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NASA NTRS1999

Interplanetary Microlaser Transponders

The feasibility of an asynchronous (i.e. independently firing) interplanetary laser transponder, capable of ranging between Earth and Mars and using the automated SLR2000 Satellite Laser Ranging (SLR) system as an Earth base station, has been suggested. Since that time, we have received a small amount of discretionary funding to further explore the transponder concept and to develop and test an engineering breadboard. Candidate operational scenarios for acquiring and tracking the opposite laser terminal over interplanetary distances have been developed, and breadboard engineering parameters were chosen to reflect the requirements of an Earth-Mars link Laboratory tests have been devised to simulate the Earth- Mars link between two independent SLR2000 transceivers and to demonstrate the transfer of range and time in single photon mode. The present paper reviews the concept of the asynchronous microlaser transponder, the transponder breadboard design, an operational scenario recently developed for an asteroid rendezvous, and the laboratory test setup. The optical head of the transponder breadboard fits within a cylinder roughly 15 cm in diameter and 32 cm in length and is mounted in a commercial two axis gimbal driven by two computer-controlled stepper motors which allows the receiver optical axis to be centered on a simulated Earth image. The optical head is built around a small optical bench which supports a 14.7 cm diameter refractive telescope, a prototype 2 kHz SLR2000 microlaser transmitter, a quadrant microchannel plate photomultiplier (MCP/PMT), a CCD array camera, spatial and spectral filters, assorted lenses and mirrors, and protective covers and sun shields. The microlaser is end-pumped by a fiber-coupled diode laser array. An annular mirror is employed as a passive transmit/receive (T/R) switch in an aperture-sharing arrangement wherein the transmitted beam passes through the central hole and illuminates only the central 2.5 cm of the common telescope (adequate to achieve a 10 arcsecond full laser beam divergence) while the receiver uses the remainder of the 14.7 cm aperture. Additional electronic instrumentation includes the diode pump array and associated heat sink and current drivers, rubidium frequency standard, timing distribution module, range gate generator, a recently developed all-digital correlation range receiver, and system computer. Acquisition of the opposite transponder terminal requires a search within a three-dimensional volume determined by the initial pointing uncertainty and a maximum 500 microsecond uncertainty in the laser time of fire at the opposite terminal for totally uncorrelated Earth and spacecraft clocks. The angular search is aided by a sensitive CCD array capable of imaging the Earth, Moon, and surrounding stars within the nominal + 0.5 degree cone of uncertainty associated with the initial pointing of a spacecraft body or microwave communications dish.

Degnan, John J.↗

NASA NTRS1978

Quick look test report: MPT static firing no. 2 test MPT-S2

The three engine cluster was fired at 70 percent power level for a nominal 15 seconds to evaluate the integrated performance of the main propulsion system. Engine ignition occurred at approximately 1403 with the planned mainstage duration achieved for all three engines. Operation of all systems was as expected with the exception of the recirculation pumps. The pumps were started while the propellant loading was in fast fill, but they cavitated and lost head at the termination of fast fill. The pumps were subsequently restarted after pressurizing the tank and draining back propellant to get good quality. Post test inspection of the engines revealed some discoloration on the inside of the thrust chamber and distorted drain lines for engine #2.

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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.

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NASA NTRS1980

Solar heating and domestic hot water system installed at Kansas City, Fire Stations, Kansas City, Missouri

The solar system was designed to provide 47 percent of the space heating, 8,800 square feet area and 75 percent of the domestic hot water (DHW) load. The solar system consists of 2,808 square feet of Solaron, model 2001, air, flat plate collector subsystem, a concrete box storage subsystem which contains 1,428 cubic feet of 0.5 inch diameter pebbles weighing 71.5 tons, a DHW preheat tank, blowers, pumps, heat exchangers, air ducting, controls and associated plumbing. Two 120 gallon electric DHW heaters supply domestic hot water which is preheated by the solar system. Auxiliary space heating is provided by three electric heat pumps with electric resistance heaters and four 30 kilowatt electric unit heaters. There are six modes of system operation.

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NASA NTRS2004

Prototype Test Results for the Single Photon Detection SLR2000 Satellite Laser Ranging System

NASA's aging Satellite Laser Ranging (SLR) network is scheduled to be replaced over the next few years with a fully automated single photon detection system. A prototype of this new system, called SLR2000, is currently undergoing field trials at the Goddard Space Flight Center in Greenbelt, Maryland to evaluate photon counting techniques and determine system hardware, software, and control algorithm performance levels and limitations. Newly developed diode pumped microchip lasers and quadrant microchannel plate-based photomultiplier tubes have enabled the development of this high repetition rate single photon detection SLR system. The SLR2000 receiver threshold is set at the single photoelectron (pe) level but tracks satellites with an average signal level typically much less than 1 pe. The 2 kHz laser fire rate aids in satellite acquisition and tracking and will enable closed loop tracking by accumulating single photon count statistics in a quadrant detector and using this information to correct for pointing errors. Laser transmitter beamwidths of 10 arcseconds (FWHM) or less are currently being used to maintain an adequate signal level for tracking while the receiver field of view (FOV) has been opened to 40 arcseconds to accommodate point ahead/look behind angular offsets. In the near future, the laser transmitter point ahead will be controlled by a pair of Risley prisms. This will allow the telescope to point behind and enable closure of the receiver FOV to roughly match the transmitter beam divergence. Bandpass filters (BPF) are removed for night tracking operations while 0.2 nm or 1 nm filters are used during daylight operation. Both day and night laser tracking of Low Earth Orbit (LEO) satellites has been achieved with a laser transmitter energy of only 65 microjoules per pulse. Satellite tracking is presently limited to LEO satellites until the brassboard laser transmitter can be upgraded or replaced. Simultaneous tracks have also been observed with NASA s SLR standard, MOBLAS 7, for the purposes of data comparison and identification of biases. Work continues to optimize the receive optics; upgrade or replace the laser transmitter; calibrate the quadrant detector, the point ahead Risley prisms, and event timer verniers; and test normal point generation with SLR2000 data. This paper will report on the satellite tracking results to date, issues yet to be resolved, and future plans for the SLR2000 system.

Zagwodzki, Thomas W.↗

NASA NTRS2006

Marshall Space Flight Center Autumn 2005

The East Test Area at Marshall Space Flight Center has five major test stands, each of which has two or more test positions, not counting the SSME and RD-180 engine test facilities in the West Test Area. These research and development facilities are capable of testing high pressure pumps, both fuel and oxidizer, injectors, chambers and sea-level engine assemblies, as well as simulating deep space environments in the 12, 15 and 20 foot vacuum chambers. Liquid propellant capabilities are high pressure hydrogen (liquid and gas), methane (liquid and gas), and RP-1 and high pressure LOX. Solid propellant capability includes thrust measurement and firing capability up to 1/6 scale Shuttle SRB segment. In the past six months MSFC supported multiple space access and exploration programs in the previous six months. Major programs were Space Exploration, Shuttle External Tank research, Reusable Solid Rocket Motor (RSRM) development, as well as research programs for NASA and other customers. At Test Stand 115 monopropellant ignition testing was conducted on one position. At the second position multiple ignition/variable burn time cycles were conducted on Vacuum Plasma Spatter (VPS) coated injectors. Each injector received fifty cycles; the propellants were LOX Hydrogen and the ignition source was TEA. Following completion of the monopropellant test series the stand was reconfigured to support ignition testing on a LOX Methane injector system. At TS 116 a thrust stand used to test Booster Separation Motors from the Shuttle SRB system was disassembled and moved from Chemical Systems Division s Coyote Canyon plant to MSFC. The stand was reassembled and readied for BSM testing. Also, a series of tests was run on a Pratt & Whitney Rocketdyne Low Element Density (LED) injector engine. The propellants for this engine are LOX and LH2. At TS 300 the 20 foot vacuum chamber was configured to support hydrogen testing in the Multipurpose Hydrogen Test Bed (MHTB) test article. This testing, which went 24/7 for fourteen consecutive days, demonstrated long duration storage methods intended to minimize losses of propellant in support of the Space Exploration Initiative. The facility is being converted to support similar research using liquid methane. The 12 foot chamber at TS 300 was used to create ascent profiles (both heat and altitude effects) for foam panel testing in support of the Shuttle External Tank program. At TS 500, one position was in build-up to support ATK Thiokol research into the gas dynamics associated with high pressure flow across the propellant joint in segmented solid rocket motors. The testing involves flowing high pressure gas through a 24 motor case. Initial tests will be conducted with simulated aluminum grain, followed by tests using actual propellant. The second position at TS 500 has been in build-up for testing a LOX methane thruster manufactured by KT Engineering. At the Solid Propulsion Test Area (SPTA), the first dual segment 24 solid rocket motor was fired for ATK Thiokol in support of the RSRM program. A new axial thrust measurement stand was designed and fabricated for this testing. Real Time Radiography (RTR) will be deployed to examine nozzle erosion on the next dual segment motor.

Allen, Mike↗

NASA NTRS2000

Application of Rapid Prototyping to the Investment Casting of Test Hardware (MSFC Center Director's Discretionary Fund Final Report, Project No. 98-08)

Investment casting masters of a selected propulsion hardware component, a fuel pump housing, were rapid prototyped on the several processes in-house, along with the new Z-Corp process acquired through this project. Also, tensile samples were prototyped and cast using the same significant parameters. The models were then shelled in-house using a commercial grade zircon-based slurry and stucco technique. Next, the shelled models were fired and cast by our in-house foundry contractor (IITRI), with NASA-23, a commonly used test hardware metal. The cast models are compared by their surface finish and overall appearance (i.e., the occurrence of pitting, warping, etc.), as well as dimensional accuracy.

Cooper, K. G.↗

NASA NTRS1979

Symposium /International/ on Combustion, 17th, Leeds University, Leeds, England, August 20-25, 1978, Proceedings

The Symposium focused on deflagration to detonation transition, coal combustion, turbulent-combustion interactions, kinetics, furnace combustion, inhibition and ignition, flame structure and chemistry, combustion studies, measurement techniques, fire and explosion, engine combustion, soot, and propellants and explosives. Papers were presented on numerical modeling of the deflagration-to-detonation transition, the interaction between turbulence and combustion, turbulent flame propagation in premixed gases, spray evaporation in recirculating flow, dissociation of nitric oxide in shock waves, pollutant emissions from partially mixed turbulent flames, energy transfer and quenching rates of laser-pumped electronically excited alkalis in flames, a study of flammability limits using counterflow flames, the unified theory of explosions with fuel consumption, and the dynamics and radiant intensity of large hydrogen flames.

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NASA NTRS1989

Hybrid propulsion technology program. Volume 2: Technology definition package

A concept design study was performed to configure two sizes of hybrid boosters; one which duplicates the advanced shuttle rocket motor vacuum thrust time curve and a smaller, quarter thrust level booster. Two sizes of hybrid boosters were configured for either pump-fed or pressure-fed oxygen feed systems. Performance analyses show improved payload capability relative to a solid propellant booster. Size optimization and fuel safety considerations resulted in a 4.57 m (180 inch) diameter large booster with an inert hydrocarbon fuel. The preferred diameter for the quarter thrust level booster is 2.53 m (96 inches). The demonstration plan would culminate with test firings of a 3.05 m (120 inch) diameter hybrid booster.

Jensen, Gordon E.↗

NASA NTRS2012

Benefits of a Single-Person Spacecraft for Weightless Operations

Historically, less than 20 percent of crew time related to extravehicular activity (EVA) is spent on productive external work.1 A single-person spacecraft with 90 percent efficiency provides productive new capabilities for maintaining the International Space Station (ISS), exploring asteroids, and servicing telescopes or satellites. With suits, going outside to inspect, service or repair a spacecraft is time-consuming, requiring pre-breathe time, donning a fitted space suit, and pumping down an airlock. For ISS, this is between 12.5 and 16 hours for each EVA, not including translation and work-site set up. The work is physically demanding requiring a day of rest between EVAs and often results in suit-induced trauma with frequent injury to astronauts fingers2. For maximum mobility, suits use a low pressure, pure oxygen atmosphere. This represents a fire hazard and requires pre-breathing to reduce the risk of decompression sickness (bends). With virtually no gravity, humans exploring asteroids cannot use legs for walking. The Manned Maneuvering Unit offers a propulsive alternative however it is no longer in NASA s flight inventory. FlexCraft is a single person spacecraft operating at the same cabin atmosphere as its host so there is no risk of the bends and no pre-breathing. This allows rapid, any-time access to space for repeated short or long EVAs by different astronauts. Integrated propulsion eliminates hand-over-hand translation or having another crew member operate the robotic arm. The one-size-fits-all FlexCraft interior eliminates the suit part inventory and crew time required to fit all astronauts. With a shirtsleeve cockpit, conventional displays and controls are used and because the work is not strenuous no rest days are required. Furthermore, there is no need for hand tools because manipulators are equipped with force multiplying end-effectors that can deliver the precise torque for the job.

Griffin, Brand N.↗

NASA NTRS2010

J-2X Turbopump Cavitation Diagnostics

The J-2X is the upper stage engine currently being designed by Pratt & Whitney Rocketdyne (PWR) for the Ares I Crew Launch Vehicle (CLV). Propellant supply requirements for the J-2X are defined by the Ares Upper Stage to J-2X Interface Control Document (ICD). Supply conditions outside ICD defined start or run boxes can induce turbopump cavitation leading to interruption of J-2X propellant flow during hot fire operation. In severe cases, cavitation can lead to uncontained engine failure with the potential to cause a vehicle catastrophic event. Turbopump and engine system performance models supported by system design information and test data are required to predict existence, severity, and consequences of a cavitation event. A cavitation model for each of the J-2X fuel and oxidizer turbopumps was developed using data from pump water flow test facilities at Pratt & Whitney Rocketdyne (PWR) and Marshall Space Flight Center (MSFC) together with data from Powerpack 1A testing at Stennis Space Center (SSC) and from heritage systems. These component models were implemented within the PWR J-2X Real Time Model (RTM) to provide a foundation for predicting system level effects following turbopump cavitation. The RTM serves as a general failure simulation platform supporting estimation of J-2X redline system effectiveness. A study to compare cavitation induced conditions with component level structural limit thresholds throughout the engine was performed using the RTM. Results provided insight into system level turbopump cavitation effects and redline system effectiveness in preventing structural limit violations. A need to better understand structural limits and redline system failure mitigation potential in the event of fuel side cavitation was indicated. This paper examines study results, efforts to mature J-2X turbopump cavitation models and structural limits, and issues with engine redline detection of cavitation and the use of vehicle-side abort triggers to augment the engine redline system.

Santi, I. Michael↗

NASA NTRS2010

A History of Welding on the Space Shuttle Main Engine (1975 to 2010)

The Space Shuttle Main Engine (SSME) is a high performance, throttleable, liquid hydrogen fueled rocket engine. High thrust and specific impulse (Isp) are achieved through a staged combustion engine cycle, combined with high combustion pressure (approx.3000psi) generated by the two-stage pump and combustion process. The SSME is continuously throttleable from 67% to 109% of design thrust level. The design criteria for this engine maximize performance and weight, resulting in a 7,800 pound rocket engine that produces over a half million pounds of thrust in vacuum with a specific impulse of 452/sec. It is the most reliable rocket engine in the world, accumulating over one million seconds of hot-fire time and achieving 100% flight success in the Space Shuttle program. A rocket engine with the unique combination of high reliability, performance, and reusability comes at the expense of manufacturing simplicity. Several innovative design features and fabrication techniques are unique to this engine. This is as true for welding as any other manufacturing process. For many of the weld joints it seemed mean cheating physics and metallurgy to meet the requirements. This paper will present a history of the welding used to produce the world s highest performance throttleable rocket engine.

Zimmerman, Frank R.↗

NASA NTRS1999

Materials Selection and Their Characteristics as Used in Rapid Prototyping

NASA's Marshall Space Flight Center (MSFC) conducted a program to evaluate six technologies used in Rapid Prototyping (RP) to produce investment casting patterns. In this paper, RP refers to the collective additive fabrication technologies known as Solid Free-Form Fabrication. Such technologies are being used with increasing frequency in manufacturing applications, due in part to their rapidly expanding capabilities to fabricate models from many types of materials. This study used ABS plastic, polycarbonate, TrueForm PM6, epoxy resin, paper, starch, and wax. The baseline model was a semi-complex prototype fuel pump housing, intended for use in the X-33 reusable launch vehicle. All models were shelled in a production- grade colloidal silica ceramic. Primary coats were zircon-base flour with zircon backup, while secondary coats were silica grains with a tabular alumina backup. Each model was shelled in an identical manner, using the same atmospheric conditions and drying times, as well as the same number of layers. Bake-outs and firing cycles were consistent with the leach ability of each material. Preheat and bath temperatures were also kept consistent. All molds were cast in vacuum using a hydrogen-resistant superalloy (NASA- 23) that was developed in-house. The final technical evaluation included detailed measurements of the model and the final casting, in order to determine any dimensional changes caused by different pattern materials, as well as documentation of all defects and any obvious refractory/model reactions. Prototype production costs were estimated for each method and taken into consideration during trade-off analysis.

Cooper, K.↗

NASA NTRS1960

Ignition of a Combustible Atmosphere by Incandescent Carbon Wear Particles

A study was made to determine whether carbon wear particles from carbon elements in sliding contact with a metal surface were sufficiently hot to cause ignition of a combustible atmosphere. In some machinery, electric potential differences and currents may appear at the carbon-metal interface. For this reason the effect of these voltages and currents on the ability of carbon wear particles to cause ignition was evaluated. The test specimens used in the investigation were carbon vanes taken from a fuel pump and flat 21-inch-diameter 2 metal disks (440-C stainless steel) representing the pump housing. During each experiment a vane was loaded against a disk with a 0.5-pound force, and the disk was rotated to give a surface speed of 3140 feet per minute. The chamber of the apparatus that housed the vane and the disk was filled with a combustible mixture of air and propane. Various voltages and amperages were applied across the vane-disk interface. Experiments were conducted at temperatures of 75, 350, 400, and 450 F. Fires were produced by incandescent carbon wear particles obtained at conditions of electric potential as low as 106 volts and 0.3 ampere at 400 F. Ignitions were obtained only with carbon wear particles produced with an electric potential across the carbon-vane-disk interface. No ignitions were obtained with carbon wear particles produced in the absence of this potential; also, the potential difference produced no ignitions in the absence of carbon wear particles. A film supplement showing ignition by incandescent wear particles is available.

Buckley, Donald H.↗

NASA NTRS2011

Application of Probabilistic Methods to Assess Risk Due to Resonance in the Design of J-2X Rocket Engine Turbine Blades

The LOX-Hydrogen J-2X Rocket Engine, which is proposed for use as an upper-stage engine for numerous earth-to-orbit and heavy lift launch vehicle architectures, is presently in the design phase and will move shortly to the initial development test phase. Analysis of the design has revealed numerous potential resonance issues with hardware in the turbomachinery turbine-side flow-path. The analysis of the fuel pump turbine blades requires particular care because resonant failure of the blades, which are rotating in excess of 30,000 revolutions/minutes (RPM), could be catastrophic for the engine and the entire launch vehicle. This paper describes a series of probabilistic analyses performed to assess the risk of failure of the turbine blades due to resonant vibration during past and present test series. Some significant results are that the probability of failure during a single complete engine hot-fire test is low (~1%) because of the small likelihood of resonance, but that the probability increases to around 30% for a more focused turbomachinery-only test because all speeds will be ramped through and there is a greater likelihood of dwelling at more speeds. These risk calculations have been invaluable for use by program management in deciding if risk-reduction methods such as dampers are necessary immediately or if the test can be performed before the risk-reduction hardware is ready.

Brown, Andrew M.↗

NASA NTRS1992

Lidar Measurements of Metallic Species in Mesopause Region

Sodium density distributions were measured over more than 20 nights since Jul. 1991 at Tokyo Metropolitan University. Our sodium lidar specifications are shown. The lidar consists of a dye laser that is pumped by a pulsed Nd:YAG laser. The dye laser is tuned to the D2 resonant absorption line of Na at the wavelength of 589 nm. A small fraction of the output beam is directed to a hollow-cathode lamp. The precise tuning of the Na D2 line is accomplished by monitoring the signal obtained from the hollow-cathode lamp and controlling the grating in the dye laser oscillator cavity. The raw data for each profile were obtained by firing the laser 5000 times for approximately 8.5 minutes. We have observed the sporadic sodium layers three times during the observation period. Recently, lidar measurements of iron atoms were also performed. Other aspects of this investigation are presented.

Nagasawa, Chikao↗

NASA NTRS1985

Flow dynamic environment data base development for the SSME

The fluid flow-induced vibration of the Space Shuttle main engine (SSME) components are being studied with a view to correlating the frequency characteristics of the pressure fluctuations in a rocket engine to its operating conditions and geometry. An overview of the data base development for SSME test firing results and the interactive computer software used to access, retrieve, and plot or print the results selectively for given thrust levels, engine numbers, etc., is presented. The various statistical methods available in the computer code for data analysis are discussed. Plots of test data, nondimensionalized using parameters such as fluid flow velocities, densities, and pressures, are presented. Results are compared with those available in the literature. Correlations between the resonant peaks observed at higher frequencies in power spectral density plots with pump geometry and operating conditions are discussed. An overview of the status of the investigation is presented and future directions are discussed.

Sundaram, C. V.↗

NASA NTRS2006

Liquid Bismuth Feed System for Electric Propulsion

Operation of Hall thrusters with bismuth propellant has been shown to be a promising path toward high-power, high-performance, long-lifetime electric propulsion for spaceflight missions. For example, the VHITAL project aims td accurately, experimentally assess the performance characteristics of 10 kW-class bismuth-fed Hall thrusters - in order to validate earlier results and resuscitate a promising technology that has been relatively dormant for about two decades. A critical element of these tests will be the precise metering of propellant to the thruster, since performance cannot be accurately assessed without an accurate accounting of mass flow rate. Earlier work used a pre/post-test propellant weighing scheme that did not provide any real-time measurement of mass flow rate while the thruster was firing, and makes subsequent performance calculations difficult. The motivation of the present work was to develop a precision liquid bismuth Propellant Management System (PMS) that provides real-time propellant mass flow rate measurement and control, enabling accurate thruster performance measurements. Additionally, our approach emphasizes the development of new liquid metal flow control components and, hence, will establish a basis for the future development of components for application in spaceflight. The design of various critical components in a bismuth PMS are described - reservoir, electromagnetic pump, hotspot flow sensor, and automated control system. Particular emphasis is given to material selection and high-temperature sealing techniques. Open loop calibration test results are reported, which validate the systems capability to deliver bismuth at mass flow rates ranging from 10 to 100 mg/sec with an uncertainty of less than +/- 5%. Results of integrated vaporizer/liquid PMS tests demonstrate all of the necessary elements of a complete bismuth feed system for electric propulsion.

Markusic, T. E.↗