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NASA NTRS2004

Technology Requirements for Affordable Single-Stage Rocket Launch Vehicles

A number of manned Earth-to-orbit (ETO) vehicle options for replacing or complementing the current Space Transportation System are being examined under the Advanced Manned Launch System (AMLS) study. The introduction of a reusable single-stage vehicle (SSV) into the U.S. launch vehicle fleet early in the next century could greatly reduce ETO launch costs. As a part of the AMLS study, the conceptual design of an SSV using a wide variety of enhancing technologies has recently been completed and is described in this paper. This paper also identifies the major enabling and enhancing technologies for a reusable rocket-powered SSV and provides examples of the mission payoff potential of a variety of important technologies. This paper also discusses the impact of technology advancements on vehicle margins, complexity, and risk, all of which influence the total system cost.

Stanley, Douglas O.↗
NASA NTRS1991

A Rocket Powered Single-Stage-to-Orbit Launch Vehicle With U.S. and Soviet Engineers

A single-stage-to-orbit launch vehicle is used to assess the applicability of Soviet Energia high-pressure-hydrocarbon engine to advanced U.S. manned space transportation systems. Two of the Soviet engines are used with three Space Shuttle Main Engines. When applied to a baseline vehicle that utilized advanced hydrocarbon engines, the higher weight of the Soviet engines resulted in a 20 percent loss of payload capability and necessitated a change in the crew compartment size and location from mid-body to forebody in order to balance the vehicle. Various combinations of Soviet and Shuttle engines were evaluated for comparison purposes, including an all hydrogen system using all Space Shuttle Main Engines. Operational aspects of the baseline vehicle are also discussed. A new mass properties program entitles Weights and Moments of Inertia (WAMI) is used in the study.

MacConochie, Ian O.↗
NASA NTRS2004

Nuclear Electric Vehicle Optimization Toolset (NEVOT)

The Nuclear Electric Vehicle Optimization Toolset (NEVOT) optimizes the design of all major nuclear electric propulsion (NEP) vehicle subsystems for a defined mission within constraints and optimization parameters chosen by a user. The tool uses a genetic algorithm (GA) search technique to combine subsystem designs and evaluate the fitness of the integrated design to fulfill a mission. The fitness of an individual is used within the GA to determine its probability of survival through successive generations in which the designs with low fitness are eliminated and replaced with combinations or mutations of designs with higher fitness. The program can find optimal solutions for different sets of fitness metrics without modification and can create and evaluate vehicle designs that might never be considered through traditional design techniques. It is anticipated that the flexible optimization methodology will expand present knowledge of the design trade-offs inherent in designing nuclear powered space vehicles and lead to improved NEP designs.

Tinker, Michael L.↗
NASA NTRS1997

Hybrid Turbine Electric Vehicle

Hybrid electric power trains may revolutionize today's ground passenger vehicles by significantly improving fuel economy and decreasing emissions. The NASA Lewis Research Center is working with industry, universities, and Government to develop and demonstrate a hybrid electric vehicle. Our partners include Bowling Green State University, the Cleveland Regional Transit Authority, Lincoln Electric Motor Division, the State of Ohio's Department of Development, and Teledyne Ryan Aeronautical. The vehicle will be a heavy class urban transit bus offering double the fuel economy of today's buses and emissions that are reduced to 1/10th of the Environmental Protection Agency's standards. At the heart of the vehicle's drive train is a natural-gas-fueled engine. Initially, a small automotive engine will be tested as a baseline. This will be followed by the introduction of an advanced gas turbine developed from an aircraft jet engine. The engine turns a high-speed generator, producing electricity. Power from both the generator and an onboard energy storage system is then provided to a variable-speed electric motor attached to the rear drive axle. An intelligent power-control system determines the most efficient operation of the engine and energy storage system.

Viterna, Larry A.↗
NASA NTRS2000

Propellant Densification Ground Testing Conducted for Launch Vehicles

The NASA Glenn Research Center at Lewis Field has taken the lead in the development of practical densified cryogenic propellants for launch vehicle applications. The technology of subcooling cryogenic propellants below their normal boiling point to produce a denser fluid is one of the key process technologies necessary to meet the challenge of single-stage-to-orbit and reusable launch vehicles. Densified propellants are critical to lowering launch costs because they enable more propellant to be packed into a given unit volume, thus improving the performance by reducing the overall size and weight of the launch vehicle. This two-pronged research and test program has evolved into (1) conducting tank loading tests using densified liquid hydrogen and (2) developing two large-scale propellant densification systems that will be performance tested next year at Glenn. The propellant-loading test program was undertaken at Glenn in coordination with Lockheed Martin Michoud Space Systems. In this testing, the liquid hydrogen recirculation and densification process was simulated, and the thermal stratification of the densified propellant was recorded throughout the tank. The test article was a flight-weight tank constructed from composite materials similar to those to be used on the X-33 launch vehicle. The tank geometry as designed by Lockheed Martin had two cylindrical lobes with a center septum. Liquid hydrogen flow rate, pressure data, and temperature data plotted over time were collected while the subscale tank was filled with 27 R (15 K) densified liquid hydrogen propellant. This testing has validated mathematical models and demonstrated the readiness of densified propellant technology for near-term use. It marks the first time that such a process has been carried out with a multiple-lobe, flight-similar tank. Glenn researchers have also been working on providing a process and critical test data for the continuous production of densified liquid hydrogen (LH2) and densified liquid oxygen (LO2). Each densification production process uses a high-efficiency, subatmospheric boiling bath heat exchanger to cool the working fluid. A near triple-point hydrogen boiling bath is used to condition and subcool hydrogen to 27 R (15 K), and a nitrogen boiling bath is used to cool the liquid oxygen to 120 R (66.7 K). Multistage centrifugal compressors operating at cryogenic inlet conditions maintain the heat exchanger bath vapor pressure below 1 atm. The LO2 propellant densification unit shown in the photograph has a 30 lb/sec capacity, whereas the LH2 unit was designed to process 8 lb/sec of propellant. Each densification unit will be transported to Glenn's South Forty area after all fabrication work is completed sometime late next year. There the LO2 and LH2 densifier performance tests will be conducted with another larger Lockheed Martin tank designated the Structural Test Article (STA). This liquid oxygen tank is a full-scale, flight-weight, prototype aluminum tank designed for the X-33. It has a capacity of 20,000 gallons of LO2. The tank loading and recirculation testing planned for next year with STA will provide the data necessary for full-scale development of propellant densification technology.

Tomsik, Thomas M.↗
NASA NTRS2005

Circulation Control in NASA's Vehicle Systems

Specific to the application of any technology to a vehicle, such as circulation control, it is important to understand the process that NASA is using to set its direction in research and development. To see how circulation control fits into any given NASA program requires the reader to understand NASA's Vehicle Systems (VS) Program. The VS Program recently celebrated its first year of existence with an annual review - an opportunity to look back on accomplishments, solicit feedback, expand national advocacy and support for the program, and recognize key contributions. Since its formation last year, Vehicle Systems has coordinated seven existing entities in a streamlined aeronautics research effort. It invests in vehicle technologies to protect the environment, make air travel more accessible and affordable for Americans, enable exploration through new aerospace missions, and augment national security. This past year has seen a series of valuable partnerships with industry, academia, and government agencies to make crucial aeronautics advances and assure America s future in flight.

Rich, Paul↗
NASA NTRS2005

Rehabilitation of the Rocket Vehicle Integration Test Stand at Edwards Air Force Base

Since initial use in 1958 for the X-15 rocket-powered research airplane, the Rocket Engine Test Facility has proven essential for testing and servicing rocket-powered vehicles at Edwards Air Force Base. For almost two decades, several successful flight-test programs utilized the capability of this facility. The Department of Defense has recently demonstrated a renewed interest in propulsion technology development with the establishment of the National Aerospace Initiative. More recently, the National Aeronautics and Space Administration is undergoing a transformation to realign the organization, focusing on the Vision for Space Exploration. These initiatives provide a clear indication that a very capable ground-test stand at Edwards Air Force Base will be beneficial to support the testing of future access-to-space vehicles. To meet the demand of full integration testing of rocket-powered vehicles, the NASA Dryden Flight Research Center, the Air Force Flight Test Center, and the Air Force Research Laboratory have combined their resources in an effort to restore and upgrade the original X-15 Rocket Engine Test Facility to become the new Rocket Vehicle Integration Test Stand. This report describes the history of the X-15 Rocket Engine Test Facility, discusses the current status of the facility, and summarizes recent efforts to rehabilitate the facility to support potential access-to-space flight-test programs. A summary of the capabilities of the facility is presented and other important issues are discussed.

Jones, Daniel S.↗
NASA NTRS2003

Control Surface Seals Investigated for Re- Entry Vehicles

Re-entry vehicles generally use control surfaces (e.g., rudders, body flaps, and elevons) to steer or guide them as they pass into and through the Earth s atmosphere. High temperature seals are required around control surfaces both along hinge lines and in areas where control surface edges seal against the vehicle body to limit hot gas ingestion and the transfer of heat to underlying low-temperature structures. Working with the NASA Johnson Space Center, the Seals Team at the NASA Glenn Research Center completed a series of tests on the baseline seal design for the rudder/fin control surface interfaces of the X-38 vehicle. This seal application was chosen as a case study to evaluate a currently available control surface seal design for applications in future re-entry vehicles. The structures of the rudder/fin assembly and its associated seals are shown in the following illustration.

Dunlap, Patrick H.↗
NASA NTRS2005

A Design Comparison of Atmospheric Flight Vehicles for the Exploration of Titan

Titan, the largest moon of Saturn, is one of the most scientifically interesting locations in the Solar System. With a very cold atmosphere that is five times as dense as Earth s, and one and a half times the surface pressure, it also provides one of the most aeronautically fascinating environments known to humankind. While this may seem the ideal place to attempt atmospheric flight, many challenges await any vehicle attempting to navigate through it. In addition to these physical challenges, any scientific exploration mission to Titan will most likely have several operational constraints. One difficult constraint is the desire for a global survey of the planet and thus, a long duration flight within the atmosphere. Since many of the scientific measurements that would be unique to a vehicle flying through the atmosphere (as opposed to an orbiting spacecraft) desire near-surface positioning of their associated instruments, the vehicle must also be able to fly within the first scale height of the atmosphere. Another difficult constraint is that interaction with the surface, whether by landing or dropped probe, is also highly desirable from a scientific perspective. Two common atmospheric flight platforms that might be used for this mission are the airplane and airship. Under the assumption of a mission architecture that would involve an orbiting relay spacecraft delivered via aerocapture and an atmospheric flight vehicle delivered via direct entry, designs were developed for both platforms that are unique to Titan. Consequently, after a viable design was achieved for each platform, their advantages and disadvantages were compared. This comparison included such factors as deployment risk, surface interaction capability, mass, and design heritage. When considering all factors, the preferred candidate platform for a global survey of Titan is an airship.

Gasbarre, Joseph F.↗
NASA NTRS2005

X-43 Hypersonic Vehicle Technology Development

NASA recently completed two major programs in Hypersonics: Hyper-X, with the record-breaking flights of the X-43A, and the Next Generation Launch Technology (NGLT) Program. The X-43A flights, the culmination of the Hyper-X Program, were the first-ever examples of a scramjet engine propelling a hypersonic vehicle and provided unique, convincing, detailed flight data required to validate the design tools needed for design and development of future operational hypersonic airbreathing vehicles. Concurrent with Hyper-X, NASA's NGLT Program focused on technologies needed for future revolutionary launch vehicles. The NGLT was "competed" by NASA in response to the President s redirection of the agency to space exploration, after making significant progress towards maturing technologies required to enable airbreathing hypersonic launch vehicles. NGLT quantified the benefits, identified technology needs, developed airframe and propulsion technology, chartered a broad University base, and developed detailed plans to mature and validate hypersonic airbreathing technology for space access. NASA is currently in the process of defining plans for a new Hypersonic Technology Program. Details of that plan are not currently available. This paper highlights results from the successful Mach 7 and 10 flights of the X-43A, and the current state of hypersonic technology.

Voland, Randall T.↗
NASA NTRS2006

Precision Pointing Control to and Accurate Target Estimation of a Non-Cooperative Vehicle

In 2004, NASA began investigating a robotic servicing mission for the Hubble Space Telescope (HST). Such a mission would not only require estimates of the HST attitude and rates in order to achieve capture by the proposed Hubble Robotic Vehicle (HRV), but also precision control to achieve the desired rate and maintain the orientation to successfully dock with HST. To generalize the situation, HST is the target vehicle and HRV is the chaser. This work presents a nonlinear approach for estimating the body rates of a non-cooperative target vehicle, and coupling this estimation to a control scheme. Non-cooperative in this context relates to the target vehicle no longer having the ability to maintain attitude control or transmit attitude knowledge.

VanEepoel, John↗
NASA NTRS2006

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons from Past and Present Missions

The United States (US) Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success.

Dumbacher, Daniel L.↗
NASA NTRS2006

The DARPA/USAF Falcon Program Small Launch Vehicles

Earlier in this decade, the U.S. Air Force Space Command and the Defense Advanced Research Projects Agency (DARPA), in recognizing the need for low-cost responsive small launch vehicles, decided to partner in addressing this national shortcoming. Later, the National Aeronautics and Space Administration (NASA) joined in supporting this effort, dubbed the Falcon Program. The objectives of the Small Launch Vehicle (SLV) element of the DARPA/USAF Falcon Program include the development of a low-cost small launch vehicle(s) that demonstrates responsive launch and has the potential for achieving a per mission cost of less than $5M when based on 20 launches per year for 10 years. This vehicle class can lift 1000 to 2000 lbm payloads to a reference low earth orbit. Responsive operations include launching the rocket within 48 hours of call up. A history of the program and the current status will be discussed with an emphasis on the potential impact on small satellites.

Weeks, David J.↗
NASA NTRS2006

Flight Testing of Hybrid Powered Vehicles

Hybrid Rocket powered vehicles have had a limited number of flights. Most recently in 2004, Scaled Composites had a successful orbital trajectory that put a private vehicle twice to over 62 miles high, the edge of space to win the X-Prize. This endeavor man rates a hybrid system. Hybrids have also been used in a number of one time launch attempts - SET-1, HYSR, HPDP. Hybrids have also been developed for use and flown in target drones. This chapter discusses various flight-test programs that have been conducted, hybrid vehicles that are in development, other hybrid vehicles that have been proposed and some strap-on applications have also been examined.

Story, George↗
NASA NTRS2006

Design of a Long Endurance Titan VTOL Vehicle

Saturn s moon Titan promises insight into many key scientific questions, many of which can be investigated only by in situ exploration of the surface and atmosphere of the moon. This research presents a vertical takeoff and landing (VTOL) vehicle designed to conduct a scientific investigation of Titan s atmosphere, clouds, haze, surface, and any possible oceans. In this investigation, multiple options for vertical takeoff and horizontal mobility were considered. A helicopter was baselined because of its many advantages over other types of vehicles, namely access to hazardous terrain and the ability to perform low speed aerial surveys. Using a nuclear power source and the atmosphere of Titan, a turbo expander cycle produces the 1.9 kW required by the vehicle for flight and operations, allowing it to sustain a long range, long duration mission that could traverse the majority of Titan. Such a power source could increase the lifespan and quality of science for planetary aerial flight to an extent that the limiting factor for the mission life is not available power but the life of the mechanical parts. Therefore, the mission could potentially last for years. This design is the first to investigate the implications of this potentially revolutionary technology on a Titan aerial vehicle.

Prakash, Ravi↗
NASA NTRS2006

Crew Launch Vehicle (CLV) Upper Stage Configuration Selection Process

The Crew Launch Vehicle (CLV), a key component of NASA's blueprint for the next generation of spacecraft to take humans back to the moon, is being designed and built by engineers at NASA s Marshall Space Flight Center (MSFC). The vehicle s design is based on the results of NASA's 2005 Exploration Systems Architecture Study (ESAS), which called for development of a crew-launch system to reduce the gap between Shuttle retirement and Crew Exploration Vehicle (CEV) Initial Operating Capability, identification of key technologies required to enable and significantly enhance these reference exploration systems, and a reprioritization of near- and far-term technology investments. The Upper Stage Element (USE) of the CLV is a clean-sheet approach that is being designed and developed in-house, with element management at MSFC. The USE concept is a self-supporting cylindrical structure, approximately 115' long and 216" in diameter, consisting of the following subsystems: Primary Structures (LOX Tank, LH2 Tank, Intertank, Thrust Structure, Spacecraft Payload Adaptor, Interstage, Forward and Aft Skirts), Secondary Structures (Systems Tunnel), Avionics and Software, Main Propulsion System, Reaction Control System, Thrust Vector Control, Auxiliary Power Unit, and Hydraulic Systems. The ESAS originally recommended a CEV to be launched atop a four-segment Space Shuttle Main Engine (SSME) CLV, utilizing an RS-25 engine-powered upper stage. However, Agency decisions to utilize fewer CLV development steps to lunar missions, reduce the overall risk for the lunar program, and provide a more balanced engine production rate requirement prompted engineers to switch to a five-segment design with a single Saturn-derived J-2X engine. This approach provides for single upper stage engine development for the CLV and an Earth Departure Stage, single Reusable Solid Rocket Booster (RSRB) development for the CLV and a Cargo Launch Vehicle, and single core SSME development. While the RSRB design has changed since the CLV Project's inception, the USE design has remained essentially a clean-sheet approach. Although a clean-sheet upper stage design inherently carries more risk than a modified design, it does offer many advantages: a design for increased reliability; built-in extensibility to allow for commonality/growth without major redesign; and incorporation of state-of-the-art materials, hardware, and design, fabrication, and test techniques and processes to facilitate a potentially better, more reliable system. Because consideration was given in the ESAS to both clean-sheet and modified USE designs, this paper will highlight the advantages and disadvantages of both approaches and provide a detailed discussion of trades/selections made that led to the final upper stage configuration.

Davis, Daniel J.↗
NASA NTRS2007

Tailored Excitation for Frequency Response Measurement Applied to the X-43A Flight Vehicle

An important aspect of any flight research project is assessing aircraft stability and flight control performance. In some programs this assessment is accomplished through the estimation of the in-flight vehicle frequency response. This estimation has traditionally been a lengthy task requiring separate swept sine inputs for each control axis at a constant flight condition. Hypersonic vehicles spend little time at any specific flight condition while they are decelerating. Accordingly, it is difficult to use traditional methods to calculate the vehicle frequency response and stability margins for this class of vehicle. A technique has been previously developed to significantly reduce the duration of the excitation input by tailoring the input to excite only the frequency range of interest. Reductions in test time were achieved by simultaneously applying tailored excitation signals to multiple control loops, allowing a quick estimate of the frequency response of a particular aircraft. This report discusses the flight results obtained from applying a tailored excitation input to the X-43A longitudinal and lateral-directional control loops during the second and third flights. The frequency responses and stability margins obtained from flight data are compared with preflight predictions.

Baumann, Ethan↗
NASA NTRS2007

High Altitude Long Endurance Air Vehicle Analysis of Alternatives and Technology Requirements Development

The objective of this study was to develop a variety of High Altitude Long Endurance (HALE) Unmanned Aerial Vehicle (UAV) conceptual designs for two operationally useful missions (hurricane science and communications relay) and compare their performance and cost characteristics. Sixteen potential HALE UAV configurations were initially developed, including heavier-than-air (HTA) and lighter-than-air (LTA) concepts with both consumable fuel and solar regenerative (SR) propulsion systems. Through an Analysis of Alternatives (AoA) down select process, the two leading consumable fuel configurations (one each from the HTA and LTA alternatives) and an HTA SR configuration were selected for further analysis. Cost effectiveness analysis of the consumable fuel configurations revealed that simply maximizing vehicle endurance can lead to a sub-optimum system solution. An LTA concept with a hybrid propulsion system (solar arrays and a hydrogen-air proton exchange membrane fuel cell) was found to have the best mission performance; however, an HTA diesel-fueled wing-body-tail configuration emerged as the preferred consumable fuel concept because of the large size and technical risk of the LTA concept. The baseline missions could not be performed by even the best HTA SR concept. Mission and SR technology trade studies were conducted to enhance understanding of the potential capabilities of such a vehicle. With near-term technology SR-powered HTA vehicles are limited to operation in favorable solar conditions, such as the long days and short nights of summer at higher latitudes. Energy storage system specific energy and solar cell efficiency were found to be the key technology areas for enhancing HTA SR performance.

Nickol, Craig L.↗