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At least 1,279 records · Page 71

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NASA NTRS2016

Transient Thermal Analysis of the 12.5 KW HERMeS Hall Thruster

NASA’s Dawn spacecraft entered orbit around the dwarf planet Ceres on March 6, 2015 thereby becoming the first mission to orbit two celestial bodies outside of the Earth-moon system. This feat was made possible due to the use of electric propulsion (EP) to provide the 11 km/s of delta-V that was necessary. This type of propulsion is also enabling for many of NASA’s future missions, such as the proposed Asteroid Redirect Robotic Mission (ARRM). Specifically, the Hall Effect Rocket with Magnetic Shielding (HERMeS) is the propulsive design baseline due to its long operational lifetime and high specific impulse. Extensive modeling is required to verify the thruster's predicted thermal performance and survival during the bounding mission phases. Since the thruster would constrain plasma on the order of tens of thousands of hours, components in the thruster must be able to accommodate much higher sustained temperatures than typical spacecraft hardware. Furthermore, the high temperatures necessitate care in analyzing thermal gradients within the thruster. In this paper, we describe a thermal model of the HERMeS thruster and focus upon the thruster's transient performance under different initial firing conditions. The thruster's transient thermal response is critical to verify margin in the thermal stresses inherent in the thruster and to determine safe start-up procedures to protect the thruster's critical components. This model is used to perform transient thermal analysis of the thruster during startup and shutdown, provide temperature maps for structural analysis, and plan for thermal cycle testing conducted at JPL. The thermal cycle testing includes thruster starts at the cold temperature limits and operation at maximum expected external heat flux. This work will support laboratory environmental testing of the HERMeS thruster, which is being conducted at JPL in 2016.

Reilly, Sean↗

NASA NTRS2017

Technology Development Plan and Preliminary Results for a Low Temperature Hybrid Mars Ascent Vehicle Concept

A hybrid propulsion system is being considered for a potential Mars Ascent Vehicle (MAV) based on its low temperature capability, ability to restart and high performance. The hybrid’s ability to survive in low and variable temperatures reduces power requirements and therefore system mass. Its ability to restart enables a Single Stage to Orbit (SSTO) design, minimizing system complexity. The hybrid’s high-performance (approximately 314 s Isp (I (sub sp)) (specific impulse in seconds) leads to a low total Gross Lift Off Mass (GLOM). These advantages set the hybrid design above the alternatives in the system studies completed at JPL (Jet Propulsion Laboratory). However, this solution has the lowest Technology Readiness Level (TRL) of the propulsion options. Therefore, a technology development effort has been undertaken to raise the TRL of the hybrid option and potentially enable its infusion into a future MAV or other in-space application. The culmination of this technology development is a flight demonstration, which is currently in the planning phases for launch in the early 2020’s.

Karp, Ashley↗

NASA NTRS2016

Silicon Emitter Needle and Array Design for Indium Electrospray Arrays for Spacecraft Propulsion

A design for silicon microfabricated emitter arrays was developed for electrospray thrusters for indium propellant in compact architectures with scalable thrust, low mass and volume, high specific impulse and high efficiency operation. The design elements include tip height, height uniformity across the array, tip radii, axial groove depth, tip angle, emitter shank sidewall angle and number of emitters. They were derived from commercial liquid metal ion source designs and modeling, fabrication and test results. The most critical results of the emitter array design analysis suggest that microfabricated silicon emitter array emitters should have a height greater than 280 microns with a height uniformity of +/-10 microns, a tip half angle of 49° for uniform turn-on voltages and current across the array, low beam divergence and high mass utilization efficiency. Elements of the design were fabricated and demonstrated in single emitter and in 400 element emitter arrays to validate the design, fabrication and performance capability. The design height and uniformity of arrays was demonstrated for 85% of the emitters in a prototype array. Required tip and sidewall angles and groove depths have been microfabricated. Single microfabricated silicon emitters demonstrated better performance in current and voltage characteristics than commercially available liquid metal ion sources. Microfabricated emitters and arrays demonstrated the required current and stability performance to enable the MEP thruster development for indium propellant.

Marrese-Reading, Colleen M.↗

NASA NTRS2019

Characterization of Low-Temperature, Co-Fired Ceramic-Manufactured Electrostatic Thruster-Closeout Report

The goal of the project was to evaluate prototypes of an experimental thruster developed by the University of Arkansas (UA), Fayetteville, AR. The design under evaluation is a radio frequency (RF) electrostatic thruster that was fabricated using the low-temperature, co-fired ceramic (LTCC) materials and fabrication process. This materials system is analogous to printed circuit board (PCB) technology with the most significant difference being that the laminate is replaced by a ceramic material and the copper layer is replaced by printed sinterable silver paste. LTCC designs are baked after fabrication and assembled to realize an entirely monolithic structure with internal conductors, vias, and cavities. In this process, the LTCC electrostatic thruster (LTCC-ET) that is the subject of the present work becomes a monolithic ceramic thruster capable of withstanding temperatures in excess of 500 ºC. The UA and NASA Marshall Space Flight Center (MSFC) jointly performed prototype testing on the LTCC-ET under a NASA Cooperative Agreement Notice (CAN) award. The LTCC-ET was tested at MSFC in May 2018 over a 1-week period. There were two goals for the test program: (1) Testing to determine the operating parameters required to create plasma ignition in the test articles. This was explored by setting a propellant flowrate and increasing RF power until plasma ignition was observed. Testing was conducted with both argon and krypton. (2) Investigate the thrust and specific impulse (Isp) performance of the thruster as a function of propellant flowrate and grid voltage. This goal was not met during the project as technical challenges in maintaining stable plasma ignition arose due to stress and heating of the RF power feed. In summary, a prototype thruster design (consisting of three packaged units) was fabricated by UA and tested for the first time under vacuum conditions at MSFC to experimentally determine basic performance metrics and functionality. It was found that the design was not sufficiently optimized or robust enough in its initial iteration to support a significant test campaign or characterization program. It was concluded that the propellant outlet channels must be reduced in size with the flowpaths adjusted to increase propellant residence time in the thruster, and that the RF connector must be replaced with a version capable of handling higher power throughput and heating. However, even in its unoptimized form, a plasma could be produced in the LTCCET, demonstrating the efficacy of the design approach. The design is especially compelling due to its low cost to manufacture and, more importantly, its scalability of size and power throughput. Low cost and scalability are also important in that additional functionalities, such as thrust vectoring and plume charge neutralization, can be integrated into future designs with minimal additional cost. This project has matured the LTCC-ET development Technology Readiness Level (TRL) from 1 to 2. The low-cost RF plasma source portion of the LTCC device was matured from TRL 2 to 4 through the demonstration of RF plasma ignition under vacuum conditions.

Huang, P.-H. A.↗

NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗

NASA NTRS2019

Small Launch Vehicle Sizing Analysis with Solid Rocket Examples

Small launch vehicles are governed by the same physics as large launch vehicles of course, but due to their small size, some aspects and sensitivities become more important and others less. This paper shows semi-empirical correlations to quantify dry mass fraction for both stage and whole vehicle optimization: mass fraction due to density, mass fraction due to thrust-to-weight, and mass fraction due to size reduction. For single-stage optimizations, a stage performance requirement can be met by a locus of mass fraction vs. specific impulse. Based on the above correlations, this alone can recommend a solid or liquid rocket for a stage. Rocket designs of similar technology levels are compared, focusing on where stages become less mass-efficient as they get smaller. The Mars Ascent Vehicle is shown to exemplify a trade between a two-stage solids vehicle and a one- or two-stage liquids vehicle.

Kibbey, Tim↗

NASA NTRS2019

Small Launch Vehicle Sizing Analysis With Solid Rocket Examples

Kibbey, Tim↗

NASA NTRS2016

Technology Development and Design of a Hybrid Mars Ascent Vehicle Concept

Hybrid propulsion has been investigated as an enhancing technology for a Mars Ascent Vehicle (MAV) concept as part of potential Mars Sample Return (MSR) because of its high specific impulse, restartability, and the ability to operate and survive at extremely low temperatures. A new wax-based hybrid fuel formulation has been developed that could withstand the harsh and variable Mars environment protected solely by a minimal layer of passive insulation. This formulation could provide substantial energy savings for a notional lander and is critical for rover mobility. Preliminary thermal cycle testing has determined that the formulation can survive the expected temperature extremes and lifetime thermal testing is currently underway. A complete preliminary design using this new fuel formulation combined with a low temperature oxidizer such as Mixed Oxides of Nitrogen (MON30) is presented. Several key features associated with a complete hybrid MAV concept are investigated to determine their mission suitability (e.g. Thrust Vector Control and restartable ignition options). Potential challenges along a path towards developing such a system are outlined and future work is suggested as a means of technology maturation. The hybrid design presented here was the lowest Gross Lift Off Mass (GLOM) result of a 2015 Jet Propulsion Laboratory (JPL) led MAV concept study.

Karp, Ashley C.↗

NASA NTRS2019

Helical Engine

A new concept for in-space propulsion is proposed in which propellant is not ejected from the engine, but instead is captured to create a nearly infinite specific impulse. The engine accelerates ions confined in a closed loop to relativistic speeds, and slightly varies their velocity to change their momentum. The engine then moves the ions back and forth along the direction of travel to produce thrust. This in-space engine is intended to be used for long-term satellite station-keeping without refueling or to propel spacecraft across interstellar distances. The engine has no moving parts other than ions traveling in a closed-loop vacuum line, trapped inside electric and magnetic fields.

Burns, David M.↗

NASA NTRS2019

New Method for Systems and Cost Analysis of Human Mars Entry Vehicles

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically not estimated until after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more efficiently. This paper describes an extension to the tool SAPE (Systems Analysis for Planetary Entry, Descent, and Landing). This extension integrates the cost modeling software SEER-H (System Estimation and Evaluation of Resources-Hardware) with a number of systems analysis tools. This new method is used to analyze several trade spaces of a HIAD (Hypersonic Inflatable Aerodynamic Decelerator) entry vehicle for human Mars missions. Key findings include quantifying the impacts of ballistic coefficient, main engine specific impulse, and thrust-to-weight ratio on the overall cost of the vehicle, and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Friz, Paul D.↗

NASA NTRS2019

13kW Advanced Electric Propulsion Flight System Development and Qualification

The next phase of robotic and human deep space exploration missions requires high performance, high power solar electric propulsion systems for large-scale science missions and cargo transportation. Aerojet Rocketdyne's Advanced Electric Propulsion System (AEPS) program is completing development and qualification of a 13kW flight EP system to support NASA exploration. The first use of the AEPS is planned for the NASA Power & Propulsion Element, which is the first element of NASA's cis-lunar Gateway. The flight AEPS system includes a magnetically shielded long-life Hall thruster, power processing unit (PPU), and xenon flow controller (XFC). The Hall thruster, originally developed and demonstrated by NASA's Glenn Research Center and the Jet Propulsion Laboratory, operates at input powers up to 13.3kW while providing a specific impulse over 2600s at an input voltage of 600V. The power processor is designed to accommodate an input voltage range of 95 to 140V, consistent with operation beyond the orbit of Mars. The integrated system is continuously throttleable between 3 and 13.3kW. The program has completed testing of the Technology Development Units and is progressing into the Engineering Development Unit test phase and the final design phase to Critical Design Review (CDR). This paper will present the high power AEPS system capabilities, overall program and design status and the latest test results for the 13kW flight system development as well as the plans for the development and qualification effort of the EP string.

in-space propulsion↗

NASA NTRS2019

Numerical Simulation on Liquid Hydrogen Chill-Down Process of Vertical Pipeline

In order to improve the cryogenic propellant management technologies for a liquid hydrogen rocket with high specific impulse, JAXA, the University of Tokyo, and the NASA Glenn Research Center have jointly organized a multi-agency model validation collaboration project. As part of this project, JAXA's boiling simulation was validated with NASA's experimental data on vertical pipeline chill-down. Simulation results were in good agreement with the experimental data obtained using an improved boiling model to reproduce the spray flow. This activity achieved liquid hydrogen turbo-pump simulation at JAXA for grasping the boiling flow phenomenon from engine cut-off to re-ignition. This joint research resulted in an international cooperative relationship for discussing the cryogenic propellant management technologies necessary to develop next-generation liquid rockets.

Umemura, Yutaka↗

NASA NTRS2018

A Cost Modeling Approach for Entry Systems Analysis of Human Mars Missions

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically not estimated until after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more efficiently. This paper describes an extension to the tool Systems Analysis for Planetary Entry, Descent, and Landing which integrates the cost modeling software System Estimation and Evaluation of Resources- Hardware with a number of systems analysis tools. This new method is used to analyze several tradespaces of an entry vehicle for human Mars missions utilizing a Hypersonic Inflatable Aerodynamic Decelerator and provide preliminary results. Key findings include quantifying how ballistic coefficient, main engine specific impulse, and thrust to weight ratio affect the cost of the vehicle and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Friz, Paul D↗

NASA NTRS2019

13kW Advanced Electric Propulsion Flight System Development and Qualification

in-space propulsion↗

NASA NTRS2020

Cryogenic Hydrogen Oxygen Propulsion System for Planetary Science Missions

A Cryogenic Hydrogen Oxygen Propulsion System (CHOPS) that uses liquid hydrogen (LH2) and liquid oxygen (LO2) propellants can dramatically enhance NASA's ability to explore the solar system due to their superior specific impulse (Isp) capability. Although these cryogenic propellants can be challenging to manage and store, they allow significant mass advantages over traditional hypergolic propulsion systems and are therefore enabling for many planetary science missions. New cryogenic storage techniques such as subcooling, advanced insulation, low thermal conductivity structures allow for the long term storage and use of cryogenic propellants for solar system exploration and hence allow NASA to deliver more payloads to targets of interest, launch on smaller and less expensive launch vehicles, or both.

Mustafi, Shouvanik↗

NASA NTRS2020

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗

NASA NTRS2019

Cost Breakeven Analysis of Lunar ISRU for Human Lunar Surface Architectures

The return of humans to the lunar surface encompasses a range of possible architectures from brief Apollo-like sorties to long-term sustainment of human presence. Any architecture in this span requires propellant for the crew’s ascent from the lunar surface, as well as consumables to support their presence on the Moon. Oxygen and hydrogen are candidates for the propellant for the ascent vehicle due to their high specific impulse and potential for production from lunar resources and also constitute important consumables for the crew. Thus, the production of oxygen and/or hydrogen from lunar resources could significantly reduce the mass that must be sent from Earth to enable future human lunar missions. To assess the merits of using lunar resources, the costs associated with developing, producing, launching, operating, and maintaining those systems must be considered relative to the costs of delivering the needed resources from Earth. The demand for those resources depends upon the nature of the lunar mission, while the costs of both Earth-derived and lunar-derived resources depend on the performance requirements and technology capabilities associated with each approach. Thus, determining which approach is more cost efficient requires modeling the performance and cost of the associated systems as well as the range of possible architectures over which such a determination might apply. This research proposes a model that parametrically captures the factors influencing the relevant costs of providing propellant and crew consumables on the lunar surface from Earth and from the Moon. Two ISRU system models are assessed relative to propellant delivery from Earth. In this model, lunar ISRU breaks even with propellant delivery from Earth at high propellant demands and mission durations with multi-year ISRU system lifetimes; however, the costs of developing the necessary technologies to support a highly reliable and autonomous lunar ISRU system were not included.

ISRU↗

NASA NTRSDate not supplied

A Cost Modeling Approach for Entry Systems Analysis of Human Mars Missions

Cost is one of the biggest obstacles to sending humans to Mars. However, spacecraft costs are typically not estimated until after the preliminary vehicle and mission concepts have been designed. By automating the cost estimation process, the effect of any change in vehicle or mission design on the mission cost can be determined more efficiently. This paper describes an extension to the tool Systems Analysis for Planetary Entry, Descent, and Landing which integrates the cost modeling software System Estimation and Evaluation of Resources-Hardware with a number of systems analysis tools. This new method is used to analyze several trade spaces of an entry vehicle for human Mars missions utilizing a Hypersonic Inflatable Aerodynamic Decelerator and provide preliminary results. Key findings include quantifying how ballistic coefficient, main engine specific impulse, and thrust to weight ratio affect the cost of the vehicle and how the payload per lander and number of landers affects the cost of a campaign to Mars.

Paul D Friz↗