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The Five Segment Reusable Solid Rocket Booster (RSRB) feasibility status is presented in viewgraph form. The Five Segment Booster (FSB) objective is to provide a low cost, low risk approach to increase reliability and safety of the Shuttle system. Topics include: booster upgrade requirements; design summary; reliability issues; booster trajectories; launch site assessment; and enhanced abort modes.
Liquid Flyback Boosters provide an opportunity to improve shuttle safety, increase performance, and reduce operating costs. The objective of the LFBB study is to establish the viability of a LFBB configuration to integrate into the shuttle vehicle and meet the goals of the Space Shuttle upgrades program. The design of a technically viable LFBB must integrate into the shuttle vehicle with acceptable impacts to the vehicle elements, i.e. orbiter and external tank and the shuttle operations infrastructure. The LFBB must also be capable of autonomous return to the launch site. The smooth integration of the LFBB into the space shuttle vehicle and the ability of the LFBB to fly back to the launch site are not mutually compatible capabilities. LFBB wing configurations optimized for ascent must also provide flight quality during the powered return back to the launch site. This paper will focus on the core booster design and ascent performance. A companion paper, "Conceptual Design for a Space Shuttle Liquid Flyback Booster" will focus on the flyback system design and performance. The LFBB study developed design and aerodynamic data to demonstrate the viability of a dual booster configuration to meet the shuttle upgrade goals, i.e. enhanced safety, improved performance and reduced operations costs.
The launch vehicle for the Solar Heliospheric Observatory (SOHO) mission is a two stage Atlas-IIAS (Atlas/Centaur). The Atlas, consists of a solid rocket booster stage powered by four Thiokol Castor IVA solid rocket boosters (SRB) and a core vehicle stage (booster and sustainer) powered by Rocketdyne MA-5A liquid propellant engines (RP-1 fuel and liquid oxygen). The multiple firing Centaur is powered by two Pratt and Whitney (RL10A-4) liquid hydrogen and liquid oxygen engines with extendible nozzles. This video shows the erection of the Atlas booster and transportation (to 36-B launching pad) and erection of the Centaur.
The Five-Segment Booster design concept was evaluated by a team that determined the concept to be feasible and capable of achieving the desired abort-to-orbit capability when used in conjunction with increased Space Shuttle main engine throttle capability. The team (NASA Johnson Space Center, NASA Marshall Space Flight Center, ATK Thiokol Propulsion, United Space Alliance, Lockheed-Martin Space Systems, and Boeing) selected the concept that provided abort-to-orbit capability while: 1) minimizing Shuttle system impacts by maintaining the current interface requirements with the orbiter, external tank, and ground operation systems; 2) minimizing changes to the flight-proven design, materials, and processes of the current four-segment Shuttle booster; 3) maximizing use of existing booster hardware; and 4) taking advantage of demonstrated Shuttle main engine throttle capability. The added capability can also provide Shuttle mission planning flexibility. Additional performance could be used to: enable implementation of more desirable Shuttle safety improvements like crew escape, while maintaining current payload capability; compensate for off nominal performance in no-fail missions; and support missions to high altitudes and inclinations. This concept is a low-cost, low-risk approach to meeting Shuttle safety upgrade objectives. The Five-Segment Booster also has the potential to support future heavy-lift missions.
The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Obsolescence issues occasionally required component recertification. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. Assembly and integration of the booster subsystems was a unique process and acceptance testing of reused hardware components was required for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.
The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.
Computational fluid dynamics assessment of the forward booster separation motor ignition over-pressure was performed on the space shuttle external tank X(sub T) 718 ice/frost ramp using the flow solver OVERFLOW. The main objective of this study was the investigation of the over-pressure during solid rocket booster separation and its affect on the local pressure and air-load environments. Delta pressure and plume impingement were investigated as a possible contributing factor to the cause of the debris loss on shuttle missions STS-125 and STS-127. A simplified computational model of the Space Shuttle Launch Vehicle was developed consisting of just the external tank and the solid rocket boosters with separation motor nozzles and plumes. The simplified model was validated by comparison to full fidelity computational model of the Space Shuttle without the separation motors. Quasi steady-state plume solutions were used to calibrate the thrust of the separation motors. Time-accurate simulations of the firing of the booster-separation motors were performed. Parametric studies of the time-step size and the number of sub-iterations were used to find the best converged solution. The computed solutions were compared to previous OVERFLOW steady-state runs of the separation motors with reaction control system jets and to ground test data. The results indicated that delta pressure from the overpressure was small and within design limits, and thus was unlikely to have contributed to the foam losses.
A wind-tunnel investigation of a 0.009 scale model of the Space Launch System (SLS) was conducted in the NASA Langley Unitary Plan Wind Tunnel to characterize the aerodynamics of the core and solid rocket boosters (SRBs) during booster separation. High-pressure air was used to simulate plumes from the booster separation motors (BSMs) located on the nose and aft skirt of the SRBs. Force and moment data were acquired on the core and SRBs. These data were used to corroborate computational fluid dynamics (CFD) calculations that were used in developing a booster separation database. The SRBs could be remotely positioned in the x-, y-, and z-direction relative to the core. Data were acquired continuously while the SRBs were moved in the axial direction. The primary parameters varied during the test were: core pitch angle; SRB pitch and yaw angles; SRB nose x-, y-, and z-position relative to the core; and BSM plenum pressure. The test was conducted at a free-stream Mach number of 4.25 and a unit Reynolds number of 1.5 million per foot.
The NASA Engineering and Safety Center (NESC) was requested to examine processing sensitivities (e.g., cure temperature control/variance, debonds, density variations) of polybenzimidazole nitrile butadiene rubber (PBI-NBR) insulation, case fiber, and resin systems and to evaluate nondestructive evaluation (NDE) and damage tolerance methods/models required to support human-rated composite motor cases. The proposed use of composite motor cases in Blocks IA and II was expected to increase performance capability through optimizing operating pressure and increasing propellant mass fraction. This assessment was to support the evaluation of risk reduction for large booster component development/fabrication, NDE of low mass-to-strength ratio material structures, and solid booster propellant formulation as requested in the Space Launch System NASA Research Announcement for Advanced Booster Engineering Demonstration and/or Risk Reduction. Composite case materials and high-energy propellants represent an enabling capability in the Agency's ability to provide affordable, high-performing advanced booster concepts. The NESC team was requested to provide an assessment of co- and multiple-cure processing of composite case and PBI-NBR insulation materials and evaluation of high-energy propellant formulations.
The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..
A wind tunnel test was run in the NASA Langley Unitary Plan Wind Tunnel simulating the separation of the two solid rocket boosters (SRB) from the core stage of the NASA Space Launch System (SLS). The test was run on a 0.9% scale model of the SLS Block 1B Cargo (27005) configuration and the SLS Block 1B Crew (28005) configuration at a Mach of 4.0. High pressure air was used to simulate plumes from the booster separation motors located at the nose and aft skirt of the two boosters. Force and moment data were taken on both SRBs and on the core stage. Schlieren still photos and video were recorded throughout testing. A set of points were acquired using Cross-correlation Doppler Global Velocimetry (CCDGV) readings to get 3 component velocity measurements between the core and the left-hand SRB. The CCDGV laser was utilized to record flow visualization in the same location, between the core and the left-hand SRB. Pressure Sensitive Paint data were taken on a separate set of runs. Computational Fluid Dynamics (CFD) runs were computed on a subset of the wind tunnel data points for comparison. A combination of the force/moment, CCDGV and Pressure Sensitive Paint (PSP) data (as well as schlieren images) at the CFD-specified test conditions will be used te the CFD simulations that will be used to build an SLS booster separation database flight conditions.
Planar flow visualizations were obtained in a wind tunnel test in the NASA Langley Research Center’s Unitary Plan Wind Tunnel using the laser-light-sheet method. This method uses a laser to illuminate fine particles generated in the wind tunnel to visualize flow structures. The test article was designed to simulate the separation of the two solid rocket boosters (SRBs) from the core stage of the NASA Space Launch System (SLS) at Mach 4 using a scale model. The test was run on of the SLS Block 1B Cargo (27005) configuration and the SLS Block 1B Crew (28005) configuration. Planar flow visualization was obtained only on the crew configuration. Air at pressures up to 1500 psi was used to simulate plumes from the booster separation motors (BSMs) located at the nose, and aft skirt of the two boosters. The facility free stream was seeded with water vapor, which condensed and froze into small ice crystals in the tunnel nozzle expansion. A continuous wave green (532 nm) laser sheet was used to illuminate the ice crystals, and the resulting Mie-scattered light was collected with a camera. The resulting images clearly identify shock waves and other flow features including BSM plume shapes. Measurements were acquired for different BSM pressures and booster separation locations.
The Fermilab Booster is currently in the process of an intensity upgrade referred to as the Proton Improvement Plan (PIP). The goal of PIP is to have the Booster provide a proton beam flux of 2 x 10{sup 17} protons/hour. This is almost double the current operation of 1.1 x 10{sup 17} protons/hour. Beam losses in the machine due to the increased flux will create larger integrated doses on aperture limiting components that will need to be mitigated. The Booster accelerates beam from 400 MeV to 8 GeV at a rep rate of 15hz and then extracts beam to the Main Injector. Several percent of the beam is lost within 3 msec after injection in the early part of acceleration. The aperture at injection energy was recently measured using corrector scans. Along with magnet survey data and aperture scan data a plan to realign the magnets in the Booster was developed and implemented in May 2012. The beam studies, analysis of the scan and alignment data, and the result of the magnet moves are presented.
The extraction bucket position in the Fermilab Booster is controlled with a cogging process that involves the comparison of the Booster rf count and the Recycler Ring revolution marker. A one rf bucket jitter in the ex-traction bucket position results from the variability of the process that phase matches the Booster to the Recycler. However, the new slow phase lock process used to lock the frequency and phase of the Booster rf to the Recycler rf has been made digital and programmable and has been modified to correct the extraction notch position. The beam loss at the Recycler injection has been reduced by 20%. Beam studies and the phase lock system will be discussed in this paper.
The extraction bucket position in the Fermilab Booster is controlled with a cogging process that involves the comparison of the Booster rf count and the Recycler Ring revolution marker. A one rf bucket jitter in the extraction bucket position results from the variability of the process that phase matches the Booster to the Recycler. However, the new slow phase lock process used to lock the frequency and phase of the Booster rf to the Recycler rf has been made digital and programmable and has been modified to correct the extraction notch position. The beam loss at the Recycler injection has been reduced by 20%.
To mitigate 8 GeV beam losses at extraction in the Fermilab Booster synchrotron, a LASER chopper system for multiturn injection that produces a beam free gap, aka “notch” in the LINAC beam pulse at 750 keV is developed. These notches in the LINAC pulse are spaced with the 400 MeV injection revolution period of the Booster. Recently, a dedicated notching pattern that keeps a single 201 MHz LINAC bunch in the middle of a notch is developed to measure the beam energy spread by studying the time evolution of this bunch in the Booster. A method complementary to this has also been realized by injecting <2 Booster turn beam and studying the time evolution of the multiple 201 MHz LINAC bunches. In this paper we present the general principle of the method and results from our measurements.
A new two-stage collimation unit (2SC) for Fermilab Booster will be installed during 2024 summer shutdown. It is a supplementary collimator for existing single stage Booster collimators. Design details of this 2SC adapted to Booster conditions are described. Results of beam dynamics simulations on collimation efficiency and evaluation of collimator shielding with MARS code on this new system are presented. The analysis on beam dynamics shows that the system will help to collimate up to about 1% of the beam in a confined way and, prompt and residual activation meet Fermilab Radiological Control limits in current as well as during PIP-II era high intensity operation of the Booster.
Detection and isotopic analysis of particle populations has seen rapid growth across several application areas, including environmental analysis, nuclear forensics, and food safety. The ability to characterize the particles' unique elemental and isotopic fingerprints could provide information related to formation, processing history, and transport. Regarding nuclear forensics, isotopic analysis of particles derived from diverse materials is often used as a tool to trace the origin and processing history. Mass spectrometric-based techniques currently used for particle population analysis often suffer from limited mass resolution, particularly when dealing with real-world samples that are affected by isobaric and polyatomic interferences from the matrix. To address these analytical challenges, we propose a novel method utilizing the liquid sampling-atmospheric pressure glow discharge (LS-APGD) microplasma ionization source coupled to an ultrahigh resolution Orbitrap mass spectrometer, further enhanced with the FTMS X2T Booster data acquisition and processing unit. The FTMS Booster enables acquisition of extended transient times of up to 3 s, significantly improving mass resolution, thereby reducing or even eliminating the need for prior separation of isobaric or polyatomic interferences. Additionally, the detection of low-abundance isotopes was improved by increasing the signal-to-noise (S/N) ratio. As proof of concept, this study demonstrates the feasibility of the LS-APGD/Orbitrap-FTMS X2T Booster platform for direct analysis using a suspension of well-characterized ∼120 nm neodymium particles. The quality of the isotope ratios values obtained from a few hundred particles were in good agreement with those obtained from homogeneous ionic solutions. These results highlight the potential of the LS-APGD/Orbitrap platform for rapid, accurate, and interference-resilient isotope ratio analysis of particle populations without the need for dissolution and subsequent chemical separations, offering significant advantages for nuclear forensics, safeguards, and environmental applications. The effort here also points to further paths forward, hopefully towards single particle (SP) analysis using microplasma ionization and the ultrahigh resolving power of the Orbitrap mass analyzer.