Nuclear systems for Mars exploration
This paper identifies breakpoints for various power and propulsion technologies, with a special focus on fission-based sources in support of NASA's Mars exploration program.
NEP↗
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Results for “Propulsion Technology”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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The Role of Analysis and Testing in the Service Life Assessment of Ion Engines
Experience from tests and flights and engineering analysis represent the two sources of information on which to base conclusions on the reliability or failure risk of aerospace flight systems. It is rarely feasible to establish high reliability at high confidence by testing aerospace flight systems or components. The limitations of testing in evaluating failure risk are discussed and an alternate statistical approach which relies on both test experience and analysis to quantitatively assess reliability is outlined. The implementation of this methodology in the service life assessment of ion thrusters is discussed and examples of failure modes being addressed in the NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) program are given.
Ion↗
Legacy of the Asteroid Redirect Robotic Mission (ARRM)
NASA’s proposed Asteroid Redirect Robotic Mission (ARRM) began with the recognition in a 2010 NASA study that emerging high-power solar electric propulsion technology could be used to rendezvous with, capture, and return an entire, very small (~10,000 kg), near Earth asteroids to the International Space Station. A 2011 workshop by the Keck Institute for Space Studies (KISS) extended the earlier NASA study to asteroid masses of order 500,000 kg by returning them to cislunar space. Subsequent detailed NASA studies in 2013-2014 confirmed the feasibility of this concept. This led to the establishment of the Asteroid Redirect Mission program that consisted of a robotic mission to return multiple tons of asteroid material to cislunar space and a crewed mission to rendezvous with the robotic vehicle, perform two extra vehicular activities (EVAs), collect samples of the asteroid material, and return this material to Earth. Implementation of ARRM got midway through Phase B before being cancelled in April 2017. Although ARRM was cancelled, it has left a near-term legacy of positive impacts to the human spaceflight community, the planetary defense community, the deep space science community, and asteroid mining interests.
Brophy, John R.↗
Urban Air Mobility: A Control-Centric Approach to Addressing Technical Challenges
Urban Air Mobility (UAM) is an emerging aviation sector and is playing an integral part in the on-demand mobility revolution. UAM is powered by the convergence of advances in distributed electrical propulsion (DEP) and vehicle autonomy. The complexity of operations in the urban environment and the unconventional vehicle configurations designed to take advantage of new propulsion technologies, result in numerous challenges that benefit from a control-centric approach. In this talk we outline some of these challenges and present our current approach to addressing them. For example, in order to achieve full market potential and access to UAM, vehicle autonomous flight is required. A key barrier to autonomous flight in a large multi-agent system is dealing with off-nominal situations and contingencies in a safe and predictable manner. We present our approach to intelligent contingency management, and share recent results and open problems. Additionally, we discuss another major barrier to ubiquitous UAM – the noise signature produced by vehicles with multiple rotors. We present our approach to minimizing such noise within the framework of the acoustically-aware vehicle.
UAM↗
Lightweight Thrust Chamber Composite Overwrap Lessons Learned
The manufacturing, design, and analysis of filament wound carbon fiber/polymer composite overwraps for additively manufactured, copper combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. Ideally, the composite overwrap acts as a light-weight structural jacket and allows significant weight reduction of the high pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication schedules. Chamber assemblies for 2000 lb. (2k) and 7000 lb. (7k) of thrust have been successfully tested at NASA’s Marshall Space Flight Center. Multiple lessons were learned throughout the overwrap process development and manufacturing trials. The lessons learned on small scale hardware, such as the 2k and 7k chambers, will guide further composite manufacturing technologies and enable a progression to larger scale assemblies with greater structural loads. Material performance requirements, manufacturing process development, and surface preparation were evaluated during the small chamber trials, with the broad thermal requirements of the resin being the primary driver for material selection and processing. Both epoxy and bismaleimide (BMI) materials were evaluated with respect to both performance in the hot-fire test and ease of fabrication. Separately, surface preparation procedures were studied with the goal of providing a smooth chamber surface to promote a non-bonded overwrap. Recent testing of the 7k trust chamber has provided data in Non-Destructive Evaluation (NDE) and processing in order to continue to evaluate the performance requirements stated.
Allison Clark↗
Integrated Crewed Mars Mission Analysis, Part II: The Trajectory Strikes Back
Crewed missions to Mars present a challenging problem involving strong interactions between a variety of spacecraft systems. Design and architecture decisions made by one system can have powerful implications for another. Siloed subsystem development and optimization efforts are unlikely to generate optimal results for the integrated system and may lead to counterproductive investments at the mission and system level. Mismatched assumptions between different subsystems can also negatively impact the final result. Integrated systems analysis, trade studies, and sensitivity analysis are a critical element of successful Mars mission design. Previous work examined the linkages between Environmental Control and Life Support System (ECLSS) loop closure, food water content, spares Probability of Sufficiency (POS), and other factors by performing an integrated mass and cost assessment of a variety of Mars habitat and transportation system designs. This paper expands upon that work by evaluating the impact of mission duration, trajectory, and propulsion technology alongside key habitat variables. Transportation system and trajectory design decisions have enormous impacts on overall system mass, and the impacts of those decisions are themselves sensitive to the mass of the habitat that is being transported. This paper examines a variety of mission cases and evaluates total departure mass for each case. An estimate of relative costs for specific cases is also provided. The results are discussed, with an emphasis on the sensitivity of mass, cost, and other figures of merit to key parameters. Interactions and dependencies between various decisions, particularly those that relate to technology investments, are also highlighted. Overall, the various elements, systems, and subsystems required to support human spaceflight should not be optimized and evaluated in isolation, but instead should be analyzed as part of an integrated system. This paper demonstrates how integrated analysis can improve system understanding and lead to more optimal and effective crewed exploration systems.
Human Spaceflight↗
Integrated Crewed Mars Mission Analysis, Part II: The Trajectory Strikes Back
Crewed missions to Mars present a challenging problem involving strong interactions between a variety of spacecraft systems. Design and architecture decisions made by one system can have powerful implications for another. Siloed subsystem development and optimization efforts are unlikely to generate optimal results for the integrated system and may lead to counterproductive investments at the mission and system level. Mismatched assumptions between different subsystems can also negatively impact the final result. Integrated systems analysis, trade studies, and sensitivity analysis are a critical element of successful Mars mission design. Previous work examined the linkages between Environmental Control and Life Support System (ECLSS) loop closure, food water content, spares Probability of Sufficiency (POS), and other factors by performing an integrated mass and cost assessment of a variety of Mars habitat and transportation system designs. This paper expands upon that work by evaluating the impact of mission duration, trajectory, and propulsion technology alongside key habitat variables. Transportation system and trajectory design decisions have enormous impacts on overall system mass, and the impacts of those decisions are themselves sensitive to the mass of the habitat that is being transported. This paper examines a variety of mission cases and evaluates total departure mass for each case. An estimate of relative costs for specific cases is also provided. The results are discussed, with an emphasis on the sensitivity of mass, cost, and other figures of merit to key parameters. Interactions and dependencies between various decisions, particularly those that relate to technology investments, are also highlighted. Overall, the various elements, systems, and subsystems required to support human spaceflight should not be optimized and evaluated in isolation, but instead should be analyzed as part of an integrated system. This paper demonstrates how integrated analysis can improve system understanding and lead to more optimal and effective crewed exploration systems.
Human Spaceflight↗
NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies
Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.
Filament Wound↗
Recent Advancements in Electrical Capacitance Mass Gauging for Cryogenic PropellantTanks
The current lack of unsettled mass gauging is a key roadblock for many space activities, such as orbital refueling, missions to the Moon and Mars, and nuclear thermal and nuclear electric propulsion technologies. Liquid can form any one of an infinite number of configurations in microgravity, such as floating in globs or accumulating on tank surfaces in discontiguous volumes, or both. Capacitive sensing requires no moving parts and dissipates close to zero heat, making it an ideal candidate for cryogenic fluid mass gauging in settled and unsettled configurations. Capacitive sensing has a history of proven use in space propellant tanks, including tanks on the space shuttle, Saturn V, and the Apollo Lunar Excursion Module. Modern capacitive sensor technology allows using the entire tank as the capacitor volume by placing electrodes on the tank walls and propellant management surfaces. Capacitance is directly related to density, and therefore to mass for fixed volumes. In this presentation, we discuss the concepts behind whole-tank capacitance mass gauging and associated engineering challenges. We describe recent efforts to develop a micro-g unsettled cryogenic mass gauge using whole-tank capacitance sensing, including the development of test beds, electronics, and algorithms. We describe several mathematical processing techniques, including empirical-based averaging, electrical capacitance volume tomography, and spatial regularization. A modeling study, performed using settled configurations in gravity and no gravity, and with a set of 100 random fluid configurations, has indicated that spatial regularization, in which capacitance measurements are weighted to account for non-uniform electric fields, yields a mass fraction accuracy of 8% for any fluid configuration. Such a sensor is expected to operate in real time with a sampling frequency of at least 1 kHz.
cryogenic↗
Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.
Additive Manufacturing↗
Interactive Mars: A Direct-Experience Mission
As NASA prepares to explore Mars, we describe an innovative architecture that could be based on public-private partnerships to offset the costs of such a mission, while demonstrating many of the key technologies—propulsion, communications, autonomy, and landing systems—that will be needed for future human exploration. We propose that NASA could use this capability to deliver dozens of small rovers to several sites on Mars to enable the creation of interactive games that would be operated commercially and sponsored privately. NASA would get a reduced cost to demonstrate a portion of the infrastructure needed for human exploration, and the private sector would get access to a new market and sponsorship opportunities for a broadly popular activity. In addition, our proposed architecture could enable a new, intuitive means for scientists to interpret data and conduct ground operations. This proposal is to broadly develop the overall concept, while focusing on the design of the novel communications system, developing requirements for the software architecture needed to control the rovers and implement gaming, and developing gaming concepts.
Carolyn R. Mercer↗
Thermal Protection Systems (TPS) for High Velocity Earth Entry Missions
The fastest man-made object to re-enter into Earth’s atmosphere, with an entry velocity of 12.8 km/s, was the Stardust capsule, which returned samples from the comet Wild 2. Sample return missions offer high and long-lasting science yield; as such, they are discussed repeatedly in the latest planetary science decadal survey, titled Origins, Worlds, and Life. An advantage of sample return missions over in situ measurements is the ability to use state-of-the-art instruments that are not limited in power, size, or complexity; conversely, in situ measurements rely on instruments optimized to fit within the limitations of the spacecraft. Additionally, sample return provides the opportunity to revisit samples as analysis techniques improve as well as to further investigate unanticipated or ambiguous results. As launch vehicle and propulsion technologies continue to advance, it is becoming feasible to consider sample return missions from further out in the Solar System beyond Mars orbit. However, returning samples from increasingly distant destinations comes with high entry velocities, and thus requires ever more capable thermal protection systems (TPS). Evaluating the capabilities of existing mature TPS materials for a range of entry conditions and sample return aeroshell configurations is key to establishing the feasibility of future mission proposals. As such, this presentation describes the comprehensive trade study done to evaluate the feasibility of high velocity Earth entry missions with the currently available TPS materials.
Hannah S Alpert↗
Electric Sail Design Sensitivities
Electric Sails (E-Sails) are a promising propulsion technology that seek to enable high characteristic propellentless acceleration for spacecraft to reach distant and/or difficult to reach orbits such as rapid transit to heliopause. The E-Sail system exchanges momentum by using positively charged electrostatic tethers to repel solar wind photons to push it through space. This concept was first theorized by Pekka Janhunen in 2004 with further developments occurring including a NASA Innovative Advanced Concepts Phase 1 and Phase 2 hosted out of NASA’s Marshall Space Flight Center (MSFC). These developments led to further maturation of the overall system, and this paper is designed to help identify different design sensitivities of an integrated Electric Sail system. To approach this, a small team at MSFC took an in-house developed three degrees of freedom (3DoF) simulation tool and a trajectory modelling tool to look at different design parameters and to determine a potential ideal E-Sail configuration. An E-Sail system has different design architectures including a barbell design, hub and spoke design, and a potential hybrid solution. The barbell design features two equally massed satellites that spin around a central point in the tether system. The hub and spoke design features a large central spacecraft with small end spacecraft to aid in formation control of the overall E-Sail system. Leveraging elements from both the hub and spoke, and barbell design, a hybrid option exists where one could have a larger central mass and one or two tethers extended to a smaller end mass [2]. In summary, the hub and spoke design is the ideal configuration for E-Sail with tethers spanning kilometers to achieve the designed design characteristic acceleration of at least one mm/s2 with this architecture being the focus of this study. Different key design parameters were varied as part of this study. These parameters include the total number of tethers, the length of the tethers, spin rate, relative spacecraft mass, tether voltage, inertia per tether, and impact of slew rate changes. These results started from an internal MSFC technology demonstration mission design and then the parameters were varied with engineering judgement to ensure that the results were consistent with expected results. These were varied in the MSFC 3DoF tool and compared to baseline results to generate a candidate ideal E-Sail design system. These results were then used to help inform the mission analysis design for the system. The 3DoF trajectory optimization was performed in the Astrodynamics and Space Science Enabling Toolbox (ASSET) and utilized collocation optimization of control vector pointing with the objective function being transfer duration. A representative model of the E-Sail force was derived as a function of the Sun-pointing vector direction. This model was initialized with a zero Sun Incidence Angle (SIA) trajectory for the initial guess generation, then with a portion of the mission optimized SIA time history for fast outbound transfers. After the trajectory is hyperbolic relative to a heliocentric frame, the SIA is maintained at 0 degrees except for any needed trajectory correction maneuvers. This trajectory optimization looked at different characteristic acceleration values to analyze the impact it had on mission performance. As a result of this study, the team can best inform mission designers and technology development efforts to mature the E-Sail system. This study will allow mission designers to have defined rules-of-thumb to design an E-Sail system to meet desired mission needs as well as providing several sample mission profiles. These design drivers will inform maturation efforts on which design requirements to consider for an integrated E-Sail design.
E-Sail↗
Thermal Protection Systems (TPS) for High Velocity Earth Entry Missions
The fastest man-made object to re-enter into Earth’s atmosphere, with an entry velocity of 12.8 km/s, was the Stardust capsule, which returned samples from the comet Wild 2. Sample return missions offer high and long-lasting science yield; as such, they are discussed repeatedly in the latest planetary science decadal survey, titled Origins, Worlds, and Life. An advantage of sample return missions over in situ measurements is the ability to use state-of-the-art instruments that are not limited in power, size, or complexity; conversely, in situ measurements rely on instruments optimized to fit within the limitations of the spacecraft. Additionally, sample return provides the opportunity to revisit samples as analysis techniques improve as well as to further investigate unanticipated or ambiguous results. As launch vehicle and propulsion technologies continue to advance, it is becoming feasible to consider sample return missions from further out in the Solar System beyond Mars orbit. However, returning samples from increasingly distant destinations comes with high entry velocities, and thus requires ever more capable thermal protection systems (TPS). Evaluating the capabilities of existing mature TPS materials for a range of entry conditions and sample return aeroshell configurations is key to establishing the feasibility of future mission proposals. As such, this presentation describes the comprehensive trade study done to evaluate the feasibility of high velocity Earth entry missions with the currently available TPS materials.
Hannah S. Alpert↗
Dynamic Mechanical Analysis of Post-Cured Bismaleimide Resins for Composite-Overwrapped Combustion Chambers Cycled From Cryogenic to High Temperatures
In support of the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project, samples made of polybismaleimide (BMI) resin were made and tested under cryogenic conditions. Neat resin samples were tested for multiple cycles, from high temperature (300°C) to cryogenic temperature (-150°C), to replicate the conditions a rocket engine assembly would experience in a test campaign and in operation. To increase the glass transition temperature (and thus mechanical stability), samples were exposed to different post-cure temperatures and were tested using a dynamic mechanical analysis (DMA) instrument. Consistent with expectations, the BMI samples post-cured at higher temperatures generally resulted in higher storage modulus under high temperature test conditions but at the expense of storage modulus values at low temperature test conditions.
Christopher Stelter↗
Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments
In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.
Post-Processing↗
Advanced research and technology program for advanced high pressure oxygen-hydrogen rocket propulsion
A research and technology program for advanced high pressure, oxygen-hydrogen rocket propulsion technology is presently being pursued by the National Aeronautics and Space Administration (NASA) to establish the basic discipline technologies, develop the analytical tools, and establish the data base necessary for an orderly evolution of the staged combustion reusable rocket engine. The need for the program is based on the premise that the USA will depend on the Shuttle and its derivative versions as its principal Earth-to-orbit transportation system for the next 20 to 30 yr. The program is focused in three principal areas of enhancement: (1) life extension, (2) performance, and (3) operations and diagnosis. Within the technological disciplines the efforts include: rotordynamics, structural dynamics, fluid and gas dynamics, materials fatigue/fracture/life, turbomachinery fluid mechanics, ignition/combustion processes, manufacturing/producibility/nondestructive evaluation methods and materials development/evaluation. An overview of the Advanced High Pressure Oxygen-Hydrogen Rocket Propulsion Technology Program Structure and Working Groups objectives are presented with highlights of several significant achievements.
Marsik, S. J.↗
Noncontacting measurement technologies for space propulsion condition monitoring
This paper describes four noncontacting measurement technologies that can be used in a turbopump condition monitoring system. The isotope wear analyzer, fiberoptic deflectometer, brushless torque-meter, and fiberoptic pyrometer can be used to monitor component wear, bearing degradation, instantaneous shaft torque, and turbine blade cracking, respectively. A complete turbopump condition monitoring system including these four technologies could predict remaining component life, thus reducing engine operating costs and increasing reliability.
Randall, M. R.↗