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NASA NTRS1973

Correlation of ion and beam current densities in Kaufman thrusters.

In the absence of direct impingement erosion, electrostatic thruster accelerator grid lifetime is defined by the charge exchange erosion that occurs at peak values of the ion beam current density. In order to maximize the thrust from an engine with a specified grid lifetime, the ion beam current density profile should therefore be as flat as possible. Knauer (1970) has suggested this can be achieved by establishing a radial plasma uniformity within the thruster discharge chamber; his tests with the radial field thruster provide an example of uniform plasma properties within the chamber and a flat ion beam profile occurring together. It is shown that, in particular, the ion density profile within the chamber determines the beam current density profile, and that a uniform ion density profile at the screen grid end of the discharge chamber should lead to a flat beam current density profile.

Wilbur, P. J.↗

NASA NTRS1957

Rocket thrust variation with foamed liquid propellants

An analysis is presented on a method for varying rocket thrust by varying the bulk density of the propellants. This density variation was accomplished by uniformly dispersing an inert, insoluble gas in the liquid propellants. Only qualitative agreement with theory was obtained from preliminary experiments with a 1000-pound-thrust ammonia - nitric acid rocket engine; the required experimental gas-flow rates were two to six times greater than those predicted by theory. It was demonstrated, however, that this method of rocket-thrust variation is feasible.

Morrell, G↗

NASA NTRS2013

UltraSail CubeSat Solar Sail Flight Experiment

UltraSail is a next-generation, highrisk, high-payoff sail system for the launch, deployment, stabilization, and control of very large (km2 class) solar sails enabling high payload mass fractions for interplanetary and deep space spacecraft. UltraSail is a non-traditional approach to propulsion technology achieved by combining propulsion and control systems developed for formation- flying microsatellites with an innovative solar sail architecture to achieve controllable sail areas approaching 1 km2, sail subsystem area densities approaching 1 g/m2, and thrust levels many times those of ion thrusters used for comparable deep space missions. UltraSail can achieve outer planetary rendezvous, a deep-space capability now reserved for high-mass nuclear and chemical systems. There is a twofold rationale behind the UltraSail concept for advanced solar sail systems. The first is that sail-andboom systems are inherently size-limited. The boom mass must be kept small, and column buckling limits the boom length to a few hundred meters. By eliminating the boom, UltraSail not only offers larger sail area, but also lower areal density, allowing larger payloads and shorter mission transit times. The second rationale for UltraSail is that sail films present deployment handling difficulties as the film thickness approaches one micrometer. The square sail requires that the film be folded in two directions for launch, and similarly unfolded for deployment. The film is stressed at the intersection of two folds, and this stress varies inversely with the film thickness. This stress can cause the film to yield, forming a permanent crease, or worse, to perforate. By rolling the film as UltraSail does, creases are prevented. Because the film is so thin, the roll thickness is small. Dynamic structural analysis of UltraSail coupled with dynamic control analysis shows that the system can be designed to eliminate longitudinal torsional waves created while controlling the pitch of the blades, while using solar photon pressure to slew the spin axis. Vacuum tests have also verified that electrostatic and molecular adhesion forces can substantially be eliminated by making the film electrically conductive, reducing the peel force of the film off the storage roll to levels of 100s of micro-N. The innovation demonstrated the capability of deploying a six-micron aluminum- coated film from a reel through a slit in vacuum. The innovation also demonstrated a spin-stabilized method for deploying a long reel of solar sail film using solar pressure to spin-up and orbit raise the satellite, and also a gravity gradient method for deploying a long reel of solar sail film using solar pressure to orbit raise the satellite. The solar sail mass fraction of 25% is consistent with high specific impulse ion systems, but without the added weight and cost of a power source and processing unit. The large sail area, coupled with low film density, is giving UltraSail a high payload fraction. The UltraSail deployment scheme unrolls a micrometerscale reflection-coated polyimide film from a storage mandrel to a maximum length of several kilometers with the aid of a blade tip satellite.

Carroll, David↗

NASA NTRS1980

Low-thrust vehicles concept studies

Low thrust chemical (hydrogen-oxygen) propulsion systems configured specifically for low acceleration orbit transfer of large space systems were studied in order to provide the required additional data to better compare new, low thrust chemical propulsion systems with other propulsion approaches such as advanced electric systems. Study results indicate that it is cost-effective and least risk to combine the low thrust OTV and stowed spacecraft in a single 65 K shuttle. Mission analysis indicates that there are 25 such missions, starting in 1987. Multiple shuttles (LSS in one, OTV in another) result in a 20% increase in LSS (SBR) diameter over single shuttle launches. Synthesis and optimization of the LSS characteristics and OTV capability resulted in determination of the optimum thrust-to-weight and thrust level. For the space based radar with radial truss arms (center thrust application), the optimum thrust-to-weight (maximum) is 0.1, giving a thrust of 2000 lb. For the annular truss (edge-on thrust application) the structure is not as sensitive, and thrust of 1000 lb appears optimum. For the geoplatform, optimum T/W is .15 (3000 lb thrust). The effects of LSS structure material, weight distribution, and unit area density were evaluated, as were the OTV engine thrust transient and number of burns.

Ketchum, W. J.↗

NASA NTRS2003

Advanced Propulsion Research Interest in Materials for Propulsion

This viewgraph presentation provides an overview of material science and technology in the area of propulsion energetics. The authors note that conventional propulsion systems are near peak performance and further refinements in manufacturing, engineering design and materials will only provide incremental increases in performance. Energetic propulsion technologies could potential solve the problems of energy storage density and energy-to-thrust conversion efficiency. Topics considered include: the limits of thermal propulsion systems, the need for energetic propulsion research, emerging energetic propulsion technologies, materials research needed for advanced propulsion, and potential research opportunities.

Cole, John↗

NASA NTRS2003

NASA/MSFC Interest in Advanced Propulsion and Power Technologies

This viewgraph representation provides an overview of research being conducted at NASA's Marshall Space Flight Center. Conventional propulsion systems are at near peak performance levels but will not enable the science and exploration deep space missions NASA envisions. Energetic propulsion technologies can make these missions possible but only if the fundamental problems of energy storage density and energy to energy thrust conversion efficiency are solved. Topics covered include: research rationale, limits of thermal propulsion systems, need for propulsion energetics research, emerging energetic propulsion technologies, and potential research opportunities.

Cole, John W.↗

NASA NTRS2011

Propulsion Physics Under the Changing Density Field Model

To grow as a space faring race, future spaceflight systems will requires new propulsion physics. Specifically a propulsion physics model that does not require mass ejection without limiting the high thrust necessary to accelerate within or beyond our solar system and return within a normal work period or lifetime. In 2004 Khoury and Weltman produced a density dependent cosmology theory they called Chameleon Cosmology, as at its nature, it is hidden within known physics. This theory represents a scalar field within and about an object, even in the vacuum. Whereby, these scalar fields can be viewed as vacuum energy fields with definable densities that permeate all matter; having implications to dark matter/energy with universe acceleration properties; implying a new force mechanism for propulsion physics. Using Chameleon Cosmology, the author has developed a new propulsion physics model, called the Changing Density Field (CDF) Model. This model relates to density changes in these density fields, where the density field density changes are related to the acceleration of matter within an object. These density changes in turn change how an object couples to the surrounding density fields. Whereby, thrust is achieved by causing a differential in the coupling to these density fields about an object. Since the model indicates that the density of the density field in an object can be changed by internal mass acceleration, even without exhausting mass, the CDF model implies a new propellant-less propulsion physics model

Robertson, Glen A.↗

NASA NTRS2005

UltraSail - Ultra-Lightweight Solar Sail Concept

UltraSail is a next-generation high-risk, high-payoff sail system for the launch, deployment, stabilization and control of very large (sq km class) solar sails enabling high payload mass fractions for high (Delta)V. Ultrasail is an innovative, non-traditional approach to propulsion technology achieved by combining propulsion and control systems developed for formation-flying micro-satellites with an innovative solar sail architecture to achieve controllable sail areas approaching 1 sq km, sail subsystem area densities approaching 1 g/sq m, and thrust levels many times those of ion thrusters used for comparable deep space missions. Ultrasail can achieve outer planetary rendezvous, a deep space capability now reserved for high-mass nuclear and chemical systems. One of the primary innovations is the near-elimination of sail supporting structures by attaching each blade tip to a formation-flying micro-satellite which deploys the sail, and then articulates the sail to provide attitude control, including spin stabilization and precession of the spin axis. These tip micro-satellites are controlled by 3-axis micro-thruster propulsion and an on-board metrology system. It is shown that an optimum spin rate exists which maximizes payload mass.

Burton, Rodney L.↗

NASA NTRS2019

Small Launch Vehicle Sizing Analysis with Solid Rocket Examples

Small launch vehicles are governed by the same physics as large launch vehicles of course, but due to their small size, some aspects and sensitivities become more important and others less. This paper shows semi-empirical correlations to quantify dry mass fraction for both stage and whole vehicle optimization: mass fraction due to density, mass fraction due to thrust-to-weight, and mass fraction due to size reduction. For single-stage optimizations, a stage performance requirement can be met by a locus of mass fraction vs. specific impulse. Based on the above correlations, this alone can recommend a solid or liquid rocket for a stage. Rocket designs of similar technology levels are compared, focusing on where stages become less mass-efficient as they get smaller. The Mars Ascent Vehicle is shown to exemplify a trade between a two-stage solids vehicle and a one- or two-stage liquids vehicle.

Kibbey, Tim↗

NASA NTRS2019

Small Launch Vehicle Sizing Analysis With Solid Rocket Examples

Kibbey, Tim↗

NASA NTRS2017

High-Power Performance of a 100-kW Class Nested Hall Thruster

Operations of a three-channel 100-kW class nested Hall thruster at total power levels from 5 to 102 kW and discharge currents from 16 to 247 A were successful. The thruster was operated in all seven available channel combinations at discharge voltages of 300, 400, and 500 V and at current densities that were 0.60 and 0.95 of the nominal value. Additional test points were also collected at 1.20 the nominal current density. The thruster was throttled through a total of forty-six unique operating conditions. At each condition, thruster performance was measured using a high-power thrust stand designed to measure up to 8 N of thrust. From these thrust measurements, specific impulse and efficiency were calculated. All seven channel combinations showed similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.42 N at 99 kW, 400 V discharge voltage. Total efficiency values 0.54 to 0.67, and total specific impulse ranged from 1800 seconds to 2650 seconds. Discharge current oscillations were also measured. Generally these oscillations increased on the inner and middle channels during multi-channel mode but stayed roughly a constant fraction of the channel discharge current for the outer channel in both single- and multi-channel operation. We also found that the thrust of the three channels firing together was not significantly higher than the sum of each channel _ring individually, a result that differs from what was found previously for nested Hall thrusters.

Hall, Scott J.↗

NASA NTRS2003

Microfabricated Liquid Rocket Motors

Under NASA Glenn Research Center sponsorship, MIT has developed the concept of micromachined, bipropellant, liquid rocket engines. This is potentially a breakthrough technology changing the cost-performance tradeoffs for small propulsion systems, enabling new applications, and redefining the meaning of the term low-cost-access-to-space. With this NASA support, a liquid-cooled, gaseous propellant version of the thrust chamber and nozzle was designed, built, and tested as a first step. DARPA is currently funding MIT to demonstrate turbopumps and controls. The work performed herein was the second year of a proposed three-year effort to develop the technology and demonstrate very high power density, regeneratively cooled, liquid bipropellant rocket engine thrust chamber and nozzles. When combined with the DARPA turbopumps and controls, this work would enable the design and demonstration of a complete rocket propulsion system. The original MIT-NASA concept used liquid oxygen-ethanol propellants. The military applications important to DARPA imply that storable liquid propellants are needed. Thus, MIT examined various storable propellant combinations including N2O4 and hydrazine, and H2O2 and various hydrocarbons. The latter are preferred since they do not have the toxicity of N2O4 and hydrazine. In reflection of the newfound interest in H2O2, it is once again in production and available commercially. A critical issue for the microrocket engine concept is cooling of the walls in a regenerative design. This is even more important at microscale than for large engines due to cube-square scaling considerations. Furthermore, the coolant behavior of rocket propellants has not been characterized at microscale. Therefore, MIT designed and constructed an apparatus expressly for this purpose. The report details measurements of two candidate microrocket fuels, JP-7 and JP-10.

Epstein, Alan H.↗

NASA NTRS1976

Swirling-flow jet noise suppressors for aircraft engines

Experimental investigations of the effects of swirling the jet exhausts of small turbofan and turbojet engines have indicated significant progress towards predicting and attaining substantial jet noise abatement with minimum thrust losses in large aircraft engines. Systematic variations of the important swirl vane and swirling flow parameters were conducted to determine their effects on jet noise reduction and engine performance. Since swirling flow becomes more effective in reducing jet noise as the density and temperature gradients increase, the significant trends in noise reduction and engine performance that were established by these parametric studies could be projected into potentially greater reductions of sound pressure levels with minimum thrust losses by controlled swirling of the jets of high thrust engines. The density and temperature gradients in the jet exhausts of high thrust engines are larger by comparison with gradients in small engines.

Schwartz, I. R.↗

NASA NTRS2005

Acoustic Emission Weld Monitoring in the 2195 Aluminum-Lithium Alloy

Due to its low density, the 2195 aluminum-lithium alloy was developed as a replacement for alloy 2219 in the Space Shuttle External Tank (ET). The external tank is the single largest component of the space shuttle system. It is 154 feet long and 27.6 feet in diameter, and serves as the structural backbone for the shuttle during launch, absorbing most of the 7 million plus pounds of thrust produced. The almost 4% decrease in density between the two materials provides an extra 7500 pounds of payload capacity necessary to put the International Space Station components into orbit. The ET is an all-welded structure; hence, the requirement is for up to five rewelds without hot cracking. Unfortunately, hot cracking during re-welding or repair operations was occurring and had to be dealt with before the new super lightweight tank could be used. Weld metal porosity formation was also of concern because it leads to hot cracking during weld repairs. Accordingly, acoustic emission (AE) nondestructive testing was employed to monitor the formation of porosity and hot cracks in order to select the best filler metal and optimize the weld schedule. The purpose of this work is to determine the feasibility of detecting hot cracking in welded aluminum-lithium (Al-Li) structures through the analysis of acoustic emission data. By acoustically characterizing the effects of reheating during a repair operation, the potential for hidden flaws coalescing and becoming "unstable" as the panel is repaired could be reduced. Identification of regions where microcrack growth is likely to occur and the location of active flaw growth in the repair weld will provide the welder with direct feedback as to the current weld quality enabling adjustments to the repair process be made in the field. An acoustic emission analysis of the source mechanisms present during welding has been conducted with the goals of locating regions in the weld line that are susceptible to damage from a repair operation, identifying the formation of critically sized flaws and providing accept/reject criteria for the quality of a weld as it is performed.

Walker, James L.↗

NASA NTRS2000

Performance of Titanium Optics on a NASA 30 Cm Ion Thruster

The results of performance tests with two titanium optics sets are presented and compared to those of molybdenum optics. All tests were conducted on a 30 cm ion thruster that was nearly identical to the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) thruster design. Optics performance tests were conducted over a thruster input power range of 0.5 to 4.6 kW. Optics performance including impingement-limited total voltages, electron backstreaming limits, screen grid ion transparencies, near-field beam current density profiles, beam divergence angles, and beam divergence thrust correction factors were determined throughout this power range. The impingement-limited total voltages for titanium optics were within 10 to 55 V of those for molybdenum optics. Electron backstreaming limit magnitude as a function of peak beam current density for both molybdenum and titanium optics were within a few volts of each other, indicating similar hot grid gaps for these two grid materials during steady-state operation. Beam divergence half-angles at 90 percent of the total beam current and thrust correction factors for both titanium optics sets were within one degree and one percent, respectively, of those for molybdenum optics. When thruster power was increased to 2.3 kW immediately following discharge ignition, the titanium screen grid came into contact with the accelerator grid within five minutes of ignition. Relative to molybdenum, titanium's larger thermal expansion and smaller thermal conductivity likely caused the screen grid to thermally expand more relative to the accelerator grid during startup.

Soulas, George C.↗

NASA NTRS2021

Performance and High-Speed Characterization of a 100-kW Nested Hall Thruster

The performance of a three-channel, 100-kW class nested Hall thruster was evaluated on xenon propellant for total powers up to 102 kW. The thruster demonstrated stable operation in all seven available channel combinations at discharge voltages from 300 V to 500 V and three different current densities. The resulting test matrix contained forty-six unique conditions ranging from 5 to 102 kW total power and 16 to 247 A discharge current. At each operating condition, thrust and telemetry was measured, and from these measurements specific impulse and efficiency were calculated. All seven channel combinations showed similar performance at a given discharge voltage and current density. The largest thrust recorded was 5.4 N ± 0.1 N at 99 kW, 400 V discharge voltage. Total efficiency and specific impulse ranged from 0.54 to 0.67 ± 0.03 and 1800 seconds to 2650 seconds ± 60 seconds, respectively. It was found that the thrust of the three channels firing together was not larger than the sum of each channel firing individually. Discharge current oscillations were also characterized with peak-to-peak and root-mean-square values and with high-speed camera analysis, which provide insight into how the discharge channels oscillate, and how those oscillations are affected by the presence of other operating channels. The implications of these results are discussed in the context of operation beyond 100 kW, as well as the general viability of NHT technology for future mission applications.

High-power↗

NASA NTRS2020

Forward Flight Rotor Performance at Martian Atmospheric Densities and Sensitivity to Low Reynolds Numbers

Much effort has been made to enhance exploration on Mars. In addition to a rover and Mars-orbiting satellites, a Mars Helicopter Technology Demonstrator was proposed by the NASA Jet Propulsion Laboratory (JPL) to augment planetary research for the Mars 2020 Mission. Understanding rotor performance is vital for operations at Martian atmospheric conditions. The work presented is a study investigating rotor performance at Martian atmospheric conditions. Forward flight rotor tests were conducted in the Planetary Aeolian Laboratory (PAL) at NASA Ames Research Center, which has the capability to evacuate the air in the chamber to reach Martian atmospheric densities. A 1-meter-diameter rotor, roughly approximating the Mars Helicopter Technology Demonstrator, was tested at multiple atmospheric densities, including that of Mars. Rotor rotational speed, thrust, torque, power, and airspeed measurements were collected during the test. These results were then correlated with simulated cases using a mid-fidelity computational fluid dynamics software, Rotorcraft CFD (RotCFD). C81Generator (C81Gen) was used to generate airfoil aerodynamic coefficient for the spanwise locations along the rotor. To observe the differences between the C81Gen flow type modes at low Reynolds number, the simulations at Martian atmospheric densities were run under the “fully turbulent”, and the fully laminar flow type. In addition, Reynolds number effects (within 2x104 to 9x104) on experimental thrust coefficient, power coefficient, and figure of merit were analyzed. Within this chord- based Reynolds number range, CT and FM decreased around 26% and 36%, respectively, while CP remained fairly constant, exhibiting variations of no more than 5.5%. Despite the challenges involved in testing at a large difference of atmospheric ensities between Earth and Mars, repeatable data was obtained in all the measurements at Martian atmospheric conditions.

Perez Perez, Brenda NAtalia↗

NASA NTRS2019

Isolated Rotor Forward Flight Testing at Martian Atmospheric Density Data Report

With the recent interest in Martian exploration using Unmanned Aerial Vehicles (UAVs), an experimental study was conducted to investigate rotor performance at Martian atmospheric conditions. Both simulation and testing of rotors is vital for evaluating rotor performance and behavior, especially for operations at Martian atmospheric densities and pressures. One critical test that has not been performed to date is helicopter forward flight testing at Martian atmospheric densities. To achieve this, a test was conducted in a tunnel facility that could be evacuated to the atmospheric pressure and density of Mars. A 40-inch-diameter rotor, roughly approximating the scale of the proposed Mars Helicopter (MH) design by the NASA Jet Propulsion Laboratory (JPL), was tested in forward flight at Mars’ atmospheric pressure at the NASA Ames Planetary Aeolian Laboratory (PAL). In this forward flight testing, the drive system of the Martian Surface Wind Tunnel (MARSWIT) was never turned on; all wind speeds read were generated either through the rotor spinning or from facility effects. The goal of this experiment was to collect rotor thrust, rotational speed, power, torque, and acoustics measurements. Subsequently, these results can be used for correlation with simulated cases using a mid-fidelity Computational Fluid Dynamics (CFD) simulation. As expected, rotor thrust and power are drastically reduced at air densities 100 times lower than at sea level on Earth. In addition, Reynolds number effects seem to play a vital role at reduced pressure that cannot be neglected in the simulation.

One Atmosphere↗