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NASA NTRS2017

Updated Mars Mission Architectures Featuring Nuclear Thermal Propulsion

Nuclear thermal propulsion (NTP) can potentially enable routine human exploration of Mars and the solar system. By using nuclear fission instead of a chemical combustion process, and using hydrogen as the propellant, NTP systems promise rocket efficiencies roughly twice that of the best chemical rocket engines currently available. The most recent major Mars architecture study featuring NTP was the Design Reference Architecture 5.0 (DRA 5.0), performed in 2009. Currently, the predominant transportation options being considered are solar electric propulsion (SEP) and chemical propulsion; however, given NTP's capabilities, an updated architectural analysis is needed. This paper provides a top-level overview of several different architectures featuring updated NTP performance data. New architectures presented include a proposed update to the DRA 5.0 as well as an investigation of architectures based on the current Evolvable Mars Campaign, which is the focus of NASA's current analyses for the Journey to Mars. Architectures investigated leverage the latest information relating to NTP performance and design considerations and address new support elements not available at the time of DRA 5.0, most notably the Orion crew module and the Space Launch System (SLS). The paper provides a top level quantitative comparison of key performance metrics as well as a qualitative discussion of improvements and key challenges still to be addressed. Preliminary results indicate that the updated NTP architectures can significantly reduce the campaign mass and subsequently the costs for assembly and number of launches.

Rodriguez, Mitchell A.↗

NASA NTRS2018

Hybrid Additive Manufacturing Deposition and Selective Laser Melting Techniques Applied to Copper-Alloy Liquid Rocket Engine Combustion Chambers

Virgin Orbit and the NASA Marshall Space Flight Center have partnered to fabricate a small, multi-metallic, regeneratively cooled thrust chamber by leveraging the strengths of two different types of additive manufacturing: Direct Metal Laser Sintering (DMLS) for the copper alloy liner and blown powder Directed Energy Deposition (DED) for the Inconel structural jacket. The DED is being developed using Virgin Orbit's DMG Mori Seiki hybrid additive/subtractive machining center to further enable unique processing and further cost savings. The materials chosen are preferred for high performance thrust chamber applications, representing a significant advancement from the compromises typically made in the production of metal 3D printed thrust chambers for rocket engines. The 1.2K-lbf thrust article is a 16" tall, 3" diameter design modified for this effort to be regeneratively cooled with water and hot fired using a RP-1/LOX pintle-style development injector from Virgin Orbit's NewtonFour upper stage engine. The thrust chamber was tested at Virgin Orbit's Necker test site in Mojave, California. Results from this test campaign are reported in addition to information characterizing the liner, jacket, and bimetallic diffusion layer materials. This paper will also highlight some of the future bimetallic thrust chamber developments that MSFC and Virgin Orbit will complete under a recently awarded NASA contract.

Zagorski, Kevin↗

NASA NTRS1996

Cooling Duct Analysis for Transpiration/Film Cooled Liquid Propellant Rocket Engines

The development of a low cost space transportation system requires that the propulsion system be reusable, have long life, with good performance and use low cost propellants. Improved performance can be achieved by operating the engine at higher pressure and temperature levels than previous designs. Increasing the chamber pressure and temperature, however, will increase wall heating rates. This necessitates the need for active cooling methods such as film cooling or transpiration cooling. But active cooling can reduce the net thrust of the engine and add considerably to the design complexity. Recently, a metal drawing process has been patented where it is possible to fabricate plates with very small holes with high uniformity with a closely specified porosity. Such a metal plate could be used for an inexpensive transpiration/film cooled liner to meet the demands of advanced reusable rocket engines, if coolant mass flow rates could be controlled to satisfy wall cooling requirements and performance. The present study investigates the possibility of controlling the coolant mass flow rate through the porous material by simple non-active fluid dynamic means. The coolant will be supplied to the porous material by series of constant geometry slots machined on the exterior of the engine.

Micklow, Gerald J.↗

NASA NTRS1990

Rocket combustion chamber life-enhancing design concepts

NASA continues to pursue technologies which can lead to an increase in life and reduce the costs of fabrication of the Space Shuttle Main Engine. The joint NASA/Air Force Advanced Launch System Program has set its prime objectives to be high reliability and low cost for their new advanced booster engine. In order to meet these objectives, NASA will utilize the results of several ongoing programs to provide the required technologies. An overview is presented of those programs which address life enhancing design concepts for the combustion chamber. Seven different design concepts, which reduce the thermal strain and/or increase the material strength of the combustion chamber liner wall are discussed. Subscale rocket test results are presented, where available, for life enhancing design concepts. Two techniques for reducing chamber fabrication costs are discussed, as well as issues relating to hydrocarbon fuels/combustion chamber liner materials compatibility.

Quentmeyer, Richard J.↗

NASA NTRS1990

Rocket combustion chamber life-enhancing design concepts

Quentmeyer, R. J.↗

NASA NTRS2001

Use of Soft Computing Technologies for a Qualitative and Reliable Engine Control System for Propulsion Systems

The problem to be addressed in this paper is to explore how the use of Soft Computing Technologies (SCT) could be employed to improve overall vehicle system safety, reliability, and rocket engine performance by development of a qualitative and reliable engine control system (QRECS). Specifically, this will be addressed by enhancing rocket engine control using SCT, innovative data mining tools, and sound software engineering practices used in Marshall's Flight Software Group (FSG). The principle goals for addressing the issue of quality are to improve software management, software development time, software maintenance, processor execution, fault tolerance and mitigation, and nonlinear control in power level transitions. The intent is not to discuss any shortcomings of existing engine control methodologies, but to provide alternative design choices for control, implementation, performance, and sustaining engineering, all relative to addressing the issue of reliability. The approaches outlined in this paper will require knowledge in the fields of rocket engine propulsion (system level), software engineering for embedded flight software systems, and soft computing technologies (i.e., neural networks, fuzzy logic, data mining, and Bayesian belief networks); some of which are briefed in this paper. For this effort, the targeted demonstration rocket engine testbed is the MC-1 engine (formerly FASTRAC) which is simulated with hardware and software in the Marshall Avionics & Software Testbed (MAST) laboratory that currently resides at NASA's Marshall Space Flight Center, building 4476, and is managed by the Avionics Department. A brief plan of action for design, development, implementation, and testing a Phase One effort for QRECS is given, along with expected results. Phase One will focus on development of a Smart Start Engine Module and a Mainstage Engine Module for proper engine start and mainstage engine operations. The overall intent is to demonstrate that by employing soft computing technologies, the quality and reliability of the overall scheme to engine controller development is further improved and vehicle safety is further insured. The final product that this paper proposes is an approach to development of an alternative low cost engine controller that would be capable of performing in unique vision spacecraft vehicles requiring low cost advanced avionics architectures for autonomous operations from engine pre-start to engine shutdown.

Trevino, Luis↗

NASA NTRS1996

Electro-Mechanical Actuator. DC Resonant Link Controller

This report summarizes the work performed on the 68 HP electro-mechanical actuator (EMA) system developed on NASA contract for the Electrical Actuation (ELA) Technology Bridging Program. The system was designed to demonstrate the capability of large, high power linear ELAs for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, drive electronics and a linear actuator capable of up to 32,00 lbs loading at 7.4 inches/second. The drive electronics are based on the Resonant DC link concept and operate at a nominal frequency of 55 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response, step response and force-velocity tests were conducted at the MOOG Aerospace facility. A complete description of the system and all test results can be found in the body of the report.

Schreiner, Kenneth E.↗

NASA NTRS1974

Extended temperature range ACPS thruster investigation

The successful hot fire demonstration of a pulsing liquid hydrogen/liquid oxygen and gaseous hydrogen/liquid oxygen attitude control propulsion system thruster is described. The test was the result of research to develop a simple, lightweight, and high performance reaction control system without the traditional requirements for extensive periods of engine thermal conditioning, or the use of complex equipment to convert both liquid propellants to gas prior to delivery to the engine. Significant departures from conventional injector design practice were employed to achieve an operable design. The work discussed includes thermal and injector manifold priming analyses, subscale injector chilldown tests, and 168 full scale and 550 N (1250 lbF) rocket engine tests. Ignition experiments, at propellant temperatures ranging from cryogenic to ambient, led to the generation of a universal spark ignition system which can reliably ignite an engine when supplied with liquid, two phase, or gaseous propellants. Electrical power requirements for spark igniter are very low.

Blubaugh, A. L.↗

NASA NTRS2015

ME8373 Spring 2015 ICME Proposal ICME Analysis of Fatigue Crack Growth Through a Weld in SA-516 Grade 70 Plate

This paper describes work accomplished to predict the service life of a flexure joint design which is a component of a diffuser duct in the A3 Test Stand, an altitude simulation rocket engine test facility at NASA's Stennis Space Center. The duct has two pressure shells separated by cooling water passages and connected by stiffening ribs and flexure joints. Rocket exhaust flows within the duct and heats the inner pressure shell while the outer pressure shell remains at ambient temperature. The flexure joints allow for differential thermal expansion of the inner and outer pressure shells and are subject to in-service loading by this thermal expansion along with water pressure in the cooling water passage, atmospheric pressure outside the duct, near vacuum conditions within the duct, and vibrational loads from operation of the facility and rocket engine. Figure 1 shows a schematic axisymmetric cross section of the diffuser pressure shells and flexure joints with a zoomed in view of the flexure joint. The flexure joints are expected to eventually fail by fatigue cracking leading to leaks from the cooling water passages to the outside. The zoomed in view in Figure 1 indicates where cracking is expected to occur, namely through a weld bead between two plates of SA-516 Grade 70 steel. This weld bead acts as the fulcrum of the flexure joint and it is clear from inspection of the geometry and loading represented in the zoomed in portion of Figure 1 that inherent in the design there is a severe notch formed between the flexure plate, weld bead, and stiffening ring that will be the site of crack initiation and location from which the crack grows to the outer surface of the weld bead.

Woods, Jody L.↗

NASA NTRS2000

Supercomputing Aspects for Simulating Incompressible Flow

The primary objective of this research is to support the design of liquid rocket systems for the Advanced Space Transportation System. Since the space launch systems in the near future are likely to rely on liquid rocket engines, increasing the efficiency and reliability of the engine components is an important task. One of the major problems in the liquid rocket engine is to understand fluid dynamics of fuel and oxidizer flows from the fuel tank to plume. Understanding the flow through the entire turbo-pump geometry through numerical simulation will be of significant value toward design. One of the milestones of this effort is to develop, apply and demonstrate the capability and accuracy of 3D CFD methods as efficient design analysis tools on high performance computer platforms. The development of the Message Passage Interface (MPI) and Multi Level Parallel (MLP) versions of the INS3D code is currently underway. The serial version of INS3D code is a multidimensional incompressible Navier-Stokes solver based on overset grid technology, INS3D-MPI is based on the explicit massage-passing interface across processors and is primarily suited for distributed memory systems. INS3D-MLP is based on multi-level parallel method and is suitable for distributed-shared memory systems. For the entire turbo-pump simulations, moving boundary capability and efficient time-accurate integration methods are built in the flow solver, To handle the geometric complexity and moving boundary problems, an overset grid scheme is incorporated with the solver so that new connectivity data will be obtained at each time step. The Chimera overlapped grid scheme allows subdomains move relative to each other, and provides a great flexibility when the boundary movement creates large displacements. Two numerical procedures, one based on artificial compressibility method and the other pressure projection method, are outlined for obtaining time-accurate solutions of the incompressible Navier-Stokes equations. The performance of the two methods is compared by obtaining unsteady solutions for the evolution of twin vortices behind a flat plate. Calculated results are compared with experimental and other numerical results. For an unsteady flow, which requires small physical time step, the pressure projection method was found to be computationally efficient since it does not require any subiteration procedure. It was observed that the artificial compressibility method requires a fast convergence scheme at each physical time step in order to satisfy the incompressibility condition. This was obtained by using a GMRES-ILU(0) solver in present computations. When a line-relaxation scheme was used, the time accuracy was degraded and time-accurate computations became very expensive.

Kwak, Dochan↗

DOE OSTI2024

Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed

Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.

Wilson, Brandon↗

NASA NTRS1966

Nuclear Rocket Technology Conference

The Lewis Research Center has a strong interest in nuclear rocket propulsion and provides active support of the graphite reactor program in such nonnuclear areas as cryogenics, two-phase flow, propellant heating, fluid systems, heat transfer, nozzle cooling, nozzle design, pumps, turbines, and startup and control problems. A parallel effort has also been expended to evaluate the engineering feasibility of a nuclear rocket reactor using tungsten-matrix fuel elements and water as the moderator. Both of these efforts have resulted in significant contributions to nuclear rocket technology. Many successful static firings of nuclear rockets have been made with graphite-core reactors. Sufficient information has also been accumulated to permit a reasonable Judgment as to the feasibility of the tungsten water-moderated reactor concept. We therefore consider that this technoIogy conference on the nuclear rocket work that has been sponsored by the Lewis Research Center is timely. The conference has been prepared by NASA personnel, but the information presented includes substantial contributions from both NASA and AEC contractors. The conference excludes from consideration the many possible mission requirements for nuclear rockets. Also excluded is the direct comparison of nuclear rocket types with each other or with other modes of propulsion. The graphite reactor support work presented on the first day of the conference was partly inspired through a close cooperative effort between the Cleveland extension of the Space Nuclear Propulsion Office (headed by Robert W. Schroeder) and the Lewis Research Center. Much of this effort was supervised by Mr. John C. Sanders, chairman for the first day of the conference, and by Mr. Hugh M. Henneberry. The tungsten water-moderated reactor concept was initiated at Lewis by Mr. Frank E. Rom and his coworkers. The supervision of the recent engineering studies has been shared by Mr. Samuel J. Kaufman, chairman for the second day of the conference, and Mr. Roy V. Humble. Dr. John C. Eward served as general chairman for the conference.

Source record↗

NASA NTRS1972

Parametric analysis of performance and design characteristics for advanced earth-to-orbit shuttles

Performance, trajectory, and design characteristics are presented for (1) a single-stage shuttle with a single advanced rocket engine, (2) a single-stage shuttle with an initial parallel chemical engine and advanced engine burn followed by an advanced engine sustainer burn, (3) a single-stage shuttle with an initial chemical engine burn followed by an advanced engine burn, and (4) a two-stage shuttle with a chemical propulsion booster stage and an advanced propulsion upper stage. The ascent trajectory profile includes a brief initial vertical rise; zero-lift flight through the sensible atmosphere; variational steering into an 83-kilometer by 185-kilometer intermediate orbit; and a fixed, 460-meter per second allowance for subsequent maneuvers. Results are given in terms of burnout mass fractions (including structure and payload), trajectory profiles, propellant loadings, and burn times. These results are generated with a trajectory analysis that includes a parametric variation of the specific impulse from 800 to 3000 seconds and the specific engine weight from 0 to 1.0.

Willis, E. A., Jr.↗

NASA NTRS1973

Calculation of eddy viscosity in a compressible turbulent boundary layer with mass injection and chemical reaction, volume 2

As described in Vol. 1, the eddy viscosity is calculated through the turbulent kinetic energy, in order to include the history of the flow and the effect of chemical reaction on boundary layer characteristics. Calculations can be performed for two different cooling concepts; that is, transpiration and regeneratively cooled wall cases. For the regenerative cooling option, coolant and gas side wall temperature and coolant bulk temperature in a rocket engine can be computed along the nozzle axis. Thus, this computer program is useful in designing coolant flow rate and cooling tube geometry, including the tube wall thickness as well as in predicting the effects of boundary layers along the gas side wall on thrust performances.

Omori, S.↗

NASA NTRS1975

JANNAF boundary layer integral matrix procedure

Accurate predictions of the thrust loss due to boundary layer effects and of the wall heat flux are very important to the design and performance evaluation of rocket nozzles. A method used in analytical procedures for liquid fuel rocket engine performance prediction and evaluation is presented. A computer program is examined that is a fast and accurate procedure for solving the set of boundary layer equation (momentum, energy, and species) for laminar or turbulent, chemically reacting flows with a wide variety of boundary conditions. Results of comparison of the various turbulent models are presented. A summary of the modifications and additions to the program is examined.

Evans, R. M.↗

NASA NTRS1996

Computer Aided Grid Interface: An Interactive CFD Pre-Processor

NASA maintains an applications oriented computational fluid dynamics (CFD) efforts complementary to and in support of the aerodynamic-propulsion design and test activities. This is especially true at NASA/MSFC where the goal is to advance and optimize present and future liquid-fueled rocket engines. Numerical grid generation plays a significant role in the fluid flow simulations utilizing CFD. An overall goal of the current project was to develop a geometry-grid generation tool that will help engineers, scientists and CFD practitioners to analyze design problems involving complex geometries in a timely fashion. This goal is accomplished by developing the Computer Aided Grid Interface system (CAGI). The CAGI system is developed by integrating CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) geometric system output and / or Initial Graphics Exchange Specification (IGES) files (including all the NASA-IGES entities), geometry manipulations and generations associated with grid constructions, and robust grid generation methodologies. This report describes the development process of the CAGI system.

Soni, Bharat K.↗

NASA NTRS1997

Computer Aided Grid Interface: An Interactive CFD Pre-Processor

NASA maintains an applications oriented computational fluid dynamics (CFD) efforts complementary to and in support of the aerodynamic-propulsion design and test activities. This is especially true at NASA/MSFC where the goal is to advance and optimize present and future liquid-fueled rocket engines. Numerical grid generation plays a significant role in the fluid flow simulations utilizing CFD. An overall goal of the current project was to develop a geometry-grid generation tool that will help engineers, scientists and CFD practitioners to analyze design problems involving complex geometries in a timely fashion. This goal is accomplished by developing the CAGI: Computer Aided Grid Interface system. The CAGI system is developed by integrating CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) geometric system output and/or Initial Graphics Exchange Specification (IGES) files (including all the NASA-IGES entities), geometry manipulations and generations associated with grid constructions, and robust grid generation methodologies. This report describes the development process of the CAGI system.

Soni, Bharat K.↗

NASA NTRS2002

Residual Stresses in Thermal Barrier Coatings for a Cu-8Cr-4Nb Substrate System

Analytical calculations were conducted to determine the thermal stresses developed in a coated copper-based alloy, Cu-8%(at.%)Cr-4%Nb (designated as GRCop-84), after plasma spraying and during heat-up in a simulated rocket engine environment. Finite element analyses were conducted for two coating systems consisting of a metallic top coat, a pure copper bond coat and the GRCop-84. The through thickness temperature variations were determined as a function of coating thickness for two metallic coatings, a Ni-17%(wt%)Cr-6%Al-0.5%Y alloy and a Ni-50%(at.%)Al alloy. The residual stresses after low-pressure plasma spraying of the NiCrAlY and NiAl coatings on GRCop-84 substrate were also evaluated. These analyses took into consideration a 50.8 mm copper bond coat and the effects of an interface coating roughness. The through the thickness thermal stresses developed in coated liners were also calculated after 15 minutes of exposure in a rocket environment with and without an interfacial roughness.

Ghosn, Louis J.↗