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NASA NTRS1983

An engineering evaluation of the Space Shuttle OMS engine after 5 orbital flights

Design features, performances on the first five flights, and condition of the Shuttle OMS engines are summarized. The engines were designed to provide a vacuum-fed 6000 lb of thrust and a 310 sec specific impulse, fueled by a combination of N2O4 and monomethylhydrazine (MMH) at a mixture ratio of 1.65. The design lifetime is 1000 starts and 15 hr of cumulative firing duration. The engine assembly is throat gimballed and features yaw actuators. No degradation of the hot components was observed during the first five flights, and the injector pattern maintained a uniform, enduring level of performance. An increase in the take-off loads have led to enhancing the wall thickness in the nozzle in affected areas. The engine is concluded to be performing to design specifications and is considered an operational system.

David, D.↗

NASA NTRS1994

The FC-1D: The profitable alternative Flying Circus Commercial Aviation Group

The FC-1D was designed as an advanced solution for a low cost commercial transport meeting or exceeding all of the 1993/1994 AIAA/Lockheed request for proposal requirements. The driving philosophy behind the design of the FC-1D was the reduction of airline direct operating costs. Every effort was made during the design process to have the customer in mind. The Flying Circus Commercial Aviation Group targeted reductions in drag, fuel consumption, manufacturing costs, and maintenance costs. Flying Circus emphasized cost reduction throughout the entire design program. Drag reduction was achieved by implementation of the aft nacelle wing configuration to reduce cruise drag and increase cruise speeds. To reduce induced drag, rather than increasing the wing span of the FC-1D, spiroids were included in the efficient wing design. Profile and friction drag are reduced by using riblets in place of paint around the fuselage and empennage of the FC-1D. Choosing a single aisle configuration enabled the Flying Circus to optimize the fuselage diameter. Thus, reducing fuselage drag while gaining high structural efficiency. To further reduce fuel consumption a weight reduction program was conducted through the use of composite materials. An additional quality of the FC-1D is its design for low cost manufacturing and assembly. As a result of this design attribute, the FC-1D will have fewer parts which reduces weight as well as maintenance and assembly costs. The FC-1D is affordable and effective, the apex of commercial transport design.

Meza, Victor J.↗

NASA NTRS1994

Carbon-carbon piston development

A new piston concept, made of carbon-carbon refractory-composite material, has been developed that overcomes a number of the shortcomings of aluminum pistons. Carbon-carbon material, developed in the early 1960's, is lighter in weight than aluminum, has higher strength and stiffness than aluminum and maintains these properties at temperatures over 2500 F. In addition, carbon-carbon material has a low coefficient of thermal expansion and excellent resistance to thermal shock. An effort, called the Advanced Carbon-Carbon Piston Program was started in 1986 to develop and test carbon-carbon pistons for use in spark ignition engines. The carbon-carbon pistons were designed to be replacements for existing aluminum pistons, using standard piston pin assemblies and using standard rings. Carbon-carbon pistons can potentially enable engines to be more reliable, more efficient and have greater power output. By utilizing the unique characteristics of carbon-carbon material a piston can: (1) have greater resistance to structural damage caused by overheating, lean air-fuel mixture conditions and detonation; (2) be designed to be lighter than an aluminum piston thus, reducing the reciprocating mass of an engine, and (3) be operated in a higher combustion temperature environment without failure.

Gorton, Mark P.↗

NASA NTRS2012

Concept Assessment of a Fission Fragment Rocket Engine (FFRE) Propelled Spacecraft

The March, 2012 issue of Aerospace America stated that ―the near-to-medium prospects for applying advanced propulsion to create a new era of space exploration are not very good. In the current world, we operate to the Moon by climbing aboard a Carnival Cruise Lines vessel (Saturn 5), sail from the harbor (liftoff) shedding whole decks of the ship (staging) along the way and, having reached the return leg of the journey, sink the ship (burnout) and return home in a lifeboat (Apollo capsule). Clearly this is an illogical way to travel, but forced on Explorers by today's propulsion technology. However, the article neglected to consider the one propulsion technology, using today's physical principles that offer continuous, substantial thrust at a theoretical specific impulse of 1,000,000 sec. This engine unequivocally can create a new era of space exploration that changes the way spacecraft operate. Today's space Explorers could travel in Cruise Liner fashion using the technology not considered by Aerospace America, the novel Dusty Plasma Fission Fragment Rocket Engine (FFRE). This NIAC study addresses the FFRE as well as its impact on Exploration Spacecraft design and operation. It uses common physics of the relativistic speed of fission fragments to produce thrust. It radiatively cools the fissioning dusty core and magnetically controls the fragments direction to practically implement previously patented, but unworkable designs. The spacecraft hosting this engine is no more complex nor more massive than the International Space Station (ISS) and would employ the successful ISS technology for assembly and check-out. The elements can be lifted in "chunks" by a Heavy Lift Launcher. This Exploration Spacecraft would require the resupply of small amounts of nuclear fuel for each journey and would be an in-space asset for decades just as any Cruise Liner on Earth. This study has synthesized versions of the FFRE, integrated one concept onto a host spacecraft designed for manned travel to Jupiter's moon, Callisto, and assessed that round trip journey. This engine, although unoptimized, produced 10 pounds force of thrust at a delivered specific impulse of 527,000 seconds for the entire 15-year mission while providing enormous amounts of electrical power to the spacecraft. A payload of 60 metric tons, included in the 300 metric ton vehicle, was carried to Callisto and back; the propellant tanks holding the 4 metric tons of fuel were not jettisoned in the process. The study concluded that the engine and spacecraft are within today's technology, could be built, tested, launched on several SLS (Space Launch System) (or similar) launchers, integrated, checked out, moved to an in-space base such as at a Lagrange point and operated for decades.

Engine↗

NASA NTRS2011

The J-2X Fuel Turbopump - Design, Development, and Test

Pratt and Whitney Rocketdyne (PWR), a NASA subcontractor, is executing the design, development, test, and evaluation (DDT&E) of a liquid oxygen, liquid hydrogen two hundred ninety four thousand pound thrust rocket engine initially intended for the Upper Stage (US) and Earth Departure Stage (EDS) of the Constellation Program Ares-I Crew Launch Vehicle (CLV). A key element of the design approach was to base the new J-2X engine on the heritage J-2S engine with the intent of uprating the engine and incorporating SSME and RS-68 lessons learned. The J-2S engine was a design upgrade of the flight proven J-2 configuration used to put American astronauts on the moon. The J-2S Fuel Turbopump (FTP) was the first Rocketdyne-designed liquid hydrogen centrifugal pump and provided many of the early lessons learned for the Space Shuttle Main Engine High Pressure Fuel Turbopumps. This paper will discuss the design trades and analyses performed for the current J-2X FTP to increase turbine life; increase structural margins, facilitate component fabrication; expedite turbopump assembly; and increase rotordynamic stability margins. Risk mitigation tests including inducer water tests, whirligig turbine blade tests, turbine air rig tests, and workhorse gas generator tests characterized operating environments, drove design modifications, or identified performance impact. Engineering design, fabrication, analysis, and assembly activities support FTP readiness for the first J-2X engine test scheduled for July 2011.

Tellier, James G.↗

NASA NTRS2008

International Space Station USOS Potable Water Dispenser Development

The International Space Station (ISS) Russian Segment currently provides potable water dispensing capability for crewmember food and beverage rehydration. All ISS crewmembers rehydrate Russian and U.S. style food packages from this location. A new United States On-orbit Segment (USOS) Potable Water Dispenser (PWD) is under development. This unit will provide additional potable water dispensing capability to support an onorbit crew of six. The PWD is designed to provide incremental quantities of hot and ambient temperature potable water to U.S. style food packages. It will receive iodinated water from the Fuel Cell Water Bus in the U.S. Laboratory element. The unit will provide potable-quality water, including active removal of biocidal iodine prior to dispensing. A heater assembly contained within the unit will be able to supply up to 2.0 liters of hot water (65 to 93oC) every thirty minutes. This quantity will allow three to four crewmembers to rehydrate their food and beverages from this location during a single meal. The unit is designed to remain functional for up to ten years with replacement of limited life items such as filters. It will be the size of two stacked Shuttle Middeck lockers (approximately the size of two small suitcases) and integrated into a science payload rack in the U.S. Laboratory element. Providing potable-quality water at the proper temperature for food and beverage reconstitution is critical to maintaining crew health and well-being. The numerous engineering challenges as well as human factors and safety considerations during the concept, design, and prototyping are outlined in this paper.

Shaw, Laura A.↗

NASA NTRS2008

Subscale Injector Testing to Support J-2X Engine Development

The J-2X engine being pursued for the Ares I will be a derivative of the J-2 engine developed by Pratt & Whitney Rocketdyne (PWR). As part of the engine development, a subscale injector was fabricated by PWR and hot-fire tested at NASA s Marshall Space Flight Center (MSFC) to evaluate performance data. This subscale injector had a reduced injector diameter and fewer elements than the full scale design, but the element density (#elements / injector area), and element geometries nearly identical to the full scale design. Three different materials were used for the LOX posts in order to test for durability. The subscale injector included 46 standard elements and 6 baffle elements, corresponding to the ratio of baffled elements to core elements in the full scale design. The baffle elements were included to demonstrate thermal compatibility of the baffles and to more closely represent the full scale performance. Fifteen hot-fire tests were conducted totaling over 200 seconds of mainstage time on the injector. Chamber pressures with oxygen/hydrogen propellants ranged from 870-1380 psig with mixture ratios ranging from 4.8-6.1. Fuel manifold inlet temperatures were varied from 190 to 300 R. Modular, water cooled, calorimeter chamber assemblies were used to provide heating rate data and evaluate the effects of characteristic length (L*). Performance was evaluated relative to the resulting characteristic velocity (C*) efficiency. Performance met the value required in order to proceed with this design for the full scale hardware. Hardware inspections show no evidence of cracking at the tip of the LOX post for any of the materials tested. Minor erosion of the baffle element tips was observed in the early testing. A design change was quickly implemented and tested, and this change resolved the issue. Development of the J-2X is continuing with this element density and design.

Protz, Christopher↗

NASA NTRS2000

Upper Stage Flight Experiment 10K Engine Design and Test Results

A 10,000 lbf thrust chamber was developed for the Upper Stage Flight Experiment (USFE). This thrust chamber uses hydrogen peroxide/JP-8 oxidizer/fuel combination. The thrust chamber comprises an oxidizer dome and manifold, catalyst bed assembly, fuel injector, and chamber/nozzle assembly. Testing of the engine was done at NASA's Stennis Space Center (SSC) to verify its performance and life for future upper stage or Reusable Launch Vehicle applications. Various combinations of silver screen catalyst beds, fuel injectors, and combustion chambers were tested. Results of the tests showed high C* efficiencies (97% - 100%) and vacuum specific impulses of 275 - 298 seconds. With fuel film cooling, heating rates were low enough that the silica/quartz phenolic throat experienced minimal erosion. Mission derived requirements were met, along with a perfect safety record.

Ross, R.↗

NASA NTRS1955

Aircraft-Fuel-Tank Design for Liquid Hydrogen

Some of the considerations involved in the design of aircraft fuel tanks for liquid hydrogen are discussed herein. Several of the physical properties of metals and thermal insulators in the temperature range from ambient to liquid-hydrogen temperatures are assembled. Calculations based on these properties indicate that it is possible to build a large-size liquid-hydrogen fuel tank which (1) will weigh less then 15 percent of the fuel weight, (2) will have a hydrogen vaporization rate less than 30 percent of the cruise fuel-flow rate, and (3) can be held in a stand-by condition and readied for flight in a short time.

Reynolds, T W↗

NASA NTRS1992

Regolith thermal energy storage for lunar nighttime power

A scheme for providing nighttime electric power to a lunar base is described. This scheme stores thermal energy in a pile of regolith. Any such scheme must somehow improve on the poor thermal conductivity of lunar regolith in vacuum. Two previous schemes accomplish this by casting or melting the regolith. The scheme described here wraps the regolith in a gas-tight bag and introduces a light gas to enhance thermal conductivity. This allows the system to be assembled with less energy and equipment than schemes which require melting of regolith. A point design based on the new scheme is presented. Its mass from Earth compares favorably with the mass of a regenerative fuel cell of equal capacity.

Tillotson, Brian↗

NASA NTRS2011

Design of Multilayer Insulation for the Multipurpose Hydrogen Test Bed

Multilayer insulation (MLI) is a critical component for future, long term space missions. These missions will require the storage of cryogenic fuels for extended periods of time with little to no boil-off and MLI is vital due to its exceptional radiation shielding properties. Several MLI test articles were designed and fabricated which explored methods of assembling and connecting blankets, yielding results for evaluation. Insight gained, along with previous design experience, will be used in the design of the replacement blanket for the Multipurpose Hydrogen Test Bed (MHTB), which is slated for upcoming tests. Future design considerations are discussed which include mechanical testing to determine robustness of such a system, as well as cryostat testing of samples to give insight to the loss of thermal performance of sewn panels in comparison to the highly efficient, albeit laborious application of the original MHTB blanket.

Marlow, Weston A.↗

NASA NTRS1992

H2 fueled flightweight ramjet construction and test

The ACES Program began the investigation of regeneratively cooled ramjet engines for propelling aircraft at Mach 6 to 8 flight regimes while collecting and processing air for later use as oxidizer in rocket propulsion into an orbit flight mode. The Marquardt Company had as its prime task the design and demonstration of a ramjet capable of steady state operating using hydrogen as the regenerative coolant and with fuel flow limited to a theta = 1. Marquardt progressed from shell type combustors to advanced tubular combustion chambers in direct connect test rigs. The first tests were made with water cooled center bodies and plug nozzles using a pebble bed air heater to simulate flight air temperature. Later tests were made on completely H2 cooled flight weight V/G assemblies direct connected to a SUE burner heater. Design studies were also conducted on integrated systems for take-off capability using offset turbojets connected to 2-D or axisymmetric inlets. An 18 inch hypersonic ramjet evaluation scale model was designed based on the hot test results using a fully V/G inlet and exit nozzle. This thruster would provide 25000 lbs. of thrust with an estimated weight of 250 lbs. A V/G inlet would also incorporate an inlet seal for possible take-off thrust by rocket operation. Hypersonic ramjet construction features and chamber thrust development are discussed.

Malek, Albert↗

NASA NTRS1980

Thermal-structural design study of an airframe-integrated Scramjet

The development and evaluation of a design concept for the cooled structures assembly for the Scramjet engine is discussed. Development concepts for engine subsystems and design concepts for the aircraft/engine interface are included. A thermal protection system was defined which makes it possible to attain a life of 100 hr and 1000 cycles, the specified goal. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six module engine, the mass per unit capture area is 1256 kg/sq m. The total mass of a six module engine assembly including the fuel system is 1502 kg.

Killackey, J. J.↗

NASA NTRS2007

Analytical Approach for Estimating Preliminary Mass of ARES I Crew Launch Vehicle Upper Stage Structural Components

In January 2004, President Bush gave the National Aeronautics and Space Administration (NASA) a vision for Space Exploration by setting our sight on a bold new path to go back to the Moon, then to Mars and beyond. In response to this vision, NASA started the Constellation Program, which is a new exploration launch vehicle program. The primary mission for the Constellation Program is to carry out a series of human expeditions ranging from Low Earth Orbit to the surface of Mars and beyond for the purposes of conducting human exploration of space, as specified by the Vision for Space Exploration (VSE). The intent is that the information and technology developed by this program will provide the foundation for broader exploration activities as our operational experience grows. The ARES I Crew Launch Vehicle (CLV) has been designated as the launch vehicle that will be developed as a "first step" to facilitate the aforementioned human expeditions. The CLV Project is broken into four major elements: First Stage, Upper Stage Engine, Upper Stage (US), and the Crew Exploration Vehicle (CEV). NASA's Marshall Space Flight Center (MSFC) is responsible for the design of the CLV and has the prime responsibility to design the upper stage of the vehicle. The US is the second propulsive stage of the CLV and provides CEV insertion into low Earth orbit (LEO) after separation from the First Stage of the Crew Launch Vehicle. The fully integrated Upper Stage is a mix of modified existing heritage hardware (J-2X Engine) and new development (primary structure, subsystems, and avionics). The Upper Stage assembly is a structurally stabilized cylindrical structure, which is powered by a single J-2X engine which is developed as a separate Element of the CLV. The primary structure includes the load bearing liquid hydrogen (LH2) and liquid oxygen (LOX) propellant tanks, a Forward Skirt, the Intertank structure, the Aft Skirt and the Thrust Structure. A Systems Tunnel, which carries fluid and electrical power functions to other Elements of the CLV, is included as secondary structure. The MSFC has an overall responsibility for the integrated US element as well as structural design an thermal control of the fuel tanks, intertank, interstage, avionics, main propulsion system, Reaction Control System (RCS) for both the Upper Stage and the First Stage. MSFC's Spacecraft and Vehicle Department, Structural and Analysis Design Division is developing a set of predicted mass of these elements. This paper details the methodology, criterion and tools used for the preliminary mass predictions of the upper stage structural assembly components. In general, weight of the cylindrical barrel sections are estimated using the commercial code Hypersizer, whereas, weight of the domes are developed using classical solutions. HyperSizer is software that performs automated structural analysis and sizing optimization based on aerospace methods for strength, stability, and stiffness. Analysis methods range from closed form, traditional hand calculations repeated every day in industry to more advanced panel buckling algorithms. Margin-of-safety reporting for every potential failure provides the engineer with a powerful insight into the structural problem. Optimization capabilities include finding minimum weight panel or beam concepts, material selections, cross sectional dimensions, thicknesses, and lay-ups from a library of 40 different stiffened and sandwich designs and a database of composite, metallic, honeycomb, and foam materials. Multiple different concepts (orthogrid, isogrid, and skin stiffener) were run for multiple loading combinations of ascent design load with and with out tank pressure as well as proof pressure condition. Subsequently, selected optimized concept obtained from Hypersizer runs was translated into a computer aid design (CAD) model to account for the wall thickness tolerance, weld land etc for developing the most probable weight of the components. The flow diram summarizes the analysis steps used in developing these predicted mass.

Aggarwal, Pravin↗

NASA NTRSDate not supplied

Coupled Reactor Multiphysics and Mass Scalability Assessment for Crewed Megawatt-Class NEP System Architectures

Nuclear Electric Propulsion (NEP) is an in-space propulsion technology capable of enabling opposition and conjunction class crewed Mars missions. NEP subsystems include the reactor for heat generation, a power conversion system (PCS), power management and distribution (PMAD), electric propulsion subsystem (EPS), and a primary heat rejection system. Specific mass, or αe (kg / kWe), is a key performance parameter (KPP) of the propulsion system which is directly scalable with the performance and mass estimates for individual components. To inform technology maturation planning, full system and component level parametric modeling is ongoing to explore the design trade space and illustrate the effect of subsystem design choices on the system KPPs. In this study, scaling of high-assay, low-enriched uranium (HALEU) reactor designs is assessed through coupled reactor physics and thermal hydraulics analyses. Scaling analyses evaluate the impact of system performance parameters (power level, interface temperatures) on mass for direct gas cooled, pumped liquid metal, and passively cooled heat pipe reactor concepts. Each concept requires specific geometries and working fluids to reach the performance goals of PCS interface conditions (temperature, pressure, flow rate) and system mass. The reactor assembly includes the active core (fuel, moderator, cladding, working fluid), axial and radial neutron reflectors, control drums, structural support / pressure vessel, and external radiation shielding. Each of these components are parametrically sized based on performance parameters for a megawatt-class power cycle. Results of this scaling analysis increase NEP propulsion system modeling fidelity and ultimately aim to support technology down-selection along with related technology development planning. The reactor and shield αe are a function of several PCS design choices, and reactor scaling with these parameters must be considered to enable an informed decision on reactor geometry and working fluid combination.

Nuclear Electric Propulsion↗

NASA NTRSDate not supplied

Coupled Reactor Multiphysics and Mass Scalability Assessment for Crewed Megawatt-Class NEP System Architectures

Nuclear Electric Propulsion (NEP) is an in-space propulsion technology capable of enabling opposition and conjunction class crewed Mars missions. NEP subsystems include the reactor for heat generation, a power conversion system (PCS), power management and distribution, electric propulsion system, and heat rejection system. Specific mass, or α (kg/kWe), is a key performance parameter (KPP) of the propulsion system which is directly scalable with the performance and mass predictions for each individual component. To inform technology maturation planning activities, full system and component level parametric modeling is ongoing to explore the design trade space and illustrate the effect of subsystem design choices on the system KPPs. In this study, scaling of high-assay, low-enriched uranium reactor designs is assessed through coupled reactor physics and thermal hydraulics analyses. Scaling analyses evaluate the impact of system performance parameters (power level, interface temperatures) on mass for direct gas cooled, pumped liquid metal, and passively-cooled heat pipe reactor concepts. Each concept requires specific geometries, fluids, and power conversion interface conditions (temperature, pressure, flow rate) to meet desired performance and mass. The reactor assembly includes the active core (fuel, moderator, cladding, working fluid), axial and radial neutron reflectors, control drums, structural support / pressure vessel, and external radiation shielding. Each of these components are parametrically sized based on performance parameters for a megawatt-class power cycle. Results of this scaling analysis increase NEP propulsion system modeling fidelity and ultimately aim to support concept down-selection along with related technology development planning. The reactor and shield α are a function of several PCS and heat rejection system design choices, and reactor scaling with these parameters must be considered to enable an informed decision on an optimal reactor geometry and working fluid combination.

Nuclear Electric Propulsion↗

NASA NTRS1978

Thermal-structural design study of an airframe-integrated Scramjet

Design concepts are developed and evaluated for a cooled structures assembly for the Scramjet engine, for engine subsystems mass, volume, and operating requirements, and for the aircraft/engine interface. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 12.4 KN/sq m. The total weight of a six-module engine assembly including the fuel system is 14.73 KN.

Killackey, J. J.↗

NASA NTRS1991

Constitutive and damage material modeling in a high pressure hydrogen environment

Numerous components in reusable space propulsion systems such as the SSME are exposed to high pressure gaseous hydrogen environments. Flow areas and passages in the fuel turbopump, fuel and oxidizer preburners, main combustion chamber, and injector assembly contain high pressure hydrogen either high in purity or as hydrogen rich steam. Accurate constitutive and damage material models applicable to high pressure hydrogen environments are therefore needed for engine design and analysis. Existing constitutive and cyclic crack initiation models were evaluated only for conditions of oxidizing environments. The main objective is to evaluate these models for applicability to high pressure hydrogen environments.

Russell, D. A.↗