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NASA NTRS2015

Solar Thermal Upper Stage Liquid Hydrogen Pressure Control Testing

High-energy cryogenic propellant is an essential element in future space exploration programs. Therefore, NASA and its industrial partners are committed to an advanced development/technology program that will broaden the experience base for the entire cryogenic fluid management community. Furthermore, the high cost of microgravity experiments has motivated NASA to establish government/aerospace industry teams to aggressively explore combinations of ground testing and analytical modeling to the greatest extent possible, thereby benefitting both industry and government entities. One such team consisting of ManTech SRS, Inc., Edwards Air Force Base, and Marshall Space Flight Center (MSFC) was formed to pursue a technology project designed to demonstrate technology readiness for an SRS liquid hydrogen (LH2) in-space propellant management concept. The subject testing was cooperatively performed June 21-30, 2000, through a partially reimbursable Space Act Agreement between SRS, MSFC, and the Air Force Research Laboratory. The joint statement of work used to guide the technical activity is presented in appendix A. The key elements of the SRS concept consisted of an LH2 storage and supply system that used all of the vented H2 for solar engine thrusting, accommodated pressure control without a thermodynamic vent system (TVS), and minimized or eliminated the need for a capillary liquid acquisition device (LAD). The strategy was to balance the LH2 storage tank pressure control requirements with the engine thrusting requirements to selectively provide either liquid or vapor H2 at a controlled rate to a solar thermal engine in the low-gravity environment of space operations. The overall test objective was to verify that the proposed concept could enable simultaneous control of LH2 tank pressure and feed system flow to the thruster without necessitating a TVS and a capillary LAD. The primary program objectives were designed to demonstrate technology readiness of the SRS concept at a system level as a first step toward actual flight vehicle demonstrations. More specific objectives included testing the pressure and feed control system concept hardware for functionality, operability, and performance. Valuable LH2 thermodynamic and fluid dynamics data were obtained for application to both the SRS concept and to future missions requiring space-based cryogen propellant management.

Moore, J. D.↗

NASA NTRS1959

Materials Problems in Chemical Liquid-Propellant Rocket Systems

With the advent of the space age, new adjustments in technical thinking and engineering experience are necessary. There is an increasing and extensive interest in the utilization of materials for components to be used at temperatures ranging from -423 to over 3500 deg F. This paper presents a description of the materials problems associated with the various components of chemical liquid rocket systems. These components include cooled and uncooled thrust chambers, injectors, turbine drive systems, propellant tanks, and cryogenic propellant containers. In addition to materials limitations associated with these components, suggested research approaches for improving materials properties are made. Materials such as high-temperature alloys, cermets, carbides, nonferrous alloys, plastics, refractory metals, and porous materials are considered.

Gilbert, L. L.↗

NASA NTRS1985

Magentically actuated compressor

A vibration free fluid compressor particularly adapted for Stirling cycle cryogenic refrigeration apparatus comprises a pair of identical opposing ferromagnetic pistons located in a housing and between a gas spring including a sealed volume of a working fluid such as gas under pressure. The gas compresses and expands in accordance with movement of the pistons to generate a compression wave which can be vented to other apparatus, for example, a displacer unit in a Stirling cycle engine. The pistons are urged outwardly due to the pressure of the gas; however, a fixed electromagnetic coil assembly located in the housing adjacent the pistons, is periodically energized to produce a magnetic field which interlinks the pistons in such a fashion that the pistons are mutually attracted to one another. The mass of the pistons, in conjunction with the compressed gas between them, form a naturally resonant system which, when the pistons are electromagnetically energized, produces an oscillating compression wave in the entrapped fluid medium.

Evans, J.↗

NASA NTRS2017

In-Space Chemical Propulsion Systems Roadmap

In-space propulsion begins where the launch vehicle upper stage leaves off, performing the functions of primary propulsion, reaction control, station keeping, precision pointing, and orbital maneuvering. The main engines used in space provide the primary propulsive force for orbit transfer, planetary trajectories and extra planetary landing and ascent. The reaction control and orbital maneuvering systems provide the propulsive force for orbit maintenance, position control, station keeping, and spacecraft attitude control. Advanced in-space propulsion technologies will enable much more effective exploration of our Solar System and will permit mission designers to plan missions to "fly anytime, anywhere, and complete a host of science objectives at the destinations" with greater reliability and safety. With wide range of possible missions and candidate propulsion technologies, the question of which technologies are "best" for future missions is a difficult one. A portfolio of propulsion technologies should be developed to provide optimum solutions for a diverse set of missions and destinations. A large fraction of the rocket engines in use today are chemical rockets; that is, they obtain the energy needed to generate thrust by chemical reactions to create a hot gas that is expanded to produce thrust. A significant limitation of chemical propulsion is that it has a relatively low specific impulse (Is, or thrust per mass flow rate of propellant). A significant improvement (>30%) in Is can be obtained by using cryogenic propellants, such as liquid oxygen and liquid hydrogen, for example. Historically, these propellants have not been applied beyond upper stages.

Oxidizers↗

NASA NTRS1985

Space shuttle electrical power generation and reactant supply system

The design philosophy and development experience of fuel cell power generation and cryogenic reactant supply systems are reviewed, beginning with the state of technology at the conclusion of the Apollo Program. Technology advancements span a period of 10 years from initial definition phase to the most recent space transportation system (STS) flights. The development program encompassed prototype, verification, and qualification hardware, as well as post-STS-1 design improvements. Focus is on the problems encountered, the scientific and engineering approaches employed to meet the technological challenges, and the results obtained. Major technology barriers are discussed, and the evolving technology development paths are traced from their conceptual beginnings to the fully man-rated systems which are now an integral part of the shuttle vehicle.

Simon, W. E.↗

NASA NTRS2006

Upper Stage Tank Thermodynamic Modeling Using SINDA/FLUINT

Modeling to predict the condition of cryogenic propellants in an upper stage of a launch vehicle is necessary for mission planning and successful execution. Traditionally, this effort was performed using custom, in-house proprietary codes, limiting accessibility and application. Phenomena responsible for influencing the thermodynamic state of the propellant have been characterized as distinct events whose sequence defines a mission. These events include thermal stratification, passive thermal control roll (rotation), slosh, and engine firing. This paper demonstrates the use of an off the shelf, commercially available, thermal/fluid-network code to predict the thermodynamic state of propellant during the coast phase between engine firings, i.e. the first three of the above identified events. Results of this effort will also be presented.

Schallhorn, Paul↗

NASA NTRS2015

Low Cost Upper Stage-Class Propulsion (LCUSP)

NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.

Vickers, John↗

NASA NTRS2005

NASA Tech Briefs, June 2005

Topics covered include: Apparatus Characterizes Transient Voltages in Real Time; Measuring Humidity in Sealed Glass Encasements; Adaptable System for Vehicle Health and Usage Monitoring; Miniature Focusing Time-of-Flight Mass Spectrometer; Cryogenic High-Sensitivity Magnetometer; Wheel Electrometer System; Carbon-Nanotube Conductive Layers for Thin-Film Solar Cells; Patch Antenna Fed via Unequal-Crossed-Arm Aperture; LC Circuits for Diagnosing Embedded Piezoelectric Devices; Nanowire Thermoelectric Devices; Code for Analyzing and Designing Spacecraft Power System Radiators; Decision Support for Emergency Operations Centers; NASA Records Database; Real-Time Principal- Component Analysis; Fuzzy/Neural Software Estimates Costs of Rocket- Engine Tests; Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings; Reactive Additives for Phenylethynyl-Containing Resins; Improved Gear Shapes for Face Worm Gear Drives; Alternative Way of Shifting Mass to Move a Spherical Robot; Parylene C as a Sacrificial Material for Microfabrication; In Situ Electrochemical Deposition of Microscopic Wires; Improved Method of Manufacturing SiC Devices; Microwave Treatment of Prostate Cancer and Hyperplasia; Ferroelectric Devices Emit Charged Particles and Radiation; Dusty-Plasma Particle Accelerator; Frozen-Plug Technique for Liquid-Oxygen Plumbing; Shock Waves in a Bose-Einstein Condensate; Progress on a Multichannel, Dual-Mixer Stability Analyzer; Development of Carbon- Nanotube/Polymer Composites; Thermal Imaging of Earth for Accurate Pointing of Deep-Space Antennas; Modifications of a Composite-Material Combustion Chamber; Modeling and Diagnostic Software for Liquefying- Fuel Rockets; and Spacecraft Antenna Clusters for High EIRP.

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NASA NTRS2008

Propulsion and Cryogenics Advanced Development (PCAD) Project Propulsion Technologies for the Lunar Lander

The Propulsion and Cryogenics Advanced Development (PCAD) Project in the Exploration Technology Development Program is developing technologies as risk mitigation for Orion and the Lunar Lander. An integrated main and reaction control propulsion system has been identified as a candidate for the Lunar Lander Ascent Module. The propellants used in this integrated system are Liquid Oxygen (LOX)/Liquid Methane (LCH4) propellants. A deep throttle pump fed Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) engine system has been identified for the Lunar Lander Descent Vehicle. The propellant combination and architecture of these propulsion systems are novel and would require risk reduction prior to detailed design and development. The PCAD Project addresses the technology requirements to obtain relevant and necessary test data to further the technology maturity of propulsion hardware utilizing these propellants. This plan and achievements to date will be presented.

Klem, Mark D.↗

NASA NTRS1990

Extraterrestrial resource utilization for economy in space missions

The NASA/University of Arizona Space Engineering Research Center is dedicated to research on the discovery, characterization, mapping, beneficiation, extraction, processing, and fabrication of useful products from extraterrestrial material. Schemes for the automated production of low-technology products that are likely to be desired in large quantities in the early stages of any large-scale space activity are identified and developed. This paper summarizes the research program, concentrating upon the production of (1) propellants, both cryogenic and storable, (2) volatiles such as water, nitrogen, and carbon dioxide for use in life-support systems (3) structural metals, and (4) refractories for use in aerobrakes and furnace linings.

Lewis, J. S.↗

NASA NTRS1986

Current wind tunnel capability and planned improvements at the NASA Langley Research Center

NASA Langley's major wing wind tunnels and the projected facilities planned to be completed by 1988 are presented. Special capabilities, uses, and the improvements done during the Langley's tunnel revitalization program are described for the following facilities: (1) the 30 x 60-ft subsonic tunnel, (2) the 4 x 7-m low-speed testing tunnel, (3) the Low-Turbulence Tunnel, (4) the Spin Tunnel, (5) the National Transonic Pressure Tunnel, (6) Transonic Cryogenic Tunnel, (7) the National Transonic Facility, (8) the 16-ft Transonic Tunnel, (9) the Transonic Dynamic Tunnel, (10) the Unitary Plan Wind Tunnel, and (11) a new 20-inch supersonic wind tunnel which is currently undergoing final checkout. The design concept of an extremely-low disturbance level supersonic tunnel, the upgrading plans for the hypersonic aerothermal complex, and the present and planned capabilities for testing the hydrogen-fueled Scramjet engines are also presented. In addition, uses of inexpensive simple-to-operate research wind tunnels are discussed. Tunnel diagrams and graphs of upgrade results are included.

Bower, R. E.↗

NASA NTRS2020

A Review of In-Space Propellant Transfer Capabilities and Challenges for Missions Involving Propellant Resupply

This paper captures and transfers knowledge of in-space propellant transfer accomplishments and communicate the remaining challenges to a new generation of NASA engineers as multiple NASA programs and centers have worked related and applicable efforts. The Propulsion Technical Discipline Team (TDT) established a plan to draft this paper as an effort to help engineers and decision makers recognize and access the various islands of experience that have formed within the agency as different NASA directorates and projects have embraced the challenges associated with propellant transfer.

Propellant Transfer↗

NASA NTRS2010

Liquid Oxygen/Liquid Methane Component Technology Development at MSFC

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. Besides existing in-house risk reduction activities, NASA has solicited from industry their participation on component technologies based on the potential application to the lunar ascent main engine (AME). Contracted and NASA efforts have ranged from valve technologies to engine system testbeds. The application for the AME is anticipated to be an expendable, pressure-fed engine for ascent from the moon at completion of its lunar stay. Additionally, the hardware is expected to provide an abort capability prior to landing, in the event that descent systems malfunction. For the past 4 years, MSFC has been working with the Glenn Research Center and the Johnson Space Center on methane technology development. This paper will focus on efforts specific to MSFC in pursuing ignition, injector performance, chamber material assessments and cryogenic valve technologies. Ignition studies have examined characteristics for torch, spark and microwave systems. Injector testing has yielded insight into combustion performance for shear, swirl and impinging type injectors. The majority of chamber testing has been conducted with ablative and radiatively cooled chambers with planned activities for regenerative and transpiration cooled chambers. Lastly, an effort is underway to examine the long duration exposure issues of cryogenic valve internal components. The paper will summarize the status of these efforts.

Robinson, Joel W.↗

NASA NTRS1987

Evaluation of seals for high-performance cryogenic turbomachines

An approach to computing flow and dynamic characteristics for seals or bearings is discussed. The local average velocity was strongly influenced by inlet and exit effects and fluid injection, which in turn drove zones of secondary flow. For the restricted three-dimensional model considered, the integral averaged results were in reasonable agreement with selected data. Unidirectional pressure measurements alone were insufficient to define such flow variations. However, for seal and bearing leakage correlations the principles of corresponding states were found to be useful. Also discussed are three phenomena encountered during testing of three eccentric nonrotating seal configurations for the Space Shuttle Main Engine (SSME) Program. Fluid injection, choking within a seal, and pressure profile crossover are related to postulated zones of secondary flow or separation and to direct stiffness.

Hendricks, R. C.↗

NASA NTRS1990

Research and technology

As the NASA center responsible for assembly, checkout, servicing, launch, recovery, and operational support of Space Transportation System elements and payloads, Kennedy Space Center (KSC) is placing increasing emphasis on KSC's research and technology program. In addition to strengthening those areas of engineering and operations technology that contribute to safer, more efficient, and more economical execution of the current mission, the technological tools needed to execute KSC's mission relative to future programs are being developed. The Engineering Development Directorate encompasses most of the laboratories and other KSC resources that are key elements of research and technology program implementation and is responsible for implementation of the majority of the projects in this KSC 1990 annual report. Projects under the following topics are covered: (1) materials science; (2) hazardous emissions and contamination monitoring; (3) biosciences; (4) autonomous systems; (5) communications and control; (6) meteorology; (7) technology utilization; and (8) mechanics, structures, and cryogenics.

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NASA NTRS1976

The U.S. 2.5-Meter Cryogenic High Reynolds Number Tunnel

The U.S. 2.5-Meter Cryogenic High Reynolds Number Tunnel is a fan-driven transonic wind tunnel scheduled for operation in 1981. It will operate at Mach numbers from 0.1 to 1.2, stagnation pressures from 1 to 9 bars, and stagnation temperatures from 352 to 80 Kelvin. The maximum Reynolds number capability will be 120 million at a Mach number of 1.0 based on a reference length of 0.25 meter. This paper describes the basis for the conceptual approach, the engineering design including unique features, and the performance operating envelopes for the tunnel.

Howell, R. R.↗

NASA NTRS2008

Liquid Acquisition Device Testing with Sub-Cooled Liquid Oxygen

When transferring propellant in space, it is most efficient to transfer single phase liquid from a propellant tank to an engine. In earth s gravity field or under acceleration, propellant transfer is fairly simple. However, in low gravity, withdrawing single-phase fluid becomes a challenge. A variety of propellant management devices (PMD) are used to ensure single-phase flow. One type of PMD, a liquid acquisition device (LAD) takes advantage of capillary flow and surface tension to acquire liquid. Previous experimental test programs conducted at NASA have collected LAD data for a number of cryogenic fluids, including: liquid nitrogen (LN2), liquid oxygen (LOX), liquid hydrogen (LH2), and liquid methane (LCH4). The present work reports on additional testing with sub-cooled LOX as part of NASA s continuing cryogenic LAD development program. Test results extend the range of LOX fluid conditions examined, and provide insight into factors affecting predicting LAD bubble point pressures.

Jurns, John M.↗

NASA NTRS1985

Orbit on demand - Will cost determine best design?

Eleven design concepts for vertical (V) and horizontal (H) take-off launch-on-demand manned orbital vehicles are discussed. Attention is given to up to three stages, Mach numbers (sub-, 2, or 3), expendable boosters, drop tanks (DT), and storable (S) or cryogenic fuels. All the concepts feature lifting bodies with circular cross-section and most have a 7 ft diam, 15 ft long payload bay as well as a crew compartment. Expendable elements impose higher costs and in some cases reduce all-azimuth launch capabilities. Single-stage vehicles simplify the logistics whether in H or V configuration. A two-stage H vehicle offers launch offset for the desired orbital plane before firing the rocket engines after take-off and subsonic acceleration. A two-stage fully reusable V form has the second lowest weight of the vehicles studied and an all-azimuth launch capability. Better definition of the prospective mission requirements is needed before choosing among the alternatives.

Macconochie, J. O.↗