NASA Sounding Rockets Program
Speaking at the 24th ESA Symposium on European Rocket Conference June 16-20, 2019. The overview is on the NASA Sounding Rockets Program.
Rosanova, Giovanni↗
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Lyman-Alpha Imaging Polarimetry with the CLASP2 Sounding Rocket Mission
Ultraviolet polarimetry offers a unique opportunity to explore the upper solar chromosphere and the transition region (TR) to the million-degree corona. These outer atmospheric regions play a key role in the transfer of mass and energy from the solar photosphere to the corona. With a sounding rocket experiment called the Chromospheric Lyman-Alpha Spectro-Polarimeter (CLASP), in September 2015 we succeeded in obtaining the first measurement of the linear polarization produced by scattering processes in the hydrogen Lyman-alpha line of the solar disk radiation. The analysis and interpretation of such spectro-polarimetric observation allowed us to obtain information on the geometrical complexity of the corrugated surface that delineates the TR, as well as on the magnetic field strength via the Hanle effect. At the same time, the CLASP slit-jaw (SJ) optics system, which is a Lyman-alpha filter imager characterized by a FWHM (Full Width Half Maximum) equals 7 nanometers, allowed us to obtain broad-band Stokes-I and Q/I images over a large field of view. The obtained broad-band Q/I images are dominated by the scattering polarization signals of the Lyman-alpha wings, and not by the much weaker line-center signals where the Hanle effect operates. On April 11, 2019, we performed another sounding rocket experiment, called the Chromospheric LAyer Spectro-Polarimeter (CLASP2). We used the same instrument after significant modifications in order to obtain spectro-polarimetric observations of a plage and a quiet region in the Mg II h & k lines. At the same time, the CLASP2 SJ optics system allowed us to obtain broad-band Q/I and U/I images around the Lyman-alpha wavelength, in addition to the well- known SJ intensity images.
Kano, Ryouhei↗
Bioreduction of Solid Rocket Motors for Planetary Protection
Solid rocket propulsion systems have been used for in-space applications including planetary exploration missions for many years. Current NASA science lander projects require solid rocket propulsion systems to touchdown on the surface of potentially life-supporting planets and moons. A critical requirement of these missions is the prevention of accidental transportation of Earth's microbes to these environments. This mission requirement places an increased importance on the ability to reduce the biological burden that may be on board the solid propulsion systems and potentially deposited in a habitable environment. Some traditional interplanetary spacecraft decontamination operations could reduce the reliability of the solid propulsion system, indicating a need for new decontamination procedures. New techniques for biological burden reduction are being studied and may become the method of choice to ensure adequate reduction has been achieved. These techniques include using innate antimicrobial capacity of chemical agents already present within the motor and cellular disruption due to assembly and operational environments induced in the mated case. Recent investigations into the effectiveness of some of these techniques have generated promising experimental results.
Boyle, Sadie↗
Analyses and Methods of Solid Rocket Motor Material Irradiation at Marshall Space Flight Center
The search for life on other worlds is among humanity’s greatest endeavors. Europa represents the most probable location to discover extraterrestrial life in our solar system, owing to its surface composition of ice covering a liquid water ocean, warmed by the tidal forces of its orbit around Jupiter. Unfortunately, the Jovian system hosts the most intense planetary radiation environment in the solar system due to the charged particles, namely electrons and protons, trapped by Jupiter’s immense magnetic field. Any mission that attempts to approach or land on Europa must survive this radiation environment [Hand et al, 2017]. Radiation effects were identified as a priority risk to the successful development of a de-orbit stage and solid rocket motor (SRM) early in the Europa Lander De-orbit Stage project concept. The effects of primary concern tend to occur very near the outer surface of the SRM. The charged particles deposit their energy quickly and are mostly stopped in the outer metallic case, but a significant portion of radiation penetrates through the bondline and outer propellant regions. High doses of ionizing radiation are known to cause significant changes to mechanical properties of many materials, especially polymers. For polymers such as the rubber-like materials (elastomers) in a solid rocket motor, the primary damage mechanism is known as cross-linking, in which ionization causes the restructuring of the matrix of long polymer chains. Ionization energy breaks the long polymer chains and allows formation of new cross-linked bonding sites. This hardens and often strengthens the polymer, but at the cost of decreased flexibility (or modulus). Propellant, insulation, liner, and pyrotechnic materials were identified as higher risk items, and so were irradiated at Marshall Space Flight Center (MSFC) for investigation of changes in mechanical and ballistic properties. This process required significant levels of analysis to evaluate how the radiation environment evolves within the spacecraft during the mission, and also to evaluate how dose is delivered into test articles within the irradiating facilities.
Caffrey, Jarvis↗
Analyses and Methods of Solid Rocket Motor Material Irradiation at Marshall Space Flight Center
The search for life on other worlds is among humanity’s greatest endeavors. Europa represents the most probable location to discover extraterrestrial life in our solar system, owing to its surface composition of ice covering a liquid water ocean, warmed by the tidal forces of its orbit around Jupiter. Unfortunately, the Jovian system hosts the most intense planetary radiation environment in the solar system due to the charged particles, namely electrons and protons, trapped by Jupiter’s immense magnetic field. Any mission that attempts to approach or land on Europa must survive this radiation environment [Hand et al, 2017]. Radiation effects were identified as a priority risk to the successful development of a de-orbit stage and solid rocket motor (SRM) early in the Europa Lander De-orbit Stage project concept. The effects of primary concern tend to occur very near the outer surface of the SRM. The charged particles deposit their energy quickly and are mostly stopped in the outer metallic case, but a significant portion of radiation penetrates through the bondline and outer propellant regions. High doses of ionizing radiation are known to cause significant changes to mechanical properties of many materials, especially polymers. For polymers such as the rubber-like materials (elastomers) in a solid rocket motor, the primary damage mechanism is known as cross-linking, in which ionization causes the restructuring of the matrix of long polymer chains. Ionization energy breaks the long polymer chains and allows formation of new cross-linked bonding sites. This hardens and often strengthens the polymer, but at the cost of decreased flexibility (or modulus). Propellant, insulation, liner, and pyrotechnic materials were identified as higher risk items, and so were irradiated at Marshall Space Flight Center (MSFC) for investigation of changes in mechanical and ballistic properties. This process required significant levels of analysis to evaluate how the radiation environment evolves within the spacecraft during the mission, and also to evaluate how dose is delivered into test articles within the irradiating facilities.
Caffrey, Jarvis↗
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↗
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↗
Progress in Additively Manufactured Copper-Alloy GRCop-84, GRCop-42, and Bimetallic Combustion Chambers for Liquid Rocket Engines
Additive Manufacturing (AM) has significantly evolved over the last decade for use in the aerospace industry, particularly for liquid rocket engines. AM offers a considerable departure from traditional manufacturing to rapidly fabricate components with complex internal features. High performance liquid rocket engine combustion chambers that operate in a high heat flux environment are fabricated using a copper-alloy liner with a series of integral coolant channels. Copper-alloys provide the necessary conductivity and material strength for adequate design margins offering high performance without the need for film coolant. Copper-alloys present unique challenges to properly melt the powder in laser-based AM processes due to their high reflectivity and conductivity. Starting in 2014, NASA’s Marshall Space Flight Center (MSFC) and Glenn Research Center (GRC) have developed a process for AM of GRCop (Copper- Chrome-Niobium) alloys using Selective Laser Melting (SLM). GRCop, originally developed at GRC, is a high conductivity, high-strength, dispersion strengthened copper-alloy for use in high-temperature, high heat flux applications. NASA has completed significant material characterization and testing, along with hot-fire testing, to demonstrate that GRCop-42 and GRCop-84 alloys are suitable for use in combustion chambers. Additional development and testing has been completed on AM bimetallic chambers using GRCop-84 liners and superalloy jackets, fabricated using two Directed Energy Deposition (DED) processes: Electron Beam Freeform Fabrication (EBF³) and Blown Powder DED. NASA completed hot-fire testing on various AM chambers using GRCop-84, GRCop-42, and bimetallic chambers in Liquid Oxygen (LOX)/Hydrogen, LOX/Methane, and LOX/Kerosene propellants.
Gradl, Paul R.↗
Fluid for Thought: SLS Rocket Aerodynamics featuring Pressure Sensitive Paint
Combining computer vision algorithms, state-of-the-art high-speed cameras, pressure sensitive paint (PSP) and transonic wind tunnel facilities, teams at NASA and Boeing study unsteady pressure over the Space Launch System (SLS) rocket model with unprecedented temporal and spatial data resolution. Post-processing visualizes pressure fluctuations over a 3D model by converting intensity data from videos of the wind tunnel test. Additionally, data analysis creates predictions of buffet forcing and aeroacoustic activity over the rocket body with the accuracy of a CFD model! The development of the technique will revolutionize aerodynamics research and reveal uncharted insights into fluid behavior and vehicle performance, enhancing aerospace technology and design as they advance. The talk will focus on the impact of the PSP technique on the SLS design and other potential aerospace applications, as well as lay out the experimental process, from wind tunnel test to insights from the data analysis.
Lucy Zhonghui Tang↗
Space Storable Hybrid Rocket Technology Development
Hybrid rocket propulsion is gaining a great deal of interest for space storable and low temperature applications. Typical hybrid propellants have been shown to survive over a wide range of temperatures, minimizing the need for thermal control. This ability to survive in low temperature environments, coupled with their high performance (comparable to liquid bipropellants) and ability to restart has made them viable candidates for a variety of missions. A technology development program at the Jet Propulsion Laboratory over the last three years has focused on increasing the Technology Readiness Level (TRL) of hybrid rockets for a potential Mars Ascent Vehicle (MAV), In Situ Resource Utilization (ISRU) and Interplanetary SmallSat applications. Results of this technology development will be presented.
Vaughan, David↗
Expedited Model Building Method for Rocket Nozzle Side Loading
Statistical analysis of test data is currently the preferred method of creating models for uncharacterized side loading in rocket nozzles. However, statistical analysis requires multiple data sets to be reliable; getting these sets requires building and testing multiple rocket motors, which is not feasible given the incredible time and cost required to do so. By using a combination of geometry, simplified finite element analysis (FEA) analogs, and algebra we can create a limited predictive model from only one test data set. Once created, the model requires only the input from one strain gauge located at each yaw and pitch attachment bracket for the actuation system. This process is not computationally intensive, therefore saving an abundance of time and budget over using full 3D FEA models to develop a similar predictive model. To develop the model, conversion factors between the strain at the gauge locations and corresponding actuator load is derived from the data. These conversion factors are used to create a “conversion ellipse” that bounds the constitutive properties of the nozzle as one lumped factor. Using a 2D cross-sectional analog of the nozzle exit plane, we create a function that allows us to determine the azimuthal location of the unexpected load based on the ratio between yaw and pitch strain readings. Combining this with the “conversion ellipse” yields a function that given the strain reading outputs an induced actuator load, regardless of the azimuthal location of the unexpected load. As previously mentioned, this predictive model is limited in its application as there is inaccuracy introduced by the use of data by only one test as well as simplifying assumptions. This approach makes a useful tool to quickly determine whether uncharacterized actuator loading events can damage actuation systems or induce loading that exceeds design limits.
Seetha A Kolli↗
Micro-X Sounding Rocket: Transitioning from First Flight to a Dark Matter Configuration
The Micro-X sounding rocket flew for the first time on July 22, 2018, becoming the first program to fly Transition-Edge Sensors and multiplexing SQUID readout electronics in space. While a rocket pointing failure led to no time on-target, the success of the flight systems was demonstrated. The successful flight operation of the instrument puts the program in a position to modify the payload for indirect galactic dark matter searches. The payload modifications are motivated by the science requirements of this observation. Micro-X can achieve world-leading sensitivity in the keV regime with a single flight. Dark matter sensitivity projections have been updated to include recent observations and the expected sensitivity of Micro-X to these observed fluxes. If a signal is seen (as seen in the X-ray satellites), Micro-X can differentiate an atomic line from a dark matter signature.
J. S. Adams↗
Hydrocarbon Cold-Flow Simulation of LOX/LH2 Rocket Aerodynamics
In FY19, this project developed a test method which employed heated ethane in the physical simulation of rocket plume aerodynamics. Based on this work, EUS partnered with significant leveraged funding. A portable, self-contained test bed was also fabricated to support validation of the new method. In FY20, this project focused on the formal validation of ethane’s performance as an aerodynamic simulant as well as the development of the analytical and hardware infrastructure required to carry out that task. The test bed was activated, a series of heated-ethane tests on one or more rocket/diffuser configurations were conducted, and characterizations of the performance of the ethane simulation compared to hot-fire were performed. A series of 127 tests were conducted on 13 aerodynamic configurations to evaluate ethane’s performance as a simulant. It was found that the new methodology can reproduce rocket plume flow fields with +/- 0.5% pressure error at ~3% physical scale. The result is a cost-per-test reduction of ~99% compared to the hot-fire subscale testing typically used to obtain equivalent data. Some initial efforts have taken place, and future efforts are being planned with LaRC supersonic retro propulsion and MSFC SLS aerodynamics teams, which are interested in using the ethane system to wind-tunnel test human-rated Mars lander retrorockets and SLS Booster. Details of the prototypical experiments were published as NASA TM 2020-5009122,and have been presented in JANNAF Virtual Conference paper, "New Developments in Retro propulsion Testing for Mars Entry, Descent and Landing".
Daniel Jones↗
A comprehensive line spread function error for the Off-plane Grating Rocket Experiment
The Off-plane Grating Rocket Experiment (OGRE) is a soft X-ray grating spectrometer to be flown on a suborbital rocket. The payload is designed to obtain the highest-resolution soft X-ray spectrum of Capella to date with a resolution goal of R(lambda/delta lambda) > 2000 at select wavelengths in its 10 - 55 A bandpass of interest. The optical design of the spectrometer realizes a maximum resolution of R 5000 with all components performing optimally, in perfect alignment, and not considering in-flight pointing errors; however, performance errors, misalignments, and in-flight pointing errors work to degrade this performance. A comprehensive line spread function (LSF) error budget has been constructed for the spectrometer to identify errors contributing to the LSF, to determine how each affects the LSF, and to inform performance requirements and alignment tolerances for the spectrometer. In this document, the comprehensive LSF error budget for the OGRE spectrometer is presented and its implications are discussed.
Benjamin D Donovan↗
An Updated Optical Design for the Off-Plane Grating Rocket Experiment
The Off-plane Grating Rocket Experiment (OGRE) is a soft X-ray spectroscopy suborbital rocket payload designed to obtain the highest-resolution soft X-ray spectrum of Capella to date. With a spectral resolution goal of R(lambda/delta lambda) > 2000 at select wavelengths in its 10-55 A bandpass of interest, the payload will be able to study the line-dominated spectrum of Capella in unprecedented detail. To achieve this performance goal, the payload will employ three key technologies: mono-crystalline silicon X-ray mirrors developed at NASA Goddard Space Flight Center, reflection gratings manufactured at The Pennsylvania State University, and electron-multiplying CCDs developed by The Open University and XCAM Ltd. In this document, an updated optical design that can achieve the performance goal of the OGRE spectrometer and a new grating alignment concept to realize this optical design are described.
Benjamin D. Donovan↗
The optomechanical design for the Off-plane Grating Rocket Experiment (OGRE)
The Off-plane Grating Rocket Experiment (OGRE) is a sounding rocket payload designed to obtain a high-resolution soft X-ray spectrum of Capella. OGRE’s optical system uses new technologies including state-of-the-art X-ray optics, custom arrays of reflection gratings, and an array of EM-CCDs. Many of these technologies will be tested for the first time in flight with OGRE. To achieve the high performance that these new technologies are capable of, the payload components must be properly aligned to meet high tolerances. This paper will outline OGRE’s opto-mechanical design for achieving alignment within these tolerances. Specifically, the design of the X-ray grating arrays will be discussed.
Bridget C. O’Meara↗
Methods for Modeling Particle Impingement in Solid Rocket Motor Nozzles
This paper describes several approaches available to analysts to capture the mechanical erosion effects of alumina droplet impingement in solid rocket motor nozzles. Supersonic alumina impingement is of great interest to solid rocket motor analysts, as it can be one of the main contributors to overall nozzle erosion, particularly in nozzles with highly contoured exit cones. An overview of the basic concepts of mechanical impingement is provided, along with discussion on some of the various methods available, ranging from the purely empirical to more physics-based techniques, and their respective advantages and disadvantages.
William Allen Till↗
Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines
Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. 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-alloy 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. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. 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 copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.
Additive Manufacturing↗