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At least 649 records · Page 36

Integrated Optimization of Mars Hybrid Solar-Electric/Chemical Propulsion Trajectories

NASA’s Human Exploration and Operation Mission Directorate is developing a reusable hybrid transportation architecture in which both chemical and solar-electric propulsion systems are used to deliver crew and cargo to the Martian sphere of influence. By combining chemical and solar-electric propulsions into a single spacecraft and applying each where it is the most effective, the hybrid architecture enables a series of Mars trajectories that are more fuel efficient than an all chemical propulsion architecture without significant increase to trip time. Solving the complex problem of low-thrust trajectory optimization coupled with the vehicle sizing requires development of an integrated trajectory analysis frame- work. Previous studies have utilized a more segmented optimization framework due to the limitation of the tools available. A new integrated optimization framework was recently developed to address the deficiencies of the previous methods that enables higher fidelity analysis to be performed and increases the efficiency of large design space explorations.

Chai, Patrick R.↗

Solar Power System Evaluated for the Human Exploration of Mars

The electric power system is a crucial element of any mission for the human exploration of the Martian surface. The bulk of the power generated will be delivered to crew life support systems, extravehicular activity suits, robotic vehicles, and predeployed in situ resource utilization (ISRU) equipment. In one mission scenario, before the crew departs for Mars, the ISRU plant operates for 435 days producing liquefied methane and oxygen for ascent-stage propellants and water for crew life support. About 200 days after ISRU production is completed, the crew arrives for a 500-day surface stay. In this scenario, the power system must operate for a total of 1130 days (equivalent to 1100 Martian "sols"), providing 400 MW-hr of energy to the ISRU plant and up to 18 kW of daytime user power. A photovoltaic power-generation system with regenerative fuel cell (RFC) energy storage has been under study at the NASA Glenn Research Center at Lewis Field. The conceptual power system is dominated by the 4000- m2 class photovoltaic array that is deployed orthogonally as four tent structures, each approximately 5 m on a side and 100-m long. The structures are composed of composite members deployed by an articulating mast, an inflatable boom, or rover vehicles, and are subsequently anchored to the ground. Array panels consist of thin polymer membranes with thin-film solar cells. The array is divided into eight independent electrical sections with solar cell strings operating at 600 V. Energy storage is provided by regenerative fuel cells based on hydrogen-oxygen proton exchange membrane technology. Hydrogen and oxygen reactants are stored in gaseous form at 3000 psi, and the water produced is stored at 14.7 psi. The fuel cell operating temperature is maintained by a 40-m2 deployable pumped-fluid loop radiator that uses water as the working fluid. The power management and distribution (PMAD) architecture features eight independent, regulated 600-Vdc channels. Power management and distribution power cables use various gauges of copper conductors with ethylene tetrafluoroethylene insulation. To assess power system design options and sizing, we developed a dedicated Fortran code to predict detailed power system performance and estimate system mass. This code also modeled the requisite Mars surface environments: solar insolation, Sun angles, dust storms, dust deposition, and thermal and ultraviolet radiation. Using this code, trade studies were performed to assess performance and mass sensitivities to power system design parameters (photovoltaic array geometry and orientation) and mission parameters (landing date and landing site latitude, terrain slope, and dust storm activity). Mission analysis cases were also run. Power results are shown in this graph for an analysis case with a September 1, 2012, landing date; 18.95 North latitude landing site; two seasonal dusts storms; and tent arrays. To meet user load requirements and the ISRU energy requirement, an 8-metric ton (MT) power system and 4000-m2 photovoltaic array area were required for the assumed advanced CuInS2 thin-film solar cell technology. In this figure, the top curve is the average daytime photovoltaic array power, the middle curve is average daytime user load power, and the bottom curve is nighttime power. At mission day 1, daytime user power exceeds 120 kW before falling off to 80 kW at the end of the mission. Throughout the mission, nighttime user power is set to the nighttime power requirement. In this analysis, "nighttime" is defined as the 13- to 15-hr period when array power output is below the daytime power requirement. During dust storms, power system capability falls off dramatically so that by mission day 900, a daily energy balance cannot be maintained. Under these conditions, the ISRU plant is placed in standby mode, and the regenerative fuel cell energy storage is gradually discharged to meet user loads.

Kerslake, Thomas W.↗

Results of Small-scale Solid Rocket Combustion Simulator testing at Marshall Space Flight Center

The Small-scale Solid Rocket Combustion Simulator (SSRCS) program was established at the Marshall Space Flight Center (MSFC), and used a government/industry team consisting of Hercules Aerospace Corporation, Aerotherm Corporation, United Technology Chemical Systems Division, Thiokol Corporation and MSFC personnel to study the feasibility of simulating the combustion species, temperatures and flow fields of a conventional solid rocket motor (SRM) with a versatile simulator system. The SSRCS design is based on hybrid rocket motor principles. The simulator uses a solid fuel and a gaseous oxidizer. Verification of the feasibility of a SSRCS system as a test bed was completed using flow field and system analyses, as well as empirical test data. A total of 27 hot firings of a subscale SSRCS motor were conducted at MSFC. Testing of the Small-scale SSRCS program was completed in October 1992. This paper, a compilation of reports from the above team members and additional analysis of the instrumentation results, will discuss the final results of the analyses and test programs.

Goldberg, Benjamin E.↗

Propellant vaporization as a criterion for rocket-engine design : experimental effect of fuel temperature on liquid-oxygen - heptane performance

Characteristic exhaust velocity of a 200-pound-thrust rocket engine was evaluated for fuel temperatures of -90 degrees, and 200 degrees f with a spray formed by two impinging heptane jets reacting in a highly atomized oxygen atmosphere. Tests covered a range of mixture ratios and chamber lengths. The characteristic exhaust-velocity efficiency increased 2 percent for a 290 degree f increase in fuel temperature. This increase in performance can be compared with that obtained by increasing chamber length by about 1/2 inch. The result agrees with the fuel-temperature effect predicted from an analysis based on droplet evaporation theory. Mixture ratio markedly affected characteristic exhaust velocity efficiency, but total flow rate and fuel temperature did not.

Heidmann, M F↗

Post-Test Analysis of a 10-Year Sodium Heat Pipe Life Test

High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 years) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described. Lessons learned and future life test plans are also discussed.

Rosenfeld, John H.↗

Ten Year Operating Test Results and Post-Test Analysis of a 1/10 Segment Stirling Sodium Heat Pipe, Phase III

High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 yr) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described.

Rosenfeld, John, H↗

The Successful Implementation of NASA Orbital Debris Requirements for the Retirement of TDRS-1

TDRS-1 was decommissioned on October 28th 2009 following more than 26 years of operation. The Grand Old Dame of the TDRSS constellation wa s launched aboard the maiden voyage of the Space Shuttle Challenger ( STS-6) in April 1983. TDRS-1 survived a malfunction of the Inertial Upper Stage eventually utilizing its own propulsion system to success fully reach its assigned station in geosynchronous orbit. The anomalo us beginning of the TDRS-1 mission was not without lasting consequenc es as the primary reaction control system (A-side) was completely di sabled with an apparent propellant leak and the secondary system (B-s ide) suffered damage to its negative roll thruster rendering the thru ster inoperable. Following decommissioning the challenge to completin g a successful TDRS-1 end-of-mission (EOM) was the implementation of the stringent orbital debris requirements of NPR 8715.6 with a parti ally functioning spacecraft not originally designed to meet those req uirements. The TDRS-1 EOM had three key goals: 1) removal of the spac ecraft from geosynchronous orbit; 2) depletion of the remaining prope llant; and 3) passivation of all other sources of energy storage or generation. The TDRS-1 EOM approach was one of minimizing risks while accomplishing the goals above. The orbit raising portion of EOM was accomplished using deltavelocity operations already proven during pre vious stationchanging maneuvers. The propellant depletion approach wa s necessarily more aggressive as over 20 hours of burn time was requ ired to deplete the remaining fuel. A novel approach utilizing a spin ning, thrusting, passively controlled spacecraft configuration was ut ilized to achieve reasonable burn durations that met schedule constra ints. This nonstandard configuration required careful analysis of ele ctrical, thermal, and communication subsystems. The configuration wa s thoroughly simulated prior to the start of operations and carefully characterized during the initial spin period and first burn. Passiva tion was by definition a unique operation not previously performed wi thin the TDRS 1-7 constellation. Use was made of a TDRS spacecraft si mulator to verify the operational procedure to mitigate risks and pro vide crew training. TDRS-1 orbit raising maneuvers commenced on June 5th 2010 and completed on June 14th with an apogee 370 km and a peri gee 352 km above geosynchronous altitude. 127 kg of propellant were e stimated to be remaining in the tanks at the completion of orbit rais ing. TDRS-1 was placed in its spinning orientation on June 16th and the first fuel depletion burn was performed the following day. A seri es of 10 depletion burns were performed ending on June 26th when both propellant tank pressures experienced dramatic drops. Final passivat ion was performed on June 27 th deactivating electronics, removing t he batteries from the bus and solar arrays, and disabling the space-t o-ground communications equipment. The Second TDRS Ground Terminal (S TGT) continued to open loop track TDRS-1 for several days attempting command reacquisition several times a day. All attempts were unsucce ssful confirming passivation was achieved. The TDRS-1 orbit at passiv ation was an orbital debris compliant 36,319 x 36,128 km in height. W hile differing spacecraft designs may preclude mimicking the exact TD RS-1 EOM approach, the TDRS-1 campaign serves to demonstrate that pr e-NPR 8715.6 designs can be made to meet the requirements resulting i n a reduced orbit debris environment for future missions

Mirczak, Walter↗

Dynamic analysis of an open-cycle gas-core nuclear rocket

Reactivity and flow disturbances were used to investigate the transient response of a conceptual open cycle gas core nuclear rocket engine. The disturbances were made with the system initially operating at its steady state design point. Results of the study show that the feedbacks associated with the propellant density and propellant temperature have a dominant effect on the response of the system. Furthermore, there appears to be a rather limited range of values of these propellant feedback coefficients for which the gas core nuclear rocket has a stable response. The system was rather insensitive to a fuel flow rate disturbance, whereas a similar disturbance in the propellant flow rate caused large changes in reactor power. For a similar disturbance in the propellant flow rate caused large changes in reactor power. For most reactivity and flow rate disturbances, the response showed oscillations of various intensity.

Turney, G. E.↗

Combustion hot section technology

The Turbine Engine Hot Section Technology Combustion Program is briefly described. The overall objective of the project is to develop and verify improved and more accurate analysis methods for increasing the ability to design with confidence the combustion system for advanced aircraft turbine engines. The approach is to first assess and evaluate existing combustor aerothermal analysis models by means of a contracted effort initiated during FY-82. The program also includes both analytical and experimental research efforts in the areas of aerothermal modeling and liner cyclic life. It is expected that the combustor model development effort will generate improved understanding in the areas of high pressure flame radiation characteristics, model numerical methods and solution schemes, complex geometrical boundary conditions, fuel spray - flow field interactions, combustion kinetics, flow and mixing of dilution jets, turbulence and heat transfer, and soot and carbon formation.

Ercegovic, D. B.↗

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗

Numerical Analysis of a Pulse Detonation Cross Flow Heat Load Experiment

A comparison between experimentally measured and numerically simulated, time-averaged, point heat transfer rates in a pulse detonation (PDE) engine is presented. The comparison includes measurements and calculations for heat transfer to a cylinder in crossflow and to the tube wall itself using a novel spool design. Measurements are obtained at several locations and under several operating conditions. The measured and computed results are shown to be in substantial agreement, thereby validating the modeling approach. The model, which is based in computational fluid dynamics (CFD) is then used to interpret the results. A preheating of the incoming fuel charge is predicted, which results in increased volumetric flow and subsequent overfilling. The effect is validated with additional measurements.

Paxson, Daniel E.↗

Preliminary Analysis of the Gradient Field Imploding Liner Fusion Propulsion Concept

The advancement of human deep space exploration requires the continued development of energetic in-space propulsion systems, advancing from current chemical engines to nuclear thermal rockets to future high energy concepts such as nuclear fusion. This paper presents the initial results of a NASA Innovative Advanced Concepts (NIAC) Phase I study funded to investigate the feasibility of a new pulsed fusion propulsion concept based on the rapid implosion of a fuel target injected at high velocity into a strong stationary magnetic field. The proposed concept takes advantage of the significant advances in terrestrial magneto-inertial fusion designs while attempting to mitigate the most common engineering impediments to in-space propulsion applications. A semi-analytic numerical model used to estimate target compression physics and energy release is presented, leading to estimates for engine performance. A preliminary vehicle design concept is outlined, and representative trajectory analyses for rapid Mars and Saturn missions are provided. The paper concludes with an overview of proposed next steps for theoretical and experimental validation of the concept.

Propulsion↗

Nonintrusive Flowmeter

The results of analytical and experimental work performed in the design, fabrication, and test of a prototype nonintrusive gaging system for use in monitoring the consumption of earth-storable fuels and oxidants in either a one-g or a zero-g environment are explained. The design specifications were those applicable to the reaction control system and to the orbital maneuvering system (OMS) fuel and oxidant on the space shuttle while in orbit. The major requirement was for the measurement of flow pulses with sufficient accuracy to provide a continuous knowledge of the fuel and oxidant remaining in the OMS system to within 1% or better. An ultrasonic frequency chirp technique was used having a high inherent rejection for signals traversing stray paths, and for random noise generated by the flowing liquid. A detailed analysis of the frequency chirp approach for two modes of operation (period and phase changes), including an error analysis are reported.

Greene, M. W.↗

Integrated digital/electric aircraft concepts study

The integrated digital/electrical aircraft (IDEA) is an aircraft concept which employs all electric secondary power systems and advanced digital flight control systems. After trade analysis, preferred systems were applied to the baseline configuration. An additional configuration, the alternate IDEA, was also considered. For this concept the design ground rules were relaxed in order to quantify additional synergistic benefits. It was proposed that an IDEA configuration and technical risks associated with the IDEA systems concepts be defined and the research and development required activities to reduce these risks be identified. The selected subsystems include: power generation, power distribution, actuators, environmental control system and flight controls systems. When the aircraft was resized, block fuel was predicted to decrease by 11.3 percent, with 7.9 percent decrease in direct operating cost. The alternate IDEA shows a further 3.4 percent reduction in block fuel and 3.1 percent reduction in direct operating cost.

Cronin, M. J.↗

High-speed research program systems analysis activities at Ames Research Center

The Ames Systems Analysis Branch has been working to support the High Speed Research Program (HSRP) for nearly one year. Both the status of methodology development activities and the results of studies are presented whether completed or underway. The discussion involves the conceptual design synthesis program used for High Speed Civil Transport (HSCT) studies, ACSYNT (aircraft synthesis), and enhancements that have been made especially for HSRP. Some results are presented for one study that has been completed and two that are underway. These are the advanced controls integration study, the fuel cost impact study, and the oblique wing configuration evaluation that is part of a larger innovative concepts study.

Kidwell, George H.↗

Hypergolic Propellant Safety Course

Under the sponsorship of the NASA Safety Training Center at the Johnson Space Center, a hypergolic propellant safety course has been developed. This is a 2-day course on guidelines for hypergolic propellant system design, materials selection, operations, storage, and transportation. Recognizing that numerous fuels and oxidizers can be hypergolic, this course is specific to the hydrazine family of fuels and nitrogen tetroxide and its variants. The objectives of the course are to enable the student to identify and evaluate the hazards of hypergolic propellants, and to understand the methods for controlling those hazards and responding to emergencies. The course covers properties and hazards of the hydrazines and oxidizers; design and operations in hypergolic facilities; materials selection for use in hypergol systems; storage vessels, piping, and component considerations; hypergol detection; fire fighting practices; operating and transportation principles and procedures; and emergency practices and considerations. A hazards analysis methodology is presented. Numerous references are provided and the applicability of certain regulatory documents is discussed. A brief overview of other propellants, including hydrogen peroxide, is given at the end of the course.

Rathgeber, Kurt A.↗

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗

Comparison of Two Multidisciplinary Optimization Strategies for Launch-Vehicle Design

The investigation focuses on development of a rapid multidisciplinary analysis and optimization capability for launch-vehicle design. Two multidisciplinary optimization strategies in which the analyses are integrated in different manners are implemented and evaluated for solution of a single-stage-to-orbit launch-vehicle design problem. Weights and sizing, propulsion, and trajectory issues are directly addressed in each optimization process. Additionally, the need to maintain a consistent vehicle model across the disciplines is discussed. Both solution strategies were shown to obtain similar solutions from two different starting points. These solutions suggests that a dual-fuel, single-stage-to-orbit vehicle with a dry weight of approximately 1.927 x 10(exp 5)lb, gross liftoff weight of 2.165 x 10(exp 6)lb, and length of 181 ft is attainable. A comparison of the two approaches demonstrates that treatment or disciplinary coupling has a direct effect on optimization convergence and the required computational effort. In comparison with the first solution strategy, which is of the general form typically used within the launch vehicle design community at present, the second optimization approach is shown to he 3-4 times more computationally efficient.

Braun, R. D.↗