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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Cold Helium Pressurization for Liquid Oxygen/Liquid Methane Propulsion Systems: Fully-Integrated Hot-Fire Test Results

Hot-fire test demonstrations were successfully conducted using a cold helium pressurization system fully integrated into a liquid oxygen (LOX) / liquid methane (LCH4) propulsion system (Figure 1). Cold helium pressurant storage at near liquid nitrogen (LN2) temperatures (-275 F and colder) and used as a heated tank pressurant provides a substantial density advantage compared to ambient temperature storage. The increased storage density reduces helium pressurant tank size and mass, creating payload increases of ~35% for small lunar-lander sized applications. This degree of mass reduction also enables pressure-fed propulsion systems for human-rated Mars ascent vehicle designs. Hot-fire test results from the highly-instrumented test bed will be used to demonstrate system performance and validate integrated models of the helium and propulsion systems. A pressurization performance metric will also be developed as a means to compare different active pressurization schemes.

Morehead, R. L.↗
NASA NTRS1982

LOX/hydrocarbon auxiliary propulsion system study

Liquid oxygen (LOX)/hydrocarbon propulsion concepts for a "second generation' orbiter auxiliary propulsion system was evaluated. The most attractive fuel and system design approach identified, and the technology advancements that are needed to provide high confidence for a subsequent system development were determined. The fuel candidates were ethanol, methane, propane, and ammonia. Even though ammonia is not a hydrocarbon, it was included for evaluation because it is clean burning and has a good technology base. The major system design options were pump versus pressure feed, cryogenic versus ambient temperature RCS propellant feed, and the degree of OMS-RCS integration. Ethanol was determined to be the best fuel candidate. It is an earth-storable fuel with a vapor pressure slightly higher than monomethyl hydrazine. A pump-fed OMS was recommended because of its high specific impulse, enabling greater velocity change and greater payload capability than a pressure fed system.

Orton, G. F.↗
NASA NTRS2016

Integrated Pressure-Fed Liquid Oxygen / Methane Propulsion Systems - Morpheus Experience, MARE, and Future Applications

An integrated liquid oxygen (LOx) and methane propulsion system where common propellants are fed to the reaction control system and main engines offers advantages in performance, simplicity, reliability, and reusability. LOx/Methane provides new capabilities to use propellants that are manufactured on the Mars surface for ascent return and to integrate with power and life support systems. The clean burning, non-toxic, high vapor pressure propellants provide significant advantages for reliable ignition in a space vacuum, and for reliable safing or purging of a space-based vehicle. The NASA Advanced Exploration Systems (AES) Morpheus lander demonstrated many of these key attributes as it completed over 65 tests including 15 flights through 2014. Morpheus is a prototype of LOx/Methane propellant lander vehicle with a fully integrated propulsion system. The Morpheus lander flight demonstrations led to the proposal to use LOx/Methane for a Discovery class mission, named Moon Aging Regolith Experiment (MARE) to land an in-situ science payload for Southwest Research Institute on the Lunar surface. Lox/Methane is extensible to human spacecraft for many transportation elements of a Mars architecture. This paper discusses LOx/Methane propulsion systems in regards to trade studies, the Morpheus project experience, the MARE NAVIS (NASA Autonomous Vehicle for In-situ Science) lander, and future possible applications. The paper also discusses technology research and development needs for Lox/Methane propulsion systems.

Hurlbert, Eric↗
NASA NTRS2003

Design and Testing of Non-Toxic RCS Thrusters for Second Generation Reusable Launch Vehicle

The current NASA Space Shuttle auxiliary propulsion system utilizes nitrogen tetroxide (NTO) and monomethylhydrazine (MMH), hypergolic propellants. This use of these propellants has resulted in high levels of maintenance and precautions that contribute to costly launch operations. By employing alternate propellant combinations, those less toxic to humans, the hazards and time required between missions can be significantly reduced. Use of alternate propellants can thereby increase the efficiency and lower the cost in launch operations. In support of NASA's Space Launch Initiative (SLI), TRW proposed a three-phase project structured to significantly increase the technology readiness of a high-performance reaction control subsystem (RCS) thruster using non-toxic propellant for an operationally efficient and reusable auxiliary propulsion system (APS). The project enables the development of an integrated primary/vernier thruster capable of providing dual-thrust levels of both 1000-lbf class thrust and 25-lbf thrust. The intent of the project is to reduce the risk associated with the development of an improved RCS flight design that meets the primary NASA objectives of improved safety and reliability while reducing systems operations and maintenance costs. TRW proposed two non-toxic auxiliary propulsion engine designs, one using liquid oxygen and liquid hydrogen and the other using liquid oxygen and liquid ethanol, as candidates to meet the goals of reliability and affordability at the RCS level. Both of these propellant combinations offer the advantage of a safe environment for maintenance, while at the same time providing adequate to excellent performance for a conventional liquid propulsion systems. The key enabling technology incorporated in both TRW thrusters is the coaxial liquid on liquid pintle injector. This paper will concentrate on only the design and testing of one of the thrusters, the liquid oxygen (LOX) and liquid hydrogen (LH2) thruster. The LOX/LH2 thruster design includes a LOX-centered pintle injector, consisting of two rows of slots that create a radial spoke spray pattern in the combustion chamber. The main fuel injector creates a continuous sheet of LH2 originating upstream of the LOX pintle injector. The two propellants impinge at the pintle slots, where the resulting momentum ratio and spray pattern determines the combustion efficiency and thermal effects on the hardware. Another enabling technology used in the design of this thruster is fuel film cooling through a duct, lining the inner wall of the combustion chamber barrel section. The duct is also acts as a secondary fuel injection point. The variation in the amount of LH2 used for the duct allows for adjustments in the cooling capacity for the thruster. The Non-Toxic LOX-LH2 RCS Workhorse Thruster was tested at the NASA Marshall Space Flight Center's Test Stand 500. Hot-fire tests were conducted between March 08, 2002 and April 05, 2002. All testing during the program base period were performed at sea-level conditions. During the test program, 7 configurations were tested, including 2 combustion chambers, 3 LOX injector pintle tips, and 4 LH2 injector stroke settings. The operating conditions that were surveyed varied thrust levels, mixture ratio and LH2 duct cooling flow. The copper heat sink chamber was used for 16 burns, each burn lasting from 0.4 to 10 seconds, totaling 51.4 seconds, followed by Haynes chamber testing ranging from 0.9 to 120 seconds, totaling 300.9 seconds. The total accumulated burn time for the test program is 352.3 seconds. C* efficiency was calculated and found to be within expectable limits for most operating conditions. The temperature on the Haynes combustion chamber remained below established material limits, with the exception of one localized hot spot. The test results demonstrate that both the coaxial liquid-on-liquid pintle injector design and fuel duct concepts are viable for the intended application. The thruster head-e design maintained cryogenic injection temperatures while firing, which validates the concept for minimal heat soak back. By injecting fuel into the duct, the throat temperatures were manageable, yet the split of fuel through the cooling duct does not compromise the overall combustion efficiency, which indicates that, provided proper design refinement, such a concept can be applied to a high-performance version of the thruster. These hot fire tests demonstrate the robustness of the duct design concept and good capability to withstand off-nominal operating conditions without adversely impacting the thermal response of the engine, a key design feature for a cryogenic thruster.

Calvignac, Jacky↗
NASA NTRS1993

Nuclear Engine System Simulation (NESS). Volume 1: Program user's guide

A Nuclear Thermal Propulsion (NTP) engine system design analysis tool is required to support current and future Space Exploration Initiative (SEI) propulsion and vehicle design studies. Currently available NTP engine design models are those developed during the NERVA program in the 1960's and early 1970's and are highly unique to that design or are modifications of current liquid propulsion system design models. To date, NTP engine-based liquid design models lack integrated design of key NTP engine design features in the areas of reactor, shielding, multi-propellant capability, and multi-redundant pump feed fuel systems. Additionally, since the SEI effort is in the initial development stage, a robust, verified NTP analysis design tool could be of great use to the community. This effort developed an NTP engine system design analysis program (tool), known as the Nuclear Engine System Simulation (NESS) program, to support ongoing and future engine system and stage design study efforts. In this effort, Science Applications International Corporation's (SAIC) NTP version of the Expanded Liquid Engine Simulation (ELES) program was modified extensively to include Westinghouse Electric Corporation's near-term solid-core reactor design model. The ELES program has extensive capability to conduct preliminary system design analysis of liquid rocket systems and vehicles. The program is modular in nature and is versatile in terms of modeling state-of-the-art component and system options as discussed. The Westinghouse reactor design model, which was integrated in the NESS program, is based on the near-term solid-core ENABLER NTP reactor design concept. This program is now capable of accurately modeling (characterizing) a complete near-term solid-core NTP engine system in great detail, for a number of design options, in an efficient manner. The following discussion summarizes the overall analysis methodology, key assumptions, and capabilities associated with the NESS presents an example problem, and compares the results to related NTP engine system designs. Initial installation instructions and program disks are in Volume 2 of the NESS Program User's Guide.

Pelaccio, Dennis G.↗
NASA NTRS2001

Unsteady Turbopump Flow Simulations

The objective of the current effort is two-fold: 1) to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine; and 2) to provide high-fidelity unsteady turbopump flow analysis capability to support the design of pump sub-systems for advanced space transportation vehicle. Since the space launch systems in the near future are likely to involve liquid propulsion system, increasing the efficiency and reliability of the turbopump components is an important task. To date, computational tools for design/analysis of turbopump flow are based on relatively lower fidelity methods. Unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available, at least, for real-world engineering applications. Present effort is an attempt to provide this capability so that developers of the vehicle will be able to extract such information as transient flow phenomena for start up, impact of non-uniform inflow, system vibration and impact on the structure. Those quantities are not readily available from simplified design tools. In this presentation, the progress being made toward complete turbo-pump simulation capability for a liquid rocket engine is reported. Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for the performance evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. Relative motion of the grid system for rotor-stator interaction was obtained by employing overset grid techniques. Time-accuracy of the scheme has been evaluated by using simple test cases. Unsteady computations for SSME turbopump, which contains 106 zones with 34.5 Million grid points, are currently underway on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability and the performance of the parallel versions of the code will be presented.

Centin, Kiris C.↗
NASA NTRS2002

A Three-Dimensional Parallel Time-Accurate Turbopump Simulation Procedure Using Overset Grid System

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and nonuniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability are presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRS2001

Time-Dependent Simulations of Turbopump Flows

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort will provide developers with information such as transient flow phenomena at start up, impact of non-uniform inflows, system vibration and impact on the structure. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Time-accuracy of the scheme has been evaluated with simple test cases. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kris, Cetin C.↗
NASA NTRS2001

A Three Dimensional Parallel Time Accurate Turbopump Simulation Procedure Using Overset Grid Systems

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort provides developers with information such as transient flow phenomena at start up, and non-uniform inflows, and will eventually impact on system vibration and structures. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. CAD to solution auto-scripting capability is being developed for turbopump applications. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 3000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kiris, Cetin↗
NASA NTRS2008

Space Shuttle Orbiter Atlantis Liquid Oxygen Pre-Valve Detent Roller Cracking Investigation

During routine inspections of the Space Shuttle s Main Propulsion System Liquid Oxygen (LO2) pre-valve, the mechanism provided to maintain the valve in the open position was found cracked. The mechanism is a Vespel roller held against the valve visor by a stack of Belleville springs. The roller has been found cracked 3 times. All three instances were in the same valve in the same location. There are 6 pre-valves on each orbiter, and only one has exhibited this problem. Every-flight inspections were instituted and the rollers were found to be cracked after only one flight. Engineers at Marshall Space Flight Center, Johnson Space Center, and Kennedy Space Center worked together to determine a solution. There were several possible contributors to the failure: a misaligned visor, an out-of-specification edge with a sharp radius, an out-of-specification tolerance stack up of a Belleville spring stack that caused un-predicted loads on the Vespel SP-21 roller, and a dimple machined into the side of the roller to indicate LO2 compatibility that created a stress riser. The detent assembly was removed and replaced with parts that were on the low side of the tolerance stack up to eliminate the potential for high loads on the detent roller. After one flight, the roller was inspected and showed fewer signs of wear and no cracks.

Holleman, Elizabeth↗
NASA NTRSDate not supplied

Cryogenic Propellant Tank Drain Simulation with a Stratified Ullage Nodal Model

Cryogenic propellant tank pressurization systems maintain tank pressure within specified limits to comply with propellant thermodynamic and tank structural design requirements. Many pump-fed cryogenic liquid propulsion systems control tank pressure using an autogenous pressurization system. Autogenous pressurization systems vaporize and heat propellant to produce the pressurant gas delivered to the tank. While autogenous pressurization systems eliminate the need for a separate pressurant gas storage and delivery system, they couple pressurant mass requirements to propellant mass requirements. Accurate prediction of autogenous pressurant mass during propellant drain is essential in optimizing cryogenic propellant tank designs.

Richard G Hibbs↗
NASA NTRS1994

Mars Sample Return: A Low Cost, Direct and Minimum Risk Design

Current NASA strategy for Mars exploration is seeking simpler, cheaper, and more reliable missions to Mars. This requirement has left virtually all previously proposed Mars Sample Return (MSR) missions as economically untenable. The MSR mission proposed in this paper represents an economical, back-to-basics approach of mission design by leveraging interplanetary trajectory design and limited surface science for shorter mission duration, advanced propulsion and thermal protection systems for mass reduction and simplified mission operations for high reliability. As a result, the proposed concept, called the Fast, Mini, Direct Mars Sample Return (FMD-MSR) mission represents the cheapest and fastest class of missions that could return a 0.5 kg sample from the surface of Mars to Earth with a total mission duration of less than 1.5 Earth years. The constraints require an aggressive mission design that dictates the use of advanced storable liquid propulsion systems and advanced TPS materials to minimize aeroshell mass. The mission does not have the high risk operations of other MSR missions such as orbit rendezvous at Mars, propulsive insertion at Mars, rover operations on the surface, and sample transfer. This paper details the key mission elements for such a mission and presents a feasible and cost effective design.

Wercinski, Paul F.↗
NASA NTRSDate not supplied

NASA's Compact High-Efficiency Rotating Detonation Rocket Engine for Mars Interplanetary Missions

NASA has successfully test fired a novel and compact liquid propulsion system known as a Rotating Detonation Rocket Engine. This is a specially designed ring-shaped thrust chamber that leverages additive manufacturing techniques and novel alloys such as GRCop-42 and GRX-810. The extreme combustion event, known as a detonation, reduces the combustion chamber length requirements down to a few inches while equivalent constant pressure rocket thrust chambers are on the order of feet. This is primarily due to rapid completion of combustion by the high-pressure detonation, an order of magnitude faster than deflagration combustion. In addition, the ring shape allows for rapid expansion of the combustion products. Depending on the thrust class and design supersonic area ratio, the full RDRE can be anywhere from 10% to 50% shorter than a traditional liquid rocket assuming the same exit diameter but is dependent on a number of design assumptions. This may enable substantial mass savings, cost savings, and broader design trade space for various mission architectures. Finally, the engine system has potential for higher Isp at identical average chamber pressure, which is currently being assessed by NASA. Experimental data obtained from testing in 2022 identified the feasibility of the novel propulsion system while multiple test series scheduled throughout 2023 and 2024 target closing the remaining critical technical gaps preventing widespread use of the technology amongst industry.

Thomas Teasley↗
NASA NTRS2007

Density and Cavitating Flow Results from a Full-Scale Optical Multiphase Cryogenic Flowmeter

Liquid propulsion systems are hampered by poor flow measurements. The measurement of flow directly impacts safe motor operations, performance parameters as well as providing feedback from ground testing and developmental work. NASA Marshall Space Flight Center, in an effort to improve propulsion sensor technology, has developed an all optical flow meter that directly measures the density of the fluid. The full-scale sensor was tested in a transient, multiphase liquid nitrogen fluid environment. Comparison with traditional density models shows excellent agreement with fluid density with an error of approximately 0.8%. Further evaluation shows the sensor is able to detect cavitation or bubbles in the flow stream and separate out their resulting effects in fluid density.

Korman, Valentin↗
NASA NTRS2022

NASA Engineering and Safety Center Technical Bulletin No. 22-08; Contaminant Reduction in High Purity Hydrazine

Hydrazine and its derivatives are used ubiquitously in liquid propulsion systems. In smaller thruster systems, contaminant build up has historically caused flow decay and consequently performance losses. Many of these contaminants are not controlled by the current revision of MIL-PRF-26536 [1], the High Purity Hydrazine (HPH) procurement specification, yet have been observed to be present in HPH at variable concentration and, often exceed potentially problematic levels for small thrusters. This technical bulletin outlines recent work aimed at identifying appropriate separation processes to remove specific target elemental and carbonaceous contamination in HPH.

Technical Bulletin No. 22-08↗
NASA NTRS2017

Fluid Transient Analysis During Priming of Evacuated Line

Pressure surges are critical in the design of spacecraft propellant feed lines. The pressure transients that occur during priming of feed lines are very important in the design and analysis of liquid propulsion systems. During the start-up of the propulsion system of a spacecraft, the process of filling of an evacuated pipeline is called priming. Priming can generate severe pressure peaks due to the slam (water hammer) of the propellant against a closed thruster valve. The downstream conditions strongly affect the pressure surge. In space systems, satellites, or interplanetary probes, the propellant lines are vacuum-pumped or filled with low pressure helium or nitrogen before the launch. Before operations, these lines are primed with a vaporizing liquid, sometimes in the presence of a non-condensable gas (NCG), which produces water hammer phenomena. The objective of the current study is to use a finite volume based network flow solver (Generalized Fluid System Simulation Program, GFSSP) for the numerical simulation of Priming in (a) a straight feedline and (b) a flow network. The geometrical configurations and dimensions for the pipe and other components used for the current study are identical to experimental study of Prickett et al.

Bandyopadhyay, Alak↗