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NASA NTRS1995

Hybrid propulsion for launch vehicle boosters: A program status update

Results obtained in studying the origin and suppression of large-amplitude pressure oscillations in a 24 in. diameter hybrid motor using a liquid oxygen/hydroxylterminated polybutadiene/polycyclopentadiene propellant system are discussed. Tests conducted with liquid oxygen flow rates varying from 10 to 40 lbm/sec were designed to gauge the effectiveness of various vaporization chamber flow fields, injector designs, and levels of heat addition in suppressing high-frequency longitudinal mode oscillations. Longitudinal acoustic modes did not arise in any tests. However, initial testing revealed the presence of high-amplitude, sinusoidal, nonacoustic oscillations persisting throughout the burn durations. Analysis showed this to be analogous to chug mode instability in liquid rocket engines brought about by a coupling of motor combustion processes and the liquid oxygen feed system. Analytical models were developed and verified by test data to predict the amplitude and frequency of feed-system-coupled combustion pressure oscillations. Subsequent testing showed that increasing the feed system impedance eliminated the bulk mode instability. This paper documents the work completed to date in performance of the Hybrid Propulsion Technology for Launch Vehicle Boosters Program (NAS8-39942) sponsored by NASA's George C. Marshall Space Flight Center.

Carpenter, R. L.↗

NASA NTRS2005

Trial by Fire

The NASa/ATK Thiokol space shuttle solid rocket motor program has doubled ground test firings and enhanced manufacturing quality and process control to increase safety for Discovery's return to flight. There are a number of places where we've strengthened our engineering and our processes, says Mike Kahn, ATK Thiokol vice president of space launch systems. Protecting the booster against corrosion in the humid Florida environment is one area that has been addressed. Since the loss of Columbia, ATK Thiokol and the Marshall Space Flight Center have completely reevaluated the shuttle solid rocket motor's design certification and found no major problems, Kahn said. The Thiokol solid motors did not play a role in the 2003 Columbia accident, but the motor's older field joint design (since replaced) was the primary cause of the 1986 Challenger accident that killed seven astronauts. The 129 X 12-ft. ATK Thiokol reusable solid rocket motor forms the core of the shuttle's two solid rocket boosters (SRBs). United Space Alliance (USA) has overall responsibility for the booster's nose-mounted systems such as recovery parachutes and aft-mounted thrust vector control systems that increase the length to 149 ft. USA and its subcontractors have also reaffirmed quality control on systems such as the booster's Hamilton Sundstrand hydraulic power units for critical thrust vector control. And to ensure greater safeguards against booster debris jeopardizing the orbiter, a bolt-catcher system to restrain the large bolts, severed at booster separation, was also redesigned.

Covault, Craig↗

NASA NTRS2008

System Engineering on the Use for Ares I,V - the Simpler, the Better

The Ares I and Ares V Vehicles will utilize the J-2X rocket engine developed for NASA by the Pratt & Whitney Rocketdyne Company. The J-2X is an improved higher power version of the original J-2 engine used during the Apollo program. With higher power and updated requirements for safety and performance, the J-2X becomes a new engine using state-of-the-art design methodology, materials and manufacturing processes. The implementation of Systems Engineering (SE) principles enables the rapid J-2X development program to remain aligned with the ARES I and V vehicle programs, Meeting the aggressive development schedule is a challenge. Coordinating the best expertise thai NASA and PWR have to offer requires effectively utilizing resources at multiple sites. This presents formidable communication challenges. SE allows honest and open discussions of issues and problems. This simple idea is often overlooked in large and complex SE programs. Regular and effective meetings linking SE objectives to component designs are used to voice differences of opinions with customer and contractor in attendance so that the best mutual decisions can be made on the shortest possible schedule. Regular technical interchange meetings on secure program wide computer networks and CM processes are effective,in the "Controlled Change" process that exemplifies good SE. Good communication is a key effective SE implementation. The System of Systems approach is the vision of the Orion program which facilitates the establishment of dynamic SE processes at all levels including the engine. SE enables requirements evolution by facilitating organizational and process agility. Flow down and distribution of requirements is controlled by Allocation Reports which breakdown numerical design objectives (weight, reliability, etc.) into quanta goals for each component area. Linked databases of design and verification requirements helps eliminate redundancy and potential mistakes inherent m separated systems. Another tool, the Architecture Design Description, is being used to control J-2X system architecture and effectively communicate configuration changes to those involved in the design process. But the proof is in successful program accomplishment. The SE is the methodology being used to meet the challenge of completing J-2X engine certification 2 years ahead of any engine program ever developed at PWR. The Ares I SE system of systems has delivered according to expectations thus far. All major design reviews (SRR. PDR, CDR) have been successfully conducted to satisfy overall program objectives using SE as the basis for accomplishment. The paper describes SE tools and techniques utilized to achieve this success.

Kelly, William↗

NASA NTRS2008

Subscale Injector Testing to Support Ares Engines Development

The J-2X and RS-68B rocket engines are being developed for NASA's Ares I and Ares V launch vehicles. In support of the development of these engines, hot-fire testing on subscale coaxial injectors has been performed at NASA s Marshall Space Flight Center (MSFC) to evaluate performance data relative to injector type, liquid oxygen (LOX) post tip design features, element density and various operating conditions. Shear coaxial injectors with element densities of 1.1, 1.6, and 2.3 elements/in2 and a swirl coaxial injector with element density of 1.6 elements/in2 were evaluated at conditions relevant to the Ares applications. Chamber pressures with oxygen/hydrogen propellants ranged from 815-1630 psig with mixture ratios ranging from 4.7-6.9. Fuel manifold inlet temperatures were varied from 90 to 270 R. Shear coaxial LOX post tip thicknesses ranged from 0.006 in. to 0.0175 in. Modular, water cooled, calorimeter chamber assemblies were used to provide heating rate data and evaluate the effects of characteristic length (L*). Performance was evaluated relative to the resulting characteristic velocity (C*) efficiency. Testing with both the 2.3 and 1.1 elements/in2 shear coaxial injectors demonstrated no improvement in performance of the "thin" tip configuration versus the "thick" tip configuration. The loss in chamber pressure and associated performance loss seen in previous testing at low fuel temperatures could not be reliably repeated, indicating that this loss is not the result of a fluidic process in the injector elements. Further, no performance loss could be demonstrated once a faceplate seal specifically designed for operation with low temperature hydrogen was implemented in the 1.1 elements/sq in shear coaxial injector. Results for the 1.6 elements/sq in swirl injector at cold fuel temperatures showed performance higher than both the 1.6 elements/in2 shear coaxial injector and the 2.3 elements/in2 shear coaxial injector.

Protz, Christopher↗

NASA NTRS1993

Advanced transportation system study: Manned launch vehicle concepts for two way transportation system payloads to LEO

The purpose of the Advanced Transportation System Study (ATSS) task area 1 study effort is to examine manned launch vehicle booster concepts and two-way cargo transfer and return vehicle concepts to determine which of the many proposed concepts best meets NASA's needs for two-way transportation to low earth orbit. The study identified specific configurations of the normally unmanned, expendable launch vehicles (such as the National Launch System family) necessary to fly manned payloads. These launch vehicle configurations were then analyzed to determine the integrated booster/spacecraft performance, operations, reliability, and cost characteristics for the payload delivery and return mission. Design impacts to the expendable launch vehicles which would be required to perform the manned payload delivery mission were also identified. These impacts included the implications of applying NASA's man-rating requirements, as well as any mission or payload unique impacts. The booster concepts evaluated included the National Launch System (NLS) family of expendable vehicles and several variations of the NLS reference configurations to deliver larger manned payload concepts (such as the crew logistics vehicle (CLV) proposed by NASA JSC). Advanced, clean sheet concepts such as an F-1A engine derived liquid rocket booster (LRB), the single stage to orbit rocket, and a NASP-derived aerospace plane were also included in the study effort. Existing expendable launch vehicles such as the Titan 4, Ariane 5, Energia, and Proton were also examined. Although several manned payload concepts were considered in the analyses, the reference manned payload was the NASA Langley Research Center's HL-20 version of the personnel launch system (PLS). A scaled up version of the PLS for combined crew/cargo delivery capability, the HL-42 configuration, was also included in the analyses of cargo transfer and return vehicle (CTRV) booster concepts. In addition to strictly manned payloads, two-way cargo transportation systems (CTRV's) were also examined. The study provided detailed design and analysis of the performance, reliability, and operations of these concepts. The study analyzed these concepts as unique systems and also analyzed several combined CTRV/booster configurations as integrated launch systems (such as for launch abort analyses). Included in the set of CTRV concepts analyzed were the medium CTRV, the integral CTRV (in both a pressurized and unpressurized configuration), the winged CTRV, and an attached cargo carrier for the PLS system known as the PLS caboose.

Duffy, James B.↗

NASA NTRS2018

The Fusion Driven Rocket: Nuclear Propulsion through Direct Conversion of Fusion Energy

The future of manned space exploration and development of space depends critically on the creation of a dramatically more efficient propulsion architecture for in-space transportation. A very persuasive reason for investigating the applicability of nuclear power in rockets is the vast energy density gain of nuclear fuel when compared to chemical combustion energy. The Fusion Driven rocket (FDR) represents a revolutionary approach to fusion propulsion where the power source releases its energy directly into the propellant, not requiring conversion to electricity. It employs a solid lithium propellant that requires no significant tankage mass. The propellant is rapidly heated and accelerated to high exhaust velocity (> 30 km/s), while having no substantial physical interaction with the spacecraft thereby avoiding damage to the rocket and limiting both the thermal heat load and radiator mass. The key to achieving this stems from research at MSNW and the UW on the magnetically driven implosion of metal foils onto a magnetized plasma target to obtain fusion conditions. A logical extension of this work leads to a method that utilizes these metal shells (or liners) to not only achieve fusion conditions, but to serve as the propellant as well. Several low-mass, magnetically driven metal liners are inductively driven to converge radially and axially and form a thick blanket surrounding the target plasmoid and compress the plasmoid to fusion conditions. Virtually all of the radiant, neutron and particle energy from the plasma is absorbed by the encapsulating, thick metal blanket thereby isolating the spacecraft from the fusion. This energy, in addition to the intense Ohmic heating at peak magnetic field compression, is adequate to vaporize and ionize the metal blanket. The expansion of this hot, ionized metal propellant through a magnetically insulated nozzle produces high thrust at the optimal Isp. The energy from the fusion process, along with the waste heat, is thus utilized at very high efficiency. The basic scheme for FDR is illustrated and described in the report (see Fig. 2) The two most critical issues in meeting challenges introduced employing magneto-inertial fusion as the power source is driver efficiency and “stand-off” – the ability to isolate and protect fusion and thruster from the resultant fusion energy. By employing metal shells for compression, it is possible to produce the desired convergent motion inductively by inserting the metal sheets along the inner surface of cylindrical or conically tapered coils. Both stand-off and energy efficiency issues are solved by this arrangement. 3 This two year effort focused on achieving three key criteria for the Fusion Driven Rocket to move forward for technological development: (1) the physics of the FDR must be fully understood and validated, (2) the design and technology development for the FDR required for its implementation in space must be fully characterized, and (3) an in-depth analysis of the rocket design and spacecraft integration as well as mission architectures enabled by the FDR need to be performed. A subscale, laboratory liner compression test facility was assembled at the University of Washington Plasma Dynamics Laboratory with sufficient liner kinetic energy (~ 0.5 MJ) to reach conditions required for fusion breakeven conditions. Detailed experimental studies of the dynamic behavior of the driven liners as well as liner convergence and magnetic compression were performed. The development of both the 1D liner dynamics code and the full 3D ANSYS® liner calculations was achieved. The characterization of both the FDR and spacecraft as well as a design architecture analysis was conducted that included an examination of a wide range of mission architectures and destinations for which this fusion propulsion system would be enabling or critical. In particular a rapid, single launch manned Mars mission was developed.

Energy↗

NASA NTRS1989

Transpiration And Regenerative Cooling Of Rocket Engine

Transpiration cooling extends limits of performance. Addition of transpiration cooling to regeneratively-cooled rocket-engine combustion chamber proposed. Modification improves performance of engine by allowing use of higher chamber pressure. Throat section of combustion-chamber wall cooled by transpiration, while chamber and nozzle sections cooled by fluid flowing in closed channels. Concept applicable to advanced, high-performance terrestrial engines or some kinds of industrial combustion chambers. With proper design, cooling scheme makes possible to achieve higher chamber pressure and higher overall performance in smaller engine.

Obrien, Charles J.↗

NASA NTRS1990

Operationally Efficient Propulsion System Study (OEPSS) data book. Volume 4: OEPSS design concepts

This study was initiated to identify operations problems and cost drivers for current propulsion systems and to identify technology and design approaches to increase the operational efficiency and reduce operations costs for future propulsion systems. To provide readily usable data for the Advanced Launch System (ALS) program, the results of the OEPSS study have been organized into a series of OEPSS Data Books. This volume describes three propulsion concepts that will simplify the propulsion system design and significantly reduce operational requirements. The concepts include: (1) a fully integrated, booster propulsion module concept for the ALS that avoids the complex system created by using autonomous engines with numerous artificial interfaces; (2) an LOX tank aft concept which avoids potentially dangerous geysering in long LOX propellant lines; and (3) an air augmented, rocket engine nozzle afterburning propulsion concept that will significantly reduce LOX propellant requirements, reduce vehicle size and simplify ground operations and ground support equipment and facilities.

Wong, George S.↗

NASA NTRS1994

Rapid prototype fabrication processes for high-performance thrust cells

The Thrust Cell Technologies Program (Air Force Phillips Laboratory Contract No. F04611-92-C-0050) is currently being performed by Rocketdyne to demonstrate advanced materials and fabrication technologies which can be utilized to produce low-cost, high-performance thrust cells for launch and space transportation rocket engines. Under Phase 2 of the Thrust Cell Technologies Program (TCTP), rapid prototyping and investment casting techniques are being employed to fabricate a 12,000-lbf thrust class combustion chamber for delivery and hot-fire testing at Phillips Lab. The integrated process of investment casting directly from rapid prototype patterns dramatically reduces design-to-delivery cycle time, and greatly enhances design flexibility over conventionally processed cast or machined parts.

Hunt, K.↗

NASA NTRS2010

SSME Electrical Harness and Cable Development and Evolution

The Space Shuttle Main Engine (SSME) electrical harness and cable system consists of the various interconnecting devices necessary for operation of complex rocket engine functions. Thirty seven harnesses incorporate unique connectors, backshell adapters, conductors, insulation, shielding, and physical barriers for a long maintenance-free life while providing the means to satisfy performance requirements and to mitigate adverse environmental influences. The objective of this paper is to provide a description of the SSME electrical harness and cable designs as well as the development history and lessons learned.

Abrams, Russ↗

NASA NTRSDate not supplied

Status of Mars Retropropulsion Testing in the Langley Unitary Plan Wind Tunnel

Future Mars human landings will be enabled by a powered descent phase starting at supersonic conditions, something which has never been done before on a Mars mission. Significant aerosciences challenges exist due to jet interactions between the retrorocket engine plumes, freestream flow, and vehicle that will affect the aerodynamic behavior during powered descent. Historically, wind tunnel tests have been used to study the interactions with inert gas exhaust simulants in place of rocket engines. On the computational side, flowfield simulations have been completed at full-scale conditions, but the available ground and flight data are not appropriate for calibrating computational uncertainties for aerodynamic interference on proposed Mars descent vehicles, due to insufficient data, dissimilar vehicle geometries, and disparate operating conditions. A wind tunnel test has been designed to begin addressing powered descent aerodynamics risks for large-scale human Mars entry concepts and to identify gaps in computational predictive capabilities. The test will be conducted in the NASA Langley Unitary Plan Wind Tunnel and is designed with improvements in model design and data products over past tests. The test campaign will be run using sub-scale model geometries derived from NASA powered descent reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry that generates higher unpowered lift. Both models have been fabricated and are ready for testing. The blunt model is equipped with the flexibility to examine the effects of nozzle pointing direction, number, location, size, and area ratio. The main measurements are heatshield aerodynamic interference forces and moments with a custom flow-through balance, discrete and distributed heatshield pressure, and high-speed flowfield visualization. This paper covers the test objectives, facility, models and instrumentation, and planned test matrix.

Mars↗

NASA NTRSDate not supplied

Status of Mars Retropropulsion Testing in the Langley Unitary Plan Wind Tunnel

Supersonic Retropropulsion↗

NASA NTRS1966

Design and development of liquid hydrogen cooled 120mm roller, 110mm roller, and 110mm tandem ball bearings for M-1 fuel turbopump

Liquid hydrogen cooled tandem ball bearings for M-1 fuel turbopump

M-1 ROCKET ENGINE↗

NASA NTRS1992

A status of the activities of the NASA. Marshall Space Flight Center Combustion Devices Technology Team

The Consortium for Computational Fluid Dynamics (CFD) Applications in Propulsion Technology was established to focus on computational fluid dynamics applications in propulsion. Specific areas of effort include developing the CFD technology required to address rocket propulsion issues, validating the technology, and applying the validated technology to design problems. The Combustion Devices Technology Team was formed to implement the above objectives in the broad area of combustion driven flows. In an effort to bring CFD to bear in the design environment, the team has focused its efforts on the Space Transportation Main Engine nozzle. The main emphasis has been on the film cooling scheme used to cool the nozzle wall. Benchmark problems have been chosen to validate CFD film cooling capabilities. CFD simulations of the subscale nozzle have been made. Also, CFD predictions of the base flow resulting from this type of nozzle have been made. The status of these calculations is presented along with future plans. Information is given in viewgraph form.

Tucker, Kevin↗

NASA NTRS1993

Advanced transportation system studies. Alternate propulsion subsystem concepts: Propulsion database

The Advanced Transportation System Studies alternate propulsion subsystem concepts propulsion database interim report is presented. The objective of the database development task is to produce a propulsion database which is easy to use and modify while also being comprehensive in the level of detail available. The database is to be available on the Macintosh computer system. The task is to extend across all three years of the contract. Consequently, a significant fraction of the effort in this first year of the task was devoted to the development of the database structure to ensure a robust base for the following years' efforts. Nonetheless, significant point design propulsion system descriptions and parametric models were also produced. Each of the two propulsion databases, parametric propulsion database and propulsion system database, are described. The descriptions include a user's guide to each code, write-ups for models used, and sample output. The parametric database has models for LOX/H2 and LOX/RP liquid engines, solid rocket boosters using three different propellants, a hybrid rocket booster, and a NERVA derived nuclear thermal rocket engine.

Levack, Daniel↗

NASA NTRS1993

Small rocket research and technology

Small chemical rockets are used on nearly all space missions. The small rocket program provides propulsion technology for civil and government space systems. Small rocket concepts are developed for systems which encompass reaction control for launch and orbit transfer systems, as well as on-board propulsion for large space systems and earth orbit and planetary spacecraft. Major roles for on-board propulsion include apogee kick, delta-V, de-orbit, drag makeup, final insertions, north-south stationkeeping, orbit change/trim, perigee kick, and reboost. The program encompasses efforts on earth-storable, space storable, and cryogenic propellants. The earth-storable propellants include nitrogen tetroxide (NTO) as an oxidizer with monomethylhydrazine (MMH) or anhydrous hydrazine (AH) as fuels. The space storable propellants include liquid oxygen (LOX) as an oxidizer with hydrazine or hydrocarbons such as liquid methane, ethane, and ethanol as fuels. Cryogenic propellants are LOX or gaseous oxygen (GOX) as oxidizers and liquid or gaseous hydrogen as fuels. Improved performance and lifetime for small chemical rockets are sought through the development of new predictive tools to understand the combustion and flow physics, the introduction of high temperature materials to eliminate fuel film cooling and its associated combustion inefficiency, and improved component designs to optimize performance. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Results indicate that modeling of the injector and combustion process in small rockets needs improvement. High temperature materials require the development of fabrication processes, a durability data base in both laboratory and rocket environments, and basic engineering property data such as strength, creep, fatigue, and work hardening properties at both room and elevated temperature. Promising materials under development include iridium-coated rhenium and a ceramic composite of mixed hafnium carbide and tantalum carbide reinforced with graphite fibers.

Schneider, Steven↗

NASA NTRS1996

STS-75 Space Shuttle Mission Report

The STS-75 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the seventy-fifth flight of the Space Shuttle Program, the fiftieth flight since the return-to-flight, and the nineteenth flight of the Orbiter Columbia (OV-102). In addition to the Orbiter, the flight vehicle consisted of an ET that was designated ET-76; three SSME's that were designated as serial numbers 2029, 2034, and 2017 in positions 1, 2, and 3, respectively; and two SRB's that were designated BI-078. The RSRM's, designated RSRM-53, were installed in each SRB and the individual RSRMs were designated as 36OW53A for the left SRB, and 36OW053B for the right SRB. The primary objectives of this flight were to perform the operations necessary to fulfill the requirements of the Tethered Satellite System-1 R (TSS-1R), and the United States Microgravity Payload-3 (USMP-3). The secondary objectives were to complete the operations of the Orbital Acceleration Research Experiment (OARE), and to meet the requirements of the Middeck Glovebox (MGBX) facility and the Commercial Protein Crystal Growth (CPCG) experiment. Appendix A provides the definition of acronyms and abbreviations used thorughout the report. All times during the flight are given in Greenwich mean time (GMT) and mission elapsed time (MET).

Fricke, Robert W., Jr.↗

NASA NTRS2014

New Laboratory-Based Satellite Impact Experiments for Breakup Fragment Characterization

A consortium consisting of the NASA Orbital Debris Program Office, U.S. Air Force's Space and Missile Systems Center, the Aerospace Corporation, and University of Florida is planning a series of hypervelocity impact experiments on mockup targets at the U.S. Air Force's Arnold Engineering Development Complex (AEDC) in early 2014. The target for the first experiment resembles a rocket upper stage whereas the target for the second experiment represents a typical 60‐cm/50‐kg class payload that incorporates modern spacecraft materials and components as well as exterior wrap of multi‐layer insulation and three solar panels. The projectile is designed with the maximum mass that AEDC's Range G two‐stage light gas gun can accelerate to an impact speed of 7 km/sec. The impact energy is expected to be close to 15 MJ to ensure catastrophic destruction of the target after the impact. Low density foam panels are installed inside the target chamber to slow down and soft‐catch the fragments for post‐impact processing. Diagnostic instruments, such as x‐ray and high speed optical cameras, will also be used to record the breakup process. The main goal of this "DebriSat" project is to characterize the physical properties, including size, mass, shape, and density distributions, of orbital debris that would be generated by a hypervelocity collision involving an upper stage or a modern satellite in the low Earth orbit environment. In addition, representative fragments will be selected for laboratory optical and radar measurements to allow for better interpretation of data obtained by telescope and radar observations. This paper will provide a preliminary report of the impact results and the plans to process, measure, and analyze the fragments.

Liou, J.-C.↗