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A sound data base was established by analytically and experimentally generating basic regenerative cooling, combustion performance, combustion stability, and combustion chamber heat transfer parameters for LOX/HC propellants, with specific application to second generation orbit maneuvering and reaction control systems (OMS/RCS) for the Space Shuttle Orbiter.
A chemical vapor deposited tungsten with dispersed carbides was selected as the material for Space Shuttle Orbital Maneuvering and Reaction Control Systems check valve poppets and seats. The selection followed a NASA-sponsored prototype check valve development program utilizing the cutter-seal shell poppet concept. The poppet material is deposited as a coating approximately 0.9 mm thick and fabricated into a shell as a free standing body. The seat material is deposited as a coating 1.1 mm thick on a seat blank, and the cutter seal is machined in the coating. Module tests demonstrated that the material could be ground and lapped to very sharp edges and could cut through typical system contaminants without excessive damage to the sealing surfaces. The material was also determined to be unaffected by exposure to a strongly oxidizing storable propellant.
A program for analyzing the flowfield parameters in the neighborhood of the Space Shuttle Orbiter has been developed. The program uses the direct simulation Monte Carlo method, which is a completely probabilistic Monte Carlo technique capable of analyzing 3-dimensional steady or unsteady flow with prescribed internal and external boundary conditions. The freestream flux densities incident on the external flowfield boundaries are calculated from the drifting Maxwellian gas properties of the freestream. The flux entering the flowfield from the internal boundary is calculated from the outgassing flux density distribution over the Shuttle external surface and the prescribed discrete source fluxes. This technique produces a numerical flowfield solution which is the probabilistic equivalent of a complete solution of the time-dependent, 3-dimensional Boltzmann equation. Flowfield results are presented for the following configurations: (1) Shuttle angles of attack of 0 and 90 deg, (2) freestream density 10 to the 9th - 10 to the 11th per cu cm, (3) Shuttle outgassing flux density, and (4) operation of the aft downfiring vernier Reaction Control System (RCS) engine. Results are presented for column density distribution of outgassed and engine species and for the flux density of outgassed and engine species incident on the Shuttle bay and the windshield.
A conventional flight-test program, which slowly and cautiously approaches more severe flight conditions, was not possible with the Orbiter. On the first flight, the Orbiter entered the atmosphere at Mach 28 and decelerated through the Mach range. (The subsonic portion of flight was also flown by another orbiter vehicle during the Approach and Landing Test Program.) Certification for the first flight was achieved by an extensive wind-tunnel test and analysis program and by restricting the flight maneuvers severely. The initial flights of the orbiter were heavily instrumented for the purpose of obtaining accurate aerodynamic data. Even without maneuvers to excite the system, the first flight provided comparisons between flight and wind-tunnel-derived predicted data in the areas of aerodynamic performance, longitudinal trim, and reaction-control jet interaction. The aerodynamic performance comparisons are presented.
A preliminary characterization of Orbital Maneuvering System (OMS) and Reaction Control System (RCS) engine point designs over a range of thrust and chamber pressure for several hydrocarbon fuels is reported. OMS and RCS engine point designs were established in two phases comprising baseline and parametric designs. Interface pressures, performance and operating parameters, combustion chamber cooling and turboprop requirements, component weights and envelopes, and propellant conditioning requirements for liquid to vapor phase engine operation are defined.
Results of comparisons of predictions of aerodynamic performance, longitudinal trim, and reaction control jet interaction with data from the initial Shuttle flight are presented. The Shuttle's control surfaces are described, and it is noted that the flight plan contained no provisions for maneuvering capability tests. Wind tunnel testing totaling 35,000 hr were used to replace graduated flight testing, and calculations were made to allow for nonsimulated structural deformation, flowfield parameters, and profile drag. The goal was to desensitize the flight control system with respect to the aerodynamics by adding variations to the predictions. Lift/drag agreed well above Mach 1, while lower drag was encountered below Mach 1. Trim characteristics were predicted accurately between Mach 2-10, and less than satisfactorily outside that range. Discrepancies were also observed for jet interaction effects for the aft yaw jets at Mach numbers greater than 10.
The completed phases of a study evaluating LOX/hydrocarbon auxiliary propulsion system concepts for a second generation Space Shuttle Orbital Maneuvering Subsystem (OMS) and Reaction Control Subsystem (RCS) are presented. The results of the preliminary system evaluation phase are summarized, and efforts regarding the in-depth system evaluation phase are described. Ethanol and methane are considered to be the best fuel candidates as both are non-coking, non-corrosive, and offer high performance capability. Ethanol affords the highest dV and total impulse capability because of its high density-specific impulse product, while methane affords the lowest system wet weight when the system is sized for a fixed dV or total impulse requirement. The LOX/ethanol system allows the use of a simple non-insulated RCS feed system, and is the most attractive LOX/hydrocarbon OMS-RCS. Its operational costs would be substantially less than the current N2O4/MMH system.
Dynamic simulation of the Gravsat's attitude and translation control system is used to provide an upper bound for the fuel supply and test the feasibility of the preliminary design. A preliminary design is made for the disturbance compensation system (DISCOS) sensor, the thruster control laws, reaction wheel control laws, and the onboard state estimators. The sensor analysis and noise measurements show no problems in scaling the Triad navigation satellite sensor design up to meet the Gravsat requirements, except for proof mass center-of-mass offset. A promising technique is proposed to measure and eliminate this error. The covariance analysis confirms that a sophisticated post-flight data fit will be necessary to reconstruct a scientifically useful proof mass state. The DISCOS sensor will have to be continuously calibrated from the inflight data to achieve this reconstruction.
A comparison of wind tunnel test results with actual flight test data from the performance of the Orbiter Reaction Control System during the STS-1 and -2 flights is presented. Jet interaction phenomena were modeled analytically and a decision was made to develop a jet interaction scaling parameter from empirical measurements wherever possible. A number of different scaling parameters resulted, and errors bounds were determined for tunnel-to-tunnel differences, model to tunnel differences, balance accuracy, real gas effects, varying nozzle configurations, and angle of sideslip. Flight test data has concentrated on the lateral/directional jet interaction of the aft yaw jets, which operate almost continuously from entry down to Mach 1 conditions. A discussion of rolling moments, side forces, and results of usage of the aft pitch and roll jets indicates an underprediction of the side force and yawing moment and overprediction of pitch and roll jet effects.
Reaction control thrustor injector requires precisely machined orifices and slots. Tooling setup consists of rotary table, numerical control system and torque sensitive drill press. Components used to drill oxidizer orifices. Electric discharge machine drills fuel-feed orifices. Device automates production of identical parts so several are completed in less time than previously.
Orbiter Orbital Maneuver Subsystem (OMS) and Reaction Control Subsystem (RCS) tankage has proved to be highly successful in shuttle flights on-orbit propellant transfer tests were done. Tank qualification tests along with flight demonstrations were carried out future uses of storable propellants are cited.
A general 3-D combustor performance program developed by Garrett was extended to predict soot and NOx emissions. The soot formation and oxidation rates were computed by quasi-global models, taking into account the influence of turbulence. Radiation heat transfer was computed by the six-flux radiation mode. The radiation properties include the influence of CO2 and H2O in addition to soot. NOx emissions were computed from a global four-step hydrocarbon oxidation scheme and a set of rate-controlled reactions involving radicals and nitrogen oxides.
The results of orbital flight tests (OFT) of the Space Shuttle are reviewed, and modifications planned for upcoming operational flights are discussed. The performance of the solid rocket boosters, external tank, main engines, structural system, propulsion system, reaction control system, electric power system, heat rejection system, hydraulic system, avionics, and other systems is described and evaluated as generally highly satisfactory. Payload servicing and deployment were also successfully demonstrated by OFT. Additional facilities planned for the operational flights are briefly described, and improvements that will make the Challenger spacecraft lighter than Columbia, provide it with more thrust, and give it a larger payload are summarized. Some software modifications being introduced are also mentioned.
Flight data obtained from three Space Transportation System orbiter entries (STS-1, 2, and 3) are processed and analyzed to determine the roll interactions caused by the firing of the entry reaction control system (RCS). Comparisons between the flight-derived parameters and the predicted derivatives without interaction effects are made. The flight-derived RCS Plume flow-field interaction effects are independently deduced by direct integration of the incremental changes in the wing upper surface pressures induced by RCS side thruster firings. The separately obtained interaction effects are compared to the predicted values and the differences are discussed.
Following the discovery of intense vehicle glow of the Space Shuttle on the STS-3 mission, a new experiment to probe this phenomenon was developed and flown on the Shuttle STS-4 mission. A conventional camera was equipped with an objective transmission grating and several photographic exposures were taken of the Shuttle tail from the aft flight deck window. Vehicle glow surrounding Shuttle surfaces exposed to the ram direction was observed on a long (400 second) exposure. From analysis of the resulting spectral data it appears that the Shuttle glow has a diffuse spectral component in the region 6300 to 8000A. In addition, it has been possible to assess the spectral character of light emitted by the firing of a reaction control system thruster. Our data show that the light emitted from the thruster gases is confined to wavelengths shorter than 7200A.
A system capable of satisfying the accuracy and stability requirements dictated by Shuttle-borne payloads utilizing large optics has been under joint NASA/Sperry development. This device, denoted the Annular Suspension and Pointing System, employs a unique combination of conventional gimbals and magnetic bearing actuators, thereby providing for the complete isolation of the payload from its external environment, as well as for extremely accurate and stable pointing (equal to about 0.01 arcsec). This effort has been pursued through the fabrication and laboratory evaluation of engineering model hardware. Results from these tests have been instrumental in generating high fidelity computer simulations of this load isolation and precision pointing system, and in permitting confident predictions of the system's on-orbit performance. The applicability of this system to the Solar Optical Telescope mission has been examined using the computer simulation. The worst case pointing error predicted for this payload while subjected to vernier reaction control system thruster firings and crew motions aboard the Shuttle was approximately 0.006 arcsec.
A baseline gaseous and particulate environment of the Shuttle bay was developed based on the various measurements which were made during the first four flights of the Shuttle. The environment is described by the time dependent pressure, density, scattered molecular fluxes, the column densities and including the transient effects of water dumps, engine firings and opening and closing of the bay doors. The particulate conditions in the ambient and on surfaces were predicted as a function of the mission time based on the available data. This basic Shuttle environment when combined with the outgassing and the particulate contributions of the payloads, can provide a description of the environment of a payload in the Shuttle bay. As an example of this application, the environment of the Space Telescope in the bay, which may be representative of the environment of several payloads, was derived. Among the many findings obtained in the process of modeling the environment, one is that the payloads environment in the bay is not substantially different or more objectionable than the self-generated environment of a large payload or spacecraft. It is, however, more severe during ground facilities operations, the first 15 to 20 hours of the flight, during and for a short period after ater was dumped overboard, and the reaction control engines are being fired.
An experiment to investigate more versatile, lower cost surface tension propellant acquisition approaches for future satellite and spacecraft propellant tanks is designed to demonstrate a propellant off-load capability for a full-tank gallery surface tension device, such as that employed in the shuttle reaction control subsystem, and demonstrate a low-cost refillable trap concept that could be used in future orbit maneuver propulsion systems for multiple engine restarts. A Plexiglas test tank, movie camera and lights, auxiliary liquid accumulator, control electronics, battery pack, and associated valving and plumbing are used. The test liquid is Freon 113, dyed blue for color movie coverage. The fully loaded experiments weighs 106 pounds and is to be installed in a NASA five-cubic-foot flight canister. Vibration tests, acoustic tests, and high and low temperature tests were performed to quality the experiment for flight.