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Ultrasonic frequency selection for aqueous fine cleaning

A study was conducted to evaluate ultrasonic cleaning systems for precision cleaning effectiveness for oxygen service hardware. This evaluation was specific for Rocketdyne Div. of Rockwell Aerospace alloys and machining soils. Machining lubricants and hydraulic fluid were applied as soils to standardized complex test specimens designed to simulate typical hardware. The study consisted of tests which included 20, 25, 30, 40, 50, and 65 kHz ultrasonic cleaning systems. Two size categories of cleaning systems were evaluated, 3- to 10-gal laboratory size tanks and 35- to 320-gal industrial size tanks. The system properties of cavitation; frequency vs. cleaning effectiveness; the two types of transducers; and the power level of the system vs. size of the cleaning tank were investigated. The data obtained from this study was used to select the ultrasonic tanks for the aqueous fine clean facility installed at Rocketdyne.

Becker, Joann F.↗

Characterization of Oribtal Debris via Hyper-Velocity Ground-Based Tests

Existing DoD and NASA satellite breakup models are based on a key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), which has supported many applications and matched on-orbit events involving older satellite designs reasonably well over the years. In order to update and improve the break-up models and the NASA Size Estimation Model (SEM) for events involving more modern satellite designs, the NASA Orbital Debris Program Office has worked in collaboration with the University of Florida to replicate a hypervelocity impact using a satellite built with modern-day spacecraft materials and construction techniques. The spacecraft, called DebriSat, was intended to be a representative of modern LEO satellites and all major designs decisions were reviewed and approved by subject matter experts at Aerospace Corporation. DebriSat is composed of 7 major subsystems including attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. All fragments down to 2 mm is size will be characterized via material, size, shape, bulk density, and the associated data will be stored in a database for multiple users to access. Laboratory radar and optical measurements will be performed on a subset of fragments to provide a better understanding of the data products from orbital debris acquired from ground-based radars and telescopes. The resulting data analysis from DebriSat will be used to update break-up models and develop the first optical SEM in conjunction with updates into the current NASA SEM. The characterization of the fragmentation will be discussed in the subsequent presentation.

Cowardin, H.↗

Guidelines for Design and Analysis of Large, Brittle Spacecraft Components

There were two related parts to this work. The first, conducted at The Aerospace Corporation was to develop and define methods for integrating the statistical theory of brittle strength with conventional finite element stress analysis, and to carry out a limited laboratory test program to illustrate the methods. The second part, separately funded at Aerojet Electronic Systems Division, was to create the finite element postprocessing program for integrating the statistical strength analysis with the structural analysis. The second part was monitored by Capt. Jeff McCann of USAF/SMC, as Special Study No.11, which authorized Aerojet to support Aerospace on this work requested by NASA. This second part is documented in Appendix A. The activity at Aerojet was guided by the Aerospace methods developed in the first part of this work. This joint work of Aerospace and Aerojet stemmed from prior related work for the Defense Support Program (DSP) Program Office, to qualify the DSP sensor main mirror and corrector lens for flight as part of a shuttle payload. These large brittle components of the DSP sensor are provided by Aerojet. This document defines rational methods for addressing the structural integrity and safety of large, brittle, payload components, which have low and variable tensile strength and can suddenly break or shatter. The methods are applicable to the evaluation and validation of such components, which, because of size and configuration restrictions, cannot be validated by direct proof test.

Robinson, E. Y.↗

High-voltage, high-power, solid-state remote power controllers for aerospace applications

Two general types of remote power controller (RPC) that combine the functions of a circuit breaker and a switch were developed for use in direct-current (dc) aerospace systems. Power-switching devices used in these designs are the relatively new gate-turnoff thyristor (GTO) and poweer metal-oxide-semiconductor field-effect transistors (MOSFET). The various RPC's can switch dc voltages to 1200 V and currents to 100 A. Seven different units were constructed and subjected to comprehensive laboratory and thermal vacuum testing. Two of these were dual units that switch both positive and negative voltages simultaneously. The RPC's using MOSFET's have slow turnon and turnoff times to limit voltage spiking from high di/dt. The GTO's have much faster transition times. All RPC's have programmable overload tripout and microsecond tripout for large overloads. The basic circuits developed can be used to build switchgear limited only by the ratings of the switching device used.

Sturman, J. C.↗

Vacuum Deployment and Testing of a 4-Quadrant Scalable Inflatable Solar Sail System

Solar sails reflect photons streaming from the sun and transfer momentum to the sail. The thrust, though small, is continuous and acts for the life of the mission without the need for propellant. Recent advances in materials and ultra-low mass gossamer structures have enabled a host of useful missions utilizing solar sail propulsion. The team of L'Garde, Jet Propulsion Laboratories, Ball Aerospace, and Langley Research Center, under the direction of the NASA In-Space Propulsion office, has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. The baseline design currently in development and testing was optimized around the 1 AU solar sentinel mission. Featuring inflatably deployed sub-T(sub g), rigidized beam components, the 10,000 sq m sail and support structure weighs only 47.5 kg, including margin, yielding an areal density of 4.8 g/sq m. Striped sail architecture, net/membrane sail design, and L'Garde's conical boom deployment technique allows scalability without high mass penalties. This same structural concept can be scaled to meet and exceed the requirements of a number of other useful NASA missions. This paper discusses the interim accomplishments of phase 3 of a 3-phase NASA program to advance the technology readiness level (TRL) of the solar sail system from 3 toward a technology readiness level of 6 in 2005. Under earlier phases of the program many test articles have been fabricated and tested successfully. Most notably an unprecedented 4-quadrant 10 m solar sail ground test article was fabricated, subjected to launch environment tests, and was successfully deployed under simulated space conditions at NASA Plum Brook s 30m vacuum facility. Phase 2 of the program has seen much development and testing of this design validating assumptions, mass estimates, and predicted mission scalability. Under Phase 3 a much larger 20 m square test article including subscale vane has been fabricated and tested. A 20 m system ambient deployment has been successfully conducted after enduring Delta-2 launch environment testing. The program will culminate in a vacuum deployment of a 20 m subscale test article at the NASA Glenn s Plum Brook 30 m vacuum test facility to bring the TRL level as close to 6 as possible in 1 g. This focused program will pave the way for a flight experiment of this highly efficient space propulsion technology.

Lichodziejewski, David↗

Reduction of Helicopter BVI Noise, Vibration, and Power Consumption Through Individual Blade Control

A wind tunnel test was conducted with a full-scale BO 105 helicopter rotor to evaluate the potential of open-loop individual blade control (IBC) to improve rotor performance, to reduce blade vortex interaction (BVI) noise, and to alleviate helicopter vibrations. The wind tunnel test was an international collaborative effort between NASA/U.S. Army AFDD, ZF Luftfahrttechnik, Eurocopter Deutschland, and the German Aerospace Laboratory (DLR) and was conducted under the auspices of the U.S./German MOU on Rotorcraft Aeromechanics. In this test the normal blade pitch links of the rotor were replaced by servo-actuators so that the pitch of each blade could be controlled independently of the other blades. The specially designed servoactuators and IBC control system were designed and manufactured by ZF Luftfahrttechnik, GmbH. The wind tunnel test was conducted in the 40- by 80-Foot Wind Tunnel at the NASA Ames Research Center. An extensive amount of measurement information was acquired for each IBC data point. These data include rotor performance, static and dynamic hub forces and moments, rotor loads, control loads, inboard and outboard blade pitch motion, and BVI noise data. The data indicated very significant (80 percent) simultaneous reductions in both BVI noise and hub vibrations could be obtained using multi-harmonic input at the critical descent (terminal approach) condition. The data also showed that performance improvements of up to 7 percent could be obtained using 2P input at high-speed forward flight conditions.

Jacklin, Stephen A.↗

New Approaches in Reusable Booster System Life Cycle Cost Modeling

This paper presents the results of a 2012 life cycle cost (LCC) study of hybrid Reusable Booster Systems (RBS) conducted by NASA Kennedy Space Center (KSC) and the Air Force Research Laboratory (AFRL). The work included the creation of a new cost estimating model and an LCC analysis, building on past work where applicable, but emphasizing the integration of new approaches in life cycle cost estimation. Specifically, the inclusion of industry processes/practices and indirect costs were a new and significant part of the analysis. The focus of LCC estimation has traditionally been from the perspective of technology, design characteristics, and related factors such as reliability. Technology has informed the cost related support to decision makers interested in risk and budget insight. This traditional emphasis on technology occurs even though it is well established that complex aerospace systems costs are mostly about indirect costs, with likely only partial influence in these indirect costs being due to the more visible technology products. Organizational considerations, processes/practices, and indirect costs are traditionally derived ("wrapped") only by relationship to tangible product characteristics. This traditional approach works well as long as it is understood that no significant changes, and by relation no significant improvements, are being pursued in the area of either the government acquisition or industry?s indirect costs. In this sense then, most launch systems cost models ignore most costs. The alternative was implemented in this LCC study, whereby the approach considered technology and process/practices in balance, with as much detail for one as the other. This RBS LCC study has avoided point-designs, for now, instead emphasizing exploring the trade-space of potential technology advances joined with potential process/practice advances. Given the range of decisions, and all their combinations, it was necessary to create a model of the original model and use genetic algorithms to explore results. A strong business case occurs when viable paths are identified for an affordable up-front investment, and these paths can credibly achieve affordable, responsive operations, characterized by smaller direct touch labor efforts at the wing level from flight to flight. The results supporting this approach, its potential, and its conclusions are presented here.

Zapata, Edgar↗

New Approaches in Reuseable Booster System Life Cycle Cost Modeling

This paper presents the results of a 2012 life cycle cost (LCC) study of hybrid Reusable Booster Systems (RBS) conducted by NASA Kennedy Space Center (KSC) and the Air Force Research Laboratory (AFRL). The work included the creation of a new cost estimating model and an LCC analysis, building on past work where applicable, but emphasizing the integration of new approaches in life cycle cost estimation. Specifically, the inclusion of industry processes/practices and indirect costs were a new and significant part of the analysis. The focus of LCC estimation has traditionally been from the perspective of technology, design characteristics, and related factors such as reliability. Technology has informed the cost related support to decision makers interested in risk and budget insight. This traditional emphasis on technology occurs even though it is well established that complex aerospace systems costs are mostly about indirect costs, with likely only partial influence in these indirect costs being due to the more visible technology products. Organizational considerations, processes/practices, and indirect costs are traditionally derived ("wrapped") only by relationship to tangible product characteristics. This traditional approach works well as long as it is understood that no significant changes, and by relation no significant improvements, are being pursued in the area of either the government acquisition or industry?s indirect costs. In this sense then, most launch systems cost models ignore most costs. The alternative was implemented in this LCC study, whereby the approach considered technology and process/practices in balance, with as much detail for one as the other. This RBS LCC study has avoided point-designs, for now, instead emphasizing exploring the trade-space of potential technology advances joined with potential process/practice advances. Given the range of decisions, and all their combinations, it was necessary to create a model of the original model and use genetic algorithms to explore results. A strong business case occurs when viable paths are identified for an affordable up-front investment, and these paths can credibly achieve affordable, responsive operations, characterized by smaller direct touch labor efforts at the wing level from flight to flight. The results supporting this approach, its potential, and its conclusions are presented here.

Zapata, Edgar↗

Kennedy's Biomedical Laboratory Makes Multi-Tasking Look Easy

If it is one thing that Florida has in abundance, it is sunshine and with that sunshine heat and humidity. For workers at the Kennedy Space Center that have to work outside in the heat and humidity, heat exhaustion/stroke is a real possibility. It might help people to know that Kennedy's Biomedical Laboratory has been testing some new Koolvests(Trademark) that can be worn underneath SCAPE suits. They have also been working on how to block out high noise levels; in fact, Don Doerr, chief of the Biomedical Lab, says, "The most enjoyable aspect is knowing that the Biomedical Lab and the skills of its employees have been used to support safe space flight, not only for the astronaut flight crew, but just as important for the ground processing personnel as well." The NASA Biomedical Laboratory has existed in the John F. Kennedy's Operations and Checkout Building since the Apollo Program. The primary mission of this laboratory has been the biomedical support to major, manned space programs that have included Apollo, Apollo-Soyuz, Skylab, and Shuttle. In this mission, the laboratory has been responsible in accomplishing much of the technical design, planning, provision, fabrication, and maintenance of flight and ground biomedical monitoring instrumentation. This includes the electronics in the launch flight suit and similar instrumentation systems in the spacecraft. (Note: The Lab checked out the system for STS-128 at Pad A using Firing room 4 and ground support equipment in the lab.) During Apollo, there were six engineers and ten technicians in the facility. This has evolved today to two NASA engineers and two NASA technicians, a Life Science Support contract physiologist and part-time support from an LSSC nurse and physician. Over the years, the lab has enjoyed collaboration with outside agencies and investigators. These have included on-site support to the Ames Research Center bed rest studies (seven years) and the European Space Agency studies in Toulouse, France (two years). The lab has also actively collaborated with the US Army Institute for Surgical Research, the USAF School of Aerospace Medicine, and the USN Naval Experimental Diving Unit. Because the lab often evaluates various forms of commercial-off-the-shelf life support equipment, the laboratory works closely with private companies, both domestic and foreign. The European companies seem to be more proactive and participatory with the advancement of personal protective equipment. Because these companies have viewed the space program's unique need for advanced forms of personal protective equipment, some have responded with new designs based on the prediction that these advances will soon find markets in the commercial sector. Using much of the same skills and equipment, the laboratory also addresses physiological testing of humans by supporting flight experiments and personnel involved with ground processing. While Johnson Space Center is primarily responsible for flight experiments, the Kennedy's Biomedical Lab provides the local support. However, as stated above, there are many challenges facing KSC workers that gain the attention of this lab in the measurement of the problem and the selection and testing of countermeasures. These include respiratory protection, whole body suits, hearing protection and heat stress, among many others.

Dunn, Carol Anne↗

Characterization of Orbital Debris Via Hyper-Velocity Ground-Based Tests

To replicate a hyper-velocity fragmentation event using modern-day spacecraft materials and construction techniques to better improve the existing DoD and NASA breakup models. DebriSat is intended to be representative of modern LEO satellites.Major design decisions were reviewed and approved by Aerospace subject matter experts from different disciplines. DebriSat includes 7 major subsystems. Attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. A key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), supporting the development of the DoD and NASA satellite breakup models was conducted at AEDC in 1992 .Breakup models based on SOCIT have supported many applications and matched on-orbit events reasonably well over the years.

Cowardin, Heather↗

DebriSat: The New Hypervelocity Impact Test for Satellite Breakup Fragment Characterization

To replicate a hyper-velocity fragmentation event using modern-day spacecraft materials and construction techniques to better improve the existing DoD and NASA breakup models: DebriSat is intended to be representative of modern LEO satellites. Major design decisions were reviewed and approved by Aerospace subject matter experts from different disciplines. DebriSat includes 7 major subsystems. Attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. center dotA key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), supporting the development of the DoD and NASA satellite breakup models was conducted at AEDC in 1992. Breakup models based on SOCIT have supported many applications and matched on-orbit events reasonably well over the years.

Cowardin, Heather↗

TPSAS-NF1676L-13013-DND

Description, capabilities and utilization of the NASA Langley Aerothermodynamics Laboratory (LAL) are presented. The LAL consists of four hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 10 (18 simulation), unit Reynolds number from 0.05 to 8 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of two different test gases (air and tetrafluoromethane, CF4), thereby making the facilities unique. The complex represents half of the conventional (as opposed to impulse) -type hypersonic wind tunnels operational in this country. LAL facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data for generating the flight aerodynamic databook and final design of the thermal protection system (TPS). Modifications and enhancements of LAL hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. The facilities are utilized to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs and were a major contributor to the Shuttle Columbia Accident Investigation, space shuttle Return-to-Flight program and Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project. The LAL has also contributed to the development of the Orion Crew Exploration Vehicle, Ares launch system, Mars Science Laboratory, Genesis Sample Return Capsule and supported DOD programs including HIFiRE, X-37, Falcon HTV-2 and X-51A.

John R Micol↗

Structural Analysis and Test Comparison of a 20-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive test program was implemented to advance the technology readiness level of the solar sail design. These tests consisted of solar sail component, subsystem, and sub-scale system ground tests that simulated the aspects of the space environment such as vacuum and thermal conditions. In July 2005, a 20-m four-quadrant solar sail system test article was tested in the NASA Glenn Research Center s Space Power Facility to measure its static and dynamic structural responses. Key to the maturation of solar sail technology is the development of validated finite element analysis (FEA) models that can be used for design and analysis of solar sails. A major objective of the program was to utilize the test data to validate the FEA models simulating the solar sail ground tests. The FEA software, ABAQUS, was used to perform the structural analyses to simulate the ground tests performed on the 20-m solar sail test article. This paper presents the details of the FEA modeling, the structural analyses simulating the ground tests, and a comparison of the pretest and post-test analysis predictions with the ground test results for the 20-m solar sail system test article. The structural responses that are compared in the paper include load-deflection curves and natural frequencies for the beam structural assembly and static shape, natural frequencies, and mode shapes for the solar sail membrane. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were unmeasured initial conditions in the test set-up.

Sleight, David W.↗

New Laboratory-Based Satellite Impact Experiments for Breakup Fragment Characterization

A consortium consisting of the NASA Orbital Debris Program Office, U.S. Air Force's Space and Missile Systems Center, the Aerospace Corporation, and University of Florida is planning a series of hypervelocity impact experiments on mockup targets at the U.S. Air Force's Arnold Engineering Development Complex (AEDC) in early 2014. The target for the first experiment resembles a rocket upper stage whereas the target for the second experiment represents a typical 60‐cm/50‐kg class payload that incorporates modern spacecraft materials and components as well as exterior wrap of multi‐layer insulation and three solar panels. The projectile is designed with the maximum mass that AEDC's Range G two‐stage light gas gun can accelerate to an impact speed of 7 km/sec. The impact energy is expected to be close to 15 MJ to ensure catastrophic destruction of the target after the impact. Low density foam panels are installed inside the target chamber to slow down and soft‐catch the fragments for post‐impact processing. Diagnostic instruments, such as x‐ray and high speed optical cameras, will also be used to record the breakup process. The main goal of this "DebriSat" project is to characterize the physical properties, including size, mass, shape, and density distributions, of orbital debris that would be generated by a hypervelocity collision involving an upper stage or a modern satellite in the low Earth orbit environment. In addition, representative fragments will be selected for laboratory optical and radar measurements to allow for better interpretation of data obtained by telescope and radar observations. This paper will provide a preliminary report of the impact results and the plans to process, measure, and analyze the fragments.

Liou, J.-C.↗

Investigation of Machine Design for Friction Stir Welding

The process of joining two pieces of metal together has not significantly changed over the last few decades. The basic idea used is to bring the pieces together and apply enough heat to melt the metal at the interface. The molten metal mixes and after cooling forms a strong joint. This process is called the fusion process. The most significant difference between the many fusion processes is how the heat is generated and applied. The Welding Institute (TWI), in Great Britain, has recently patented an innovative application of mechanical friction. TWI designed a tool and process called Friction Stir Welding (FSW) that uses friction to heat the metal to within a few hundred degrees Fahrenheit of melting, just to the point of being plastic-like. The tool then stirs the plasticized metal together forming a joint that has been shown to be as good or better than an equivalent fusion joint. The FSW process is well suited for the joining of the aluminum alloys used in the aerospace industry. The relatively low melting point of aluminum eliminates the requirements for exotic materials for pin tool design. The FSW process has been successfully used to join alloys such as 7075 which were before considered "unweldable", and aluminum-lithium 2195 which exhibits many problems when fusion welded. The objective this summer was to investigate the design of a FSW system that could take this process from the laboratory to the manufacturing floor. In particular, it was the goal of my NASA colleague to develop a concept for applying the FSW process to the manufacturing of aluminum cryogenic oxygen and hydrogen tanks, of the sort used to make the Shuttle External Tank.

Romine, Peter L.↗

Finite Element Analysis and Test Correlation of a 10-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA's future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from vibration tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

Structural Analysis of an Inflation-Deployed Solar Sail With Experimental Validation

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from structural dynamics tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

A Single Stage to Orbit Design for a Hybrid Mars Ascent

A Single Stage to Orbit (SSTO) hybrid propulsion system has been previously studied as an option for a conceptual Mars Ascent Vehicle (MAV). The hybrid motor uses a wax-based fuel developed specifically for this application, so it can take advantage of a single port design. The oxidizer is Mixed Oxides of Nitrogen (MON-25). Higher Nitric Oxide concentrations have been discussed in the past, however, the lower temperature capability is no longer needed. The MAV Payload Assembly (MPA), which would house the Orbiting Sample (OS) has changed substantially from previous iterations and has become more compact. Benefits of the hybrid option include its predicted low temperature behavior, high performance and ability to restart (enabling the SSTO). However, the hybrid technology remained at a relatively low Technology Readiness Level (TRL). In an attempt to increase the TRL, a technology development program has been underway for the past four years. The results of the technology development program are now being incorporated to an updated concept for a hybrid Mars Ascent Vehicle, with the eventual goal of informing a hybrid propulsion design that closes under the guidelines currently envisioned for a potential Mars Sample Return campaign. This paper focuses on the hybrid propulsion system design and the preliminary results from the first part of the FY19 technology development program (October 2018 to July 2019) and includes some results from a Preliminary Architecture Assessment (PAA) study. In the PAA, experts from all relevant subsystems (propulsion, avionics, GN&C, structures, thermal, etc.) are brought together to determine an updated vehicle design. The PAA is being run out of Marshall Space Flight Center (MSFC) in coordination with the Mars Sample Return study lead by the Jet Propulsion Laboratory (JPL). Currently, it is thought that the Mars Ascent Vehicle would be housed in a Sample Retrieval Lander (SRL), along with a fetch rover. The SRL would be responsible for several crucial functions on the MAV including heating, erection and providing the ignition signal. This paper will also outline the future testing and path forward through the rest of the fiscal year. This includes full scale testing at Whittinghill Aerospace, hypergolic additive testing at Purdue, evaluation of adding hypergolic additives to a full-scale grain. A hybrid fuel formulation has been updated with a reduced regression rate, which again was developed by Space Propulsion Group. This design will be used to determine the benefits of a hybrid versus solid propulsion system for a MAV, as they fit into the larger vision for a potential Mars Sample Return campaign.

Story, George↗