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This is an overview presentation of In Space Propulsion Technology products that have been developed under the sponsorship of the Planetary Science Division of NASA's Science Mission Directorate. The materials have been prepared for Outer Planetary Assessment Group Meeting in Atlanta, GA in January 2013.
NASA is making space exploration more affordable and viable by developing and utilizing innovative manufacturing technologies. Technology development efforts at NASA in propulsion are committed to continuous innovation of design and manufacturing technologies for rocket engines in order to reduce the cost of NASA's journey to Mars. The Low Cost Upper Stage-Class Propulsion (LCUSP) effort will develop and utilize emerging Additive Manufacturing (AM) to significantly reduce the development time and cost for complex rocket propulsion hardware. Benefit of Additive Manufacturing (3-D Printing) Current rocket propulsion manufacturing techniques are costly and have lengthy development times. In order to fabricate rocket engines, numerous complex parts made of different materials are assembled in a way that allow the propellant to collect heat at the right places to drive the turbopump and simultaneously keep the thrust chamber from melting. The heat conditioned fuel and oxidizer come together and burn inside the combustion chamber to provide thrust. The efforts to make multiple parts precisely fit together and not leak after experiencing cryogenic temperatures on one-side and combustion temperatures on the other is quite challenging. Additive manufacturing has the potential to significantly reduce the time and cost of making rocket parts like the copper liner and Nickel-alloy jackets found in rocket combustion chambers where super-cold cryogenic propellants are heated and mixed to the extreme temperatures needed to propel rockets in space. The Selective Laser Melting (SLM) machine fuses 8,255 layers of copper powder to make a section of the chamber in 10 days. Machining an equivalent part and assembling it with welding and brazing techniques could take months to accomplish with potential failures or leaks that could require fixes. The design process is also enhanced since it does not require the 3D model to be converted to 2-D drawings. The design and fabrication process can be sped up and improved with fewer errors to be accomplished in weeks instead of months.
The reliability and development of aerospace materials in extreme environments relies on a comprehensive understanding of their thermochemical properties. Such properties are commonly used for equilibrium phase stability calculations of interactions with corrosive environments at very high temperatures. These calculations can lead to in-depth understanding of degradation mechanisms in both coatings and components for applications such as nuclear thermal propulsion and gas turbine engines, both of which are part of NASA’s current R&D focus for improving propulsion systems for aerospace missions. The first part of this talk summarizes and discuss our current thermochemical calculations of the behavior of ceramic-ceramic (cercer) UN-based fuels and their coating systems during nuclear thermal rocket operation. The second part of the talk summarizes and discuss the energetics of reactions of ceramic coating materials and their binary oxide components with silicate melts measured by high temperature reaction calorimetry.
NASA is developing a solar sail propulsion system for use on the Near Earth Asteroid (NEA) Scout reconnaissance mission and laying the groundwork for their use in future deep space science and exploration missions. Solar sails use sunlight to propel vehicles through space by reflecting solar photons from a large, mirror-like sail made of a lightweight, highly reflective material. This continuous photon pressure provides propellantless thrust, allowing for very high Delta V maneuvers on long-duration, deep space exploration. Since reflected light produces thrust, solar sails require no onboard propellant. The Near Earth Asteroid (NEA) Scout mission, funded by NASA's Advanced Exploration Systems Program and managed by NASA MSFC, will use the sail as primary propulsion allowing it to survey and image Asteroid 1991VG and, potentially, other NEA's of interest for possible future human exploration. NEA Scout uses a 6U cubesat (to be provided by NASA's Jet Propulsion Laboratory), an 86 m(exp. 2) solar sail and will weigh less than 12 kilograms. NEA Scout will be launched on the first flight of the Space Launch System in 2018. The solar sail for NEA Scout will be based on the technology developed and flown by the NASA NanoSail-D and The Planetary Society's Lightsail-A. Four approximately 7 m stainless steel booms wrapped on two spools (two overlapping booms per spool) will be motor deployed and pull the sail from its stowed volume. The sail material is an aluminized polyimide approximately 2.5 microns thick. As the technology matures, solar sails will increasingly be used to enable science and exploration missions that are currently impossible or prohibitively expensive using traditional chemical and electric propulsion systems. This paper will summarize the status of the NEA Scout mission and solar sail technology in general.
Many interesting ideas have been conceived for building space-based infrastructure in cislunar space. From O'Neill's space colonies, to solar power satellite farms, and even prospecting retrieved near earth asteroids. In all the scenarios, one thing remained fixed - the need for space resources at the outpost. To satisfy this need, O'Neill suggested an electromagnetic railgun to deliver resources from the lunar surface, while NASA's Asteroid Redirect Mission called for a solar electric tug to deliver asteroid materials from interplanetary space. At Made In Space, we propose an entirely new concept. One which is scalable, cost effective, and ensures that the abundant material wealth of the inner solar system becomes readily available to humankind in a nearly automated fashion. We propose the RAMA architecture, which turns asteroids into self-contained spacecraft capable of moving themselves back to cislunar space. The RAMA architecture is just as capable of transporting conventional-sized asteroids on the 10-meter length scale as transporting asteroids 100 meters or larger, making it the most versatile asteroid retrieval architecture in terms of retrieved-mass capability. This report describes the results of the Phase I study funded by the NASA NIAC program for Made In Space to establish the concept feasibility of using space manufacturing to convert asteroids into autonomous, mechanical spacecraft. Project RAMA, Reconstituting Asteroids into Mechanical Automata, is designed to leverage the future advances of additive manufacturing (AM), in-situ resource utilization (ISRU) and in-situ manufacturing (ISM) to realize enormous efficiencies in repeated asteroid redirect missions. A team of engineers at Made In Space performed the study work with consultation from the asteroid mining industry, academia, and NASA. Previous studies for asteroid retrieval have been constrained to studying only asteroids that are both large enough to be discovered, and small enough to be captured and transported using Earth-launched propulsion technology. Project RAMA is not forced into this constraint. The mission concept studied involved transporting a much larger approximately 50-meter asteroid to cislunar space. Demonstration of transport of a 50-meter-class asteroid has several ground-breaking advantages. First, the returned material is of an industrial, rather than just scientific, quantity (greater than 10,000 tonnes versus approximately10s of tonnes). Second, the "useless" material in the asteroid is gathered and expended as part of the asteroid's propulsion system, allowing the returned asteroid to be considerably "purer" than a conventional asteroid retrieval mission. Third, the infrastructure used to convert and return the asteroid is reusable, and capable of continually returning asteroids to cislunar space.
Advanced structural reliability methods are utilized on the Probabilistic Structural Analysis Methods (PSAM) project to provide a tool for analysis and design of space propulsion system hardware. The role of the effort at the University of Arizona is to provide reliability technology support to this project. PSAM computer programs will provide a design tool for analyzing uncertainty associated with thermal and mechanical loading, material behavior, geometry, and the analysis methods used. Specifically, reliability methods are employed to perform sensitivity analyses, to establish the distribution of a critical response variable (e.g., stress, deflection), to perform reliability assessment, and ultimately to produce a design which will minimize cost and/or weight. Uncertainties in the design factors of space propulsion hardware are described by probability models constructed using statistical analysis of data. Statistical methods are employed to produce a probability model, i.e., a statistical synthesis or summary of each design variable in a format suitable for reliability analysis and ultimately, design decisions.
Topics addressed are: (1) cryogenic tankage; (2) launch vehicle TPS/insulation; (3) durable passive thermal control devices and/or coatings; (4) development and characterization of processing methods to reduce anisotropy of material properties in Al-Li; (5) durable thermal protection system (TPS); (6) unpressurized Al-Li structures (interstages, thrust structures); (7) near net shape sections; (8) pressurized structures; (9) welding and joining; (10) micrometeoroid and debris hypervelocity shields; (11) state-of-the-art shell buckling structure optimizer program to serve as a rapid design tool; (12) test philosophy; (13) reduced load cycle time; (14) structural analysis methods; (15) optimization of structural criteria; and (16) develop an engineering approach to properly trade material and structural concepts selection, fabrication, facilities, and cost.
Given sufficient warning time, Earth-impacting asteroids and comets can be deflected with a variety of different "slow push/pull" techniques. The gravity tractor is one technique that uses the gravitational attraction of a rendezvous spacecraft to the impactor and a low-thrust, high-efficiency propulsion system to provide a gradual velocity change and alter its trajectory. An innovation to this technique, known as the Enhanced Gravity Tractor (EGT), uses mass collected in-situ to augment the mass of the spacecraft, thereby greatly increasing the gravitational force between the objects. The collected material can be a single boulder, multiple boulders, regolith or a combination of different sources. The collected mass would likely range from tens to hundreds of metric tons depending on the size of the impactor and warning time available. Depending on the propulsion system's capability and the mass collected, the EGT approach can reduce the deflection times by a factor of 10 to 50 or more, thus reducing the deflection times of several decades to years or less and overcoming the main criticism of the traditional gravity tractor approach. Additionally, multiple spacecraft can orbit the target in formation to provide the necessary velocity change and further reduce the time needed by the EGT technique to divert hazardous asteroids and comets. The robotic segment of NASA's Asteroid Redirect Mission (ARM) will collect a multi-ton boulder from the surface of a large Near-Earth Asteroid (NEA) and will provide the first ever demonstration of the EGT technique and validate one method of collecting in-situ mass on an asteroid of hazardous size.
NASA is developing a solar sail propulsion system for use on the Near Earth Asteroid (NEA) Scout reconnaissance mission and laying the groundwork for their use in future deep space science and exploration missions. Solar sails use sunlight to propel vehicles through space by reflecting solar photons from a large, mirror-like sail made of a lightweight, highly reflective material. This continuous photon pressure provides propellant-less thrust, allowing for very high delta V maneuvers on long-duration, deep space exploration. Since reflected light produces thrust, solar sails require no onboard propellant. The Near Earth Asteroid (NEA) Scout mission, funded by NASA’s Advanced Exploration Systems Program and managed by NASA MSFC, will use the sail as primary propulsion allowing it to survey and image Asteroid 1991VG and, potentially, other NEA’s of interest for possible future human exploration. The NEA Scout spacecraft is housed in a 6U CubeSat-form factor and utilizes an 86 square meter solar sail for a total mass less than 14 kilograms. The mission is in partnership with the Jet Propulsion Laboratory with support from Langley Research Center and science participants from various institutions. NEA Scout will be launched on the maiden flight of the Space Launch System in 2019. The solar sail for NEA Scout will be based on the technology developed and flown by the NASA NanoSail-D and flown on The Planetary Society’s Lightsail-A. Four approximately-7-meter stainless steel booms wrapped on two spools (two overlapping booms per spool) will be motor driven and pull the sail from its stowed volume. The sail material is an aluminized polyimide approximately 2.5 microns thick. As the technology matures, solar sails will increasingly be used to enable science and exploration missions that are currently impossible or prohibitively expensive using traditional chemical and electric propulsion systems. This paper will summarize the status of the NEA Scout mission and solar sail technology in general.
NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.
NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.
One of the most favorable characteristics of the Space Shuttle Program is the reusability of two of its primary components: the orbiter itself and the Solid Rocket Boosters (SRB). The SRB's provide the primary source of propulsion for the Space Shuttle during take-off after which they are recovered for refurbishment and reuse. During refurbishment, the SRB's are stripped of all remaining ablative (heat resistant) coating. A new layer is applied to the appropriate sections (nose cone, frustum, forward skirt, and aft skirt). It is the process of applying the ablative coating which provided the impetus for this project. The thickness of this protective layer is considered to be of primary importance to the level of thermal protection provided. The objectives of this effort are to investigate possible techniques for measuring the thickness of MCC, and if possible to test the specific capabilities of those considered good candidates for implementation. The system would be able to take measurements in real-time as close to the spray gun as possible. This will allow the information to be used in the control of the process without an inordinate time delay between a measurement and its appropriate response. The thickness of the deposited material is to be measured with less than 0.100 in if uncertainty. This is the defined tolerance window for the ablator thickness. Finally, it must operate within the confines of the chamber which encloses the turntable, robot, and spray system, and therefore is required to be insensitive to, or at least maintainable in, that environment.
The environmental and instrumentation requirements for long term testing of electrical propulsion thrusters which impose severe and unusual requirements upon the simulation facility were studied. High speed ions ejected from a mercury thruster erode material from collecting surfaces, which is then scattered and redeposited upon other surfaces, with resultant damage to the chamber and test article. By collecting the thruster plume on a frozen mercury surface damage to the thruster and chamber by back-scattered erosion products was minimized. Provisions for unattended operation, remote data acquisition, personnel safety, and instrumentation for assessing thruster performance are also discussed.
A quantitative assessment is made of the long-term risk of earth reencounter and reentry associated with aborted disposal of hazardous material in the space environment. Numerical results are presented for 10 candidate disposal options covering a broad spectrum of disposal destinations and deployment propulsion systems. Based on representative models of system failure, the probability that a single payload will return and collide with earth within a period of 250,000 years is found to lie in the range .0002-.006. Proportionately smaller risk attaches to shorter time intervals. Risk-critical factors related to trajectory geometry and system reliability are identified as possible mechanisms of hazard reduction.
The opportunity to conduct microgravity and related research still exists, even with the temporary delay in the U.S. Space Shuttle program. Several ground-based facilities are available and use of these facilities is highly recommended for the preparation of near and far term shuttle or space station experiments. Drop tubes, drop towers, aircraft, sounding rockets and a wide variety of other ground-based equipment can be used to simulate microgravity. This paper concentrates on the materials processing capabilities available at NASA Lewis Research Center (NASA Lewis), Marshall Space Flight Center (MSFC), and the California Institute of Technology Jet Propulsion Laboratory (JPL). Also included is information on gaining access to these facilities.
The opportunity to conduct microgravity and related research still exists, even with the temporary delay in the U.S. Space Shuttle program. Several ground-based facilities are available, and use of these facilities is highly recommended for the preparation of near and far term Shuttle or Space Station experiments. Drop tubes, drop towers, aircraft, sounding rockets, and a wide variety of other ground-based equipment can be used to simulate microgravity. This paper concentrates on the materials processing capabilities available at NASA Lewis Research Center (NASA Lewis), Marshall Space Flight Center (MSFC), and the California Institute of Technology Jet Propulsion Laboratory (JPL). Also included is information on gaining access to these facilities.
Under NASA-sponsored High Speed Research (HSR) programs, the materials and processing requirements have been identified for overcoming the environmental and economic barriers of the next generation High Speed Civil Transport (HSCT) propulsion system. The long (2 to 5 hours) supersonic cruise portion of the HSCT cycle will place additional durability requirements on all hot section engine components. Low emissions combustor designs will require high temperature ceramic matrix composite liners to meet an emission goal of less than 5g NO(x) per Kg fuel burned. Large axisymmetric and two-dimensional exhaust nozzle designs are now under development to meet or exceed FAR 36 Stage III noise requirements, and will require lightweight, high temperature metallic, intermetallic, and ceramic matrix composites to reduce nozzle weight and meet structural and acoustic component performance goals. This paper describes and discusses the turbomachinery, combustor, and exhaust nozzle requirements of the High Speed Civil Transport propulsion system.
A refueling tanker that could deliver 155,000 lb of liquid hydrogen to a hypersonic tanker in 15 min was designed. A flying boom system was chosen to fit strict delivery criteria. Tank design and material specification were also addressed. To assure the flow required, it was important to cancel the pressure drop phenomenon. Geometry, aerodynamics, weight considerations, propulsion, stability, and performance for the tanker were also considered. Finally, the cost of developing three prototypes was estimated.