reliable comparative measures. Statistical methods are generally suitable for real-time health monitoring because they do not deal with the physical complexities of engine operation. The utility of statistical methods in rocket engine health monitoring is hindered by practical limits on the quantity and quality of available data. This is due to the difficulty and high cost of data acquisition, the limited number of available test engines, and the problem of simulating flight conditions in ground test facilities. In addition, statistical methods incur a penalty for disregarding flow complexity and are therefore limited in their ability to define performance shift causality. Rule based methods infer the health state of the engine system based on comparison of individual measurements or combinations of measurements with defined health norms or rules. This does not mean that rule based methods are necessarily simple. Although binary yes-no health assessment can sometimes be established by relatively simple rules, the causality assignment needed for refined health monitoring often requires an exceptionally complex rule base involving complicated logical maps. Structuring the rule system to be clear and unambiguous can be difficult, and the expert input required to maintain a large logic network and associated rule base can be prohibitive.

Santi, L. Michael↗

NASA NTRS2013

Scale Model Thruster Acoustic Measurement Results

The Space Launch System (SLS) Scale Model Acoustic Test (SMAT) is a 5% scale representation of the SLS vehicle, mobile launcher, tower, and launch pad trench. The SLS launch propulsion system will be comprised of the Rocket Assisted Take-Off (RATO) motors representing the solid boosters and 4 Gas Hydrogen (GH2) thrusters representing the core engines. The GH2 thrusters were tested in a horizontal configuration in order to characterize their performance. In Phase 1, a single thruster was fired to determine the engine performance parameters necessary for scaling a single engine. A cluster configuration, consisting of the 4 thrusters, was tested in Phase 2 to integrate the system and determine their combined performance. Acoustic and overpressure data was collected during both test phases in order to characterize the system's acoustic performance. The results from the single thruster and 4- thuster system are discussed and compared.

Vargas, Magda↗

NASA NTRS1992

SSME improved characterization using highly instrumented engine test data

This paper discusses the analysis of Space Shuttle Main Engine (SSME) 3001 test data and its applications to steady-state models. Engine 3001 is a highly instrumented Phase II (current configuration) SSME that was tested at the Technology Test Bed facility located at Marshall Space Flight Center. A test series covering a carefully selected range of operating conditions was performed during 1991. An analysis of pressure, temperature and flowrate data was performed to evaluate the ability of steady-state models to accurately characterize the internal system of an SSME. Much of the special instrumentation was used to acquire data never before measured at the engine level prior to Engine 3001 testing. The analysis revealed that modifications are needed to improve model calculations of internal Hydrogen and Oxygen flows. Modifying steady-state models to more accurately simulate the internal flow system of an SSME should improve both engine performance evaluations and prediction capabilities.

Piekarski, Brian↗

NASA NTRS1975

Noise addendum experimental clean combustor program, phase 1

The development of advanced CTOL aircraft engines with reduced exhaust emissions is discussed. Combustor noise information provided during the basic emissions program and used to advantage in securing reduced levels of combustion noise is included. Results are presented of internal pressure transducer measurements made during the scheduled emissions test program on ten configurations involving variations of three basic combustor designs.

Sofrin, T. G.↗

NASA NTRS1993

FNAS/summer faculty fellowship research continuation program. Task 6: Integrated model development for liquid fueled rocket propulsion systems. Task 9: Aspects of model-based rocket engine condition monitoring and control

The objective of Phase I of this research effort was to develop an advanced mathematical-empirical model of SSME steady-state performance. Task 6 of Phase I is to develop component specific modification strategy for baseline case influence coefficient matrices. This report describes the background of SSME performance characteristics and provides a description of the control variable basis of three different gains models. The procedure used to establish influence coefficients for each of these three models is also described. Gains model analysis results are compared to Rocketdyne's power balance model (PBM).

Santi, L. Michael↗

NASA NTRS2015

Affordable Development and Demonstration of a Small NTR Engine and Stage: A Preliminary NASA, DOE, and Industry Assessment

The Nuclear Thermal Rocket (NTR) represents the next evolutionary step in cryogenic liquid rocket engines. Deriving its energy from fission of uranium-235 atoms contained within fuel elements that comprise the engine's reactor core, the NTR can generate high thrust at a specific impulse of approx. 900 seconds or more - twice that of today's best chemical rockets. In FY'11, as part of the AISP project, NASA proposed a Nuclear Thermal Propulsion (NTP) effort that envisioned two key activities - "Foundational Technology Development" followed by system-level "Technology Demonstrations". Five near-term NTP activities identified for Foundational Technology Development became the basis for the NCPS project started in FY'12 and funded by NASA's AES program. During Phase 1 (FY'12-14), the NCPS project was focused on (1) Recapturing fuel processing techniques and fabricating partial length "heritage" fuel elements for the two candidate fuel forms identified by NASA and the DOE - NERVA graphite "composite" and the uranium dioxide (UO2) in tungsten "cermet". The Phase 1 effort also included: (2) Engine Conceptual Design; (3) Mission Analysis and Requirements Definition; (4) Identification of Affordable Options for Ground Testing; and (5) Formulation of an Affordable and Sustainable NTP Development Strategy. During FY'14, a preliminary plan for DDT&E was outlined by GRC, the DOE and industry for NASA HQ that involved significant system-level demonstration projects that included GTD tests at the NNSS, followed by a FTD mission. To reduce development costs, the GTD and FTD tests use a small, low thrust (approx. 7.5 or 16.5 klbf) engine. Both engines use graphite composite fuel and a "common" fuel element design that is scalable to higher thrust (approx. 25 klbf) engines by increasing the number of elements in a larger diameter core that can produce greater thermal power output. To keep the FTD mission cost down, a simple "1-burn" lunar flyby mission was considered along with maximizing the use of existing and flight proven liquid rocket and stage hardware (e.g., from the RL10-B2 engine and Delta Cryogenic Second Stage) to further ensure affordability. This paper provides a preliminary NASA, DOE and industry assessment of what is required - the key DDT&E activities, development options, and the associated schedule - to affordably build, ground test and fly a small NTR engine and stage within a 10-year timeframe.

Nuclear rocket engines↗

NASA NTRS1998

Injector Design Tool Improvements: User's manual for FDNS V.4.5

The major emphasis of the current effort is in the development and validation of an efficient parallel machine computational model, based on the FDNS code, to analyze the fluid dynamics of a wide variety of liquid jet configurations for general liquid rocket engine injection system applications. This model includes physical models for droplet atomization, breakup/coalescence, evaporation, turbulence mixing and gas-phase combustion. Benchmark validation cases for liquid rocket engine chamber combustion conditions will be performed for model validation purpose. Test cases may include shear coaxial, swirl coaxial and impinging injection systems with combinations LOXIH2 or LOXISP-1 propellant injector elements used in rocket engine designs. As a final goal of this project, a well tested parallel CFD performance methodology together with a user's operation description in a final technical report will be reported at the end of the proposed research effort.

Chen, Yen-Sen↗

NASA NTRS2005

Systems Engineering in NASA's R&TD Programs

Systems engineering is largely the analysis and planning that support the design, development, and operation of systems. The most common application of systems engineering is in guiding systems development projects that use a phased process of requirements, specifications, design, and development. This paper investigates how systems engineering techniques should be applied in research and technology development programs for advanced space systems. These programs should include anticipatory engineering of future space flight systems and a project portfolio selection process, as well as systems engineering for multiple development projects.

Jones, Harry↗

NASA NTRS1993

NTP comparison process

The systems engineering process for the concept definition phase of the program involves requirements definition, system definition, and consistent concept definition. The requirements definition process involves obtaining a complete understanding of the system requirements based on customer needs, mission scenarios, and nuclear thermal propulsion (NTP) operating characteristics. A system functional analysis is performed to provide a comprehensive traceability and verification of top-level requirements down to detailed system specifications and provides significant insight into the measures of system effectiveness to be utilized in system evaluation. The second key element in the process is the definition of system concepts to meet the requirements. This part of the process involves engine system and reactor contractor teams to develop alternative NTP system concepts that can be evaluated against specific attributes, as well as a reference configuration against which to compare system benefits and merits. Quality function deployment (QFD), as an excellent tool within Total Quality Management (TQM) techniques, can provide the required structure and provide a link to the voice of the customer in establishing critical system qualities and their relationships. The third element of the process is the consistent performance comparison. The comparison process involves validating developed concept data and quantifying system merits through analysis, computer modeling, simulation, and rapid prototyping of the proposed high risk NTP subsystems. The maximum amount possible of quantitative data will be developed and/or validated to be utilized in the QFD evaluation matrix. If upon evaluation of a new concept or its associated subsystems determine to have substantial merit, those features will be incorporated into the reference configuration for subsequent system definition and comparison efforts.

Corban, Robert↗

NASA NTRS2011

Liquid Oxygen Liquid Acquisition Device Bubble Point Tests with High Pressure LOX at Elevated Temperatures

When transferring propellant in space, it is most efficient to transfer single phase liquid from a propellant tank to an engine. In earth s gravity field or under acceleration, propellant transfer is fairly simple. However, in low gravity, withdrawing single-phase fluid becomes a challenge. A variety of propellant management devices (PMD) are used to ensure single-phase flow. One type of PMD, a liquid acquisition device (LAD) takes advantage of capillary flow and surface tension to acquire liquid. The present work reports on testing with liquid oxygen (LOX) at elevated pressures (and thus temperatures) (maximum pressure 1724 kPa and maximum temperature 122K) as part of NASA s continuing cryogenic LAD development program. These tests evaluate LAD performance for LOX stored in higher pressure vessels that may be used in propellant systems using pressure fed engines. Test data shows a significant drop in LAD bubble point values at higher liquid temperatures, consistent with lower liquid surface tension at those temperatures. Test data also indicates that there are no first order effects of helium solubility in LOX on LAD bubble point prediction. Test results here extend the range of data for LOX fluid conditions, and provide insight into factors affecting predicting LAD bubble point pressures.

Jurns, John M.↗

NASA NTRS1991

F-15 composite engine access door

This paper presents a summary of the successfully concluded phase 1 of the two-phase Design and Manufacture of Advanced Thermoplastic Structures (DMATS) program. It addresses the design, manufacture, and validation testing of a thermoplastic F-15E forward engine access door and includes lessons learned during the concurrent product and process design development phases of the program.

Ramkumar, Ramaswamy L.↗

NASA NTRS1993

Optimization in the systems engineering process

The essential elements of the design process consist of the mission definition phase that provides the system requirements, the conceptual design, the preliminary design and finally the detailed design. Mission definition is performed largely by operations analysts in conjunction with the customer. The result of their study is handed off to the systems engineers for documentation as the systems requirements. The document that provides these requirements is the basis for the further design work of the design engineers at the Lockheed-Georgia Company. The design phase actually begins with conceptual design, which is generally conducted by a small group of engineers using multidisciplinary design programs. Because of the complexity of the design problem, the analyses are relatively simple and generally dependent on parametric analyses of the configuration. The result of this phase is a baseline configuration from which preliminary design may be initiated.

Lemmerman, Loren A.↗

NASA NTRS2012

Space Environments and Spacecraft Effects Concept: Transitioning Research to Operations and Applications

The National Aeronautics and Space Administration (NASA) is embarking on a course to expand human presence beyond Low Earth Orbit (LEO) while expanding its mission to explore the solar system. Destinations such as Near Earth Asteroids (NEA), Mars and its moons, and the outer planets are but a few of the mission targets. NASA has established numerous organizations specializing in specific space environments disciplines that will serve to enable these missions. To complement these existing discipline organizations, a concept is presented focusing on the development of a space environment and spacecraft effects organization. This includes space climate, space weather, natural and induced space environments, and effects on spacecraft materials and systems. This space environment and spacecraft effects organization would be comprised of Technical Working Groups (TWG) focusing on, for example: a) Charged Particles (CP), b) Space Environmental Effects (SEE), and c) Interplanetary and Extraterrestrial Environments (IEE). These technical working groups will generate products and provide knowledge supporting four functional areas: design environments, environment effects, operational support, and programmatic support. The four functional areas align with phases in the program mission lifecycle and are briefly described below. Design environments are used primarily in the mission concept and design phases of a program. Environment effects focuses on the material, component, sub-system and system-level selection and the testing to verify design and operational performance. Operational support provides products based on real time or near real time space weather observations to mission operators to aid in real time and near-term decision-making. The programmatic support function maintains an interface with the numerous programs within NASA and other federal agencies to ensure that communications are well established and the needs of the programs are being met. The programmatic support function also includes working in coordination with the program in anomaly resolution and generation of lesson learned documentation. The goal of this space environment and spacecraft effects organization is to develop decision-making tools and engineering products to support the mission phases of mission concept through operations by focusing on transitioning research to application. Products generated by this space environments and spacecraft effects organization are suitable for use in anomaly investigations. This paper will describe the organizational structure for this space environments and spacecraft effects organization, and outline the scope of conceptual TWG's and their relationship to the functional areas.

Edwards, D. L.↗

NASA NTRS2000

Use of Concurrent Engineering in Space Mission Design

In recent years, conceptual-phase (proposal level) design of space missions has been improved considerably. Team structures, tool linkage, specialized facilities known as design centers and scripted processes have been demonstrated to cut proposal-level engineering design time from a few months to a few weeks.

concurent Engineering-Space Mission Design↗

NASA NTRS2019

Transfer-Function Determination for Infinite-Tube-Probe Pressure Transducers with Application to Turbofan Core/Combustor Noise

Turbofan hot-section unsteady pressure measurements are complicated by environmental limitations of current-generation sensors. Accurate direct measurements are normally not possible and engine-external measurement techniques, using sufficiently long sense lines, are utilized instead. Remote measurement comes at a cost, however, as it introduces a magnitude reduction within the line as well as a phase lag relative to the desired engine-internal measurement location. Determination, or validation, of a transfer function relating the engine internal pressure to the observed remote value is necessary. Transfer functions are examined for various configurations of the so-called infinite-tube-probe arrangement in order to optimize measurement performance. The experimental setup uses a normal-incidence tube that ordinarily is utilized for impedance eduction. Here, its downstream end instead is made up of a hard-wall termination instrumented with a flush-mounted microphone and a Kulite pressure transducer as well as a sense line connection. This allows the remote and direct measurements to be related under controlled conditions. Transfer-function measurements are presented and compared to predictions for several parametric variations.

Combustor Noise↗

NASA NTRS2019

Transfer-Function Determination for Infinite-Tube-Probe Pressure Transducers with Application to Turbofan Core/Combuster Noise

Turbomachinery Noise↗

NASA NTRS1986

An investigation of selected on-orbit satellite servicing issues

The results of three separate investigations performed by Science Applications International Corporation (SAIC) between August 1985 and October 1986 as the second phase of the two-phase Satellite Services System Program Plan contract for the Engineering Directorate of the Lyndon B. Johnson Space Center are discussed. The objectives of the first phase of this contract (reported in SAIC-85/1762) were to determine the potential for servicing a diverse range of spacecraft from the Space Shuttle Orbiter and to assess NASA's role as the catalyst in enabling routine on-orbit servicing. The second area of investigation was prompted by the need to understand satellite servicing requirements in the far term (1995 to 2010) and how results from the first phase of this contract could support these requirements. The mission model developed during the first phase was extended using new data and information from studies which address the later time period. The third area of investigation looked at a new servicing mode which had not been studied previously. This mode involves the on-orbit exchange of very large modules with masses greater than approximately 9,000 kilograms and/or lengths greater than approximately nine meters. The viewgraphs used for the final briefing for each of the three investigations, as presented to NASA are given.

Hoffman, Stephen J.↗