Results for “Rocket Engine Design” — Page 91

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRS2006

Space Shuttle Main Engine Low Pressure Oxidizer Turbo-Pump Inducer Dynamic Environment Characterization through Water Model and Hot-Fire Testing

The Low Pressure Oxidizer Turbopump (LPOTP) inducer on the Block II configuration Space Shuttle Main Engine (SSME) experienced blade leading edge ripples during hot firing. This undesirable condition led to a minor redesign of the inducer blades. This resulted in the need to evaluate the performance and the dynamic environment of the redesign, relative to the current configuration, as part of the design acceptance process. Sub-scale water model tests of the two inducer configurations were performed, with emphasis on the dynamic environment due to cavitation induced vibrations. Water model tests were performed over a wide range of inlet flow coefficient and pressure conditions, representative of the scaled operating envelope of the Block II SSME, both in flight and in ground hot-fire tests, including all power levels. The water test hardware, facility set-up, type and placement of instrumentation, the scope of the test program, specific test objectives, data evaluation process and water test results that characterize and compare the two SSME LPOTP inducers are discussed. In addition, dynamic characteristics of the two water models were compared to hot fire data from specially instrumented ground tests. In general, good agreement between the water model and hot fire data was found, which confirms the value of water model testing for dynamic characterization of rocket engine turbomachinery.

Patrick Arellano↗

NASA NTRS1974

Effect of gaseous and solid simulated jet plumes on an 040A space shuttle launch configuration at m=1.6 to 2.2

The effect of plume-induced flow separation and aspiration effects due to operation of both orbiter and the solid rocket motors on a 0.019-scale model of the launch configuration of the Space Shuttle Vehicle is determined. Longitudinal and lateral-directional stability data were obtained at Mach numbers of 1.6, 2.0, and 2.2 with and without the engines operating. The plumes exiting from the engines were simulated by a cold-gas jet supplied by an auxiliary 200-atm air supply system and solid-body plume simulators. The aerodynamic effects produced by these two simulation procedures are compared. The parameters most significantly affected by the jet plumes are pitching moment, elevon control effectiveness, axial force, and orbiter wing loads. The solid rocket motor (SRM) plumes have the largest effect on the aerodynamic characteristics. The effect of the orbiter plumes in combination with the SRM plumes is also significant. Variations in the nozzle design parameters and configuration changes can reduce the jet plume-induced aerodynamic effects.

Dods, J. B., Jr.↗

NASA NTRS1982

U.S. launch systems evolution

Shuttle improvements and Shuttle-derived vehicles which could answer projected launch system demands for the 1990s are explored. Traffic volume is suggested to be at levels exceeding the STS ability to deliver, thereby necessitating use of unmanned launch vehicles. Some payload delivery increase is possible using an Aft Cargo Carrier attached to the bottom of the external tank. This configuration would handle cargo with a diameter larger than the 15 ft allowable in the Orbiter bay. Various configurations of solid rocket booster cargo rockets are described, together with use of a module containing the Shuttle main engines and avionics as a recoverable part of a system able to place cargo 30 ft in diam and 90-100 ft tall in orbit. Using liquid reusable boosters would permit an increase of cargo capacity by the Shuttle of 50%, while a side-mount cargo vehicle (unmanned) offers a payload capacity of 165-200 klb. It is predicted that launch vehicles in the beginning of the 21st century will be of a fully reusable design.

Marshall, W. R.↗

NASA NTRS1993

Additional support for the TDK/MABL computer program

An advanced version of the Two-Dimensional Kinetics (TDK) computer program was developed under contract and released to the propulsion community in early 1989. Exposure of the code to this community indicated a need for improvements in certain areas. In particular, the TDK code needed to be adapted to the special requirements imposed by the Space Transportation Main Engine (STME) development program. This engine utilizes injection of the gas generator exhaust into the primary nozzle by means of a set of slots. The subsequent mixing of this secondary stream with the primary stream with finite rate chemical reaction can have a major impact on the engine performance and the thermal protection of the nozzle wall. In attempting to calculate this reacting boundary layer problem, the Mass Addition Boundary Layer (MABL) module of TDK was found to be deficient in several respects. For example, when finite rate chemistry was used to determine gas properties, (MABL-K option) the program run times became excessive because extremely small step sizes were required to maintain numerical stability. A robust solution algorithm was required so that the MABL-K option could be viable as a rocket propulsion industry design tool. Solving this problem was a primary goal of the phase 1 work effort.

Nickerson, G. R.↗

NASA NTRS2000

Fault Tree in the Trenches, A Success Story

Getting caught up in the explanation of Fault Tree Analysis (FTA) minutiae is easy. In fact, most FTA literature tends to address FTA concepts and methodology. Yet there seems to be few articles addressing actual design changes resulting from the successful application of fault tree analysis. This paper demonstrates how fault tree analysis was used to identify and solve a potentially catastrophic mechanical problem at a rocket motor manufacturer. While developing the fault tree given in this example, the analyst was told by several organizations that the piece of equipment in question had been evaluated by several committees and organizations, and that the analyst was wasting his time. The fault tree/cutset analysis resulted in a joint-redesign of the control system by the tool engineering group and the fault tree analyst, as well as bragging rights for the analyst. (That the fault tree found problems where other engineering reviews had failed was not lost on the other engineering groups.) Even more interesting was that this was the analyst's first fault tree which further demonstrates how effective fault tree analysis can be in guiding (i.e., forcing) the analyst to take a methodical approach in evaluating complex systems.

Long, R. Allen↗

NASA NTRS2017

Investigation of a Tricarbide Grooved Ring Fuel Element for a Nuclear Thermal Rocket

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nuclear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the temperature limitations of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment.

Taylor, Brian D.↗

NASA NTRS1987

Liquid Engine Jet Atomization Workshop report

The workshop was oriented to disclose information and unsettled problems to understand the fundamental physical mechanism of the droplet formation process. Based on presentation and discussion of results, recommendations were made which should lead to associated future activities. To accomplish this task, existing observations and experiments, contributing to the basic knowledge, providing data for analytical concept verification, and forming a basis for empirical correlations were solicited. Advanced analytical modeling methods or results from specific studies were requested as well as the experience and advice from injector designers. All effort is directed to advance current analytical techniques, simulating the flow behavior downstream of the injection elements in a liquid rocket combustion chamber. Such a tool can be used to optimize injector designs with respect to short length weight savings, wall material protection, or large heat energy transport to a regenerative cooling fluid, while simultaneously achieving the maximum specific impulse in performance. The liquid atomization process also forms a sound basis for combustion instability analysis.

Gross, Klaus W.↗

NASA NTRS2016

Additive Manufacturing a Liquid Hydrogen Rocket Engine

Space Propulsion is a 5 day event being held from 2nd May to the 6th May 2016 at the Rome Marriott Park Hotel in Rome, Italy. This event showcases products like Propulsion sub-systems and components, Production and manufacturing issues, Liquid, Solid, Hybrid and Air-breathing Propulsion Systems for Launcher and Upper Stages, Overview of current programmes, AIV issues and tools, Flight testing and experience, Technology building blocks for Future Space Transportation Propulsion Systems : Launchers, Exploration platforms & Space Tourism, Green Propulsion for Space Transportation, New propellants, Rocket propulsion & global environment, Cost related aspects of Space Transportation propulsion, Modelling, Pressure-Thrust oscillations issues, Impact of new requirements and regulations on design etc. in the Automotive, Manufacturing, Fabrication, Repair & Maintenance industries.

Jones, Carl P.↗

NASA NTRS1973

The Space Shuttle Main Engine

The Space Shuttle Main Engine is the highest performance large rocket engine being developed in the world. This engine will be used to put the Space Shuttle orbiter vehicle into earth orbit and will be the workhorse propulsion system of the 1970s and 1980s. The propulsion requirements demand maximum performance from the liquid oxygen/hydrogen propellants with a minimum hardware weight. The system is being developed at low cost with a required early flight schedule of 1978. The engine system and components are based on the latest technology using advanced materials and high-pressure combustion. Engine weight and performance are discussed. This paper describes engine design, the program and present progress, the technology of advanced components, experimental results, and development areas underway.

Sanchini, D. J.↗

NASA NTRS1984

Propulsion options for orbit-on-demand vehicles

Vehicles which can achieve orbit within minutes of a command decision may be needed in the future for a variety of missions. Such orbit-on-demand vehicles may have propulsion requirements that are somewhat different from vehicles designed for routine transportation, but the propulsion evaluation studies of the past need to be considered as a starting point for orbit-on-demand vehicle studies. This paper surveys airbreathing propulsion studies including composite, airturbo-rocket, and scramjet systems and rocket propulsion studies including composite, airturborocket, and scramjet and rocket propulsion studies including dual-fuel and pure hydrocarbon systems. One indication from the results is that a horizontal takeoff airbreathing system with supersonic staging will have a higher development cost than rocket systems primarily because of the cost of the airbreathing engine development. Another indication is that pure hydrocarbon rocket propulsion for a vertical takeoff system may be feasible. Eliminating the requirement for hydrogen fuel may be worthwhile for orbit-on-demand vehicles.

Martin, J. A.↗

NASA NTRS1993

New Mars vehicle concepts

The paper briefly reviews the evolution of the Mars vehicle design concepts from 1952 to 1990, and the currently understood requirements, constraints, and options for manned Mars missions in the early decades of the 21st century. The most up-to-date integrated Mars vehicle concepts for crew-carrying transfer and excursion vehicles are presented together with the Mars descent-ascent mission phases. Particular attention is given to a reusable transfer ship, which is a modular vehicle launched to earth orbit on six 185 t-class boosters and assembled there robotically; it uses dual nuclear-thermal rocket engines and liquid hydrogen propellant. The lander concept is capable of supporting many kinds of surface missions anywhere on Mars.

Sherwood, Brent↗

NASA NTRS1995

A transient model of the RL10A-3-3A rocket engine

RL10A-3-3A rocket engines have served as the main propulsion system for Centaur upper stage vehicles since the early 1980's. This hydrogen/oxygen expander cycle engine continues to play a major role in the American launch industry. The Space Propulsion Technology Division at the NASA Lewis Research Center has created a computer model of the RL10 engine, based on detailed component analyses and available test data. This RL10 engine model can predict the performance of the engine over a wide range of operating conditions. The model may also be used to predict the effects of any proposed design changes and anticipated failure scenarios. In this paper, the results of the component analyses are discussed. Simulation results from the new system model are compared with engine test and flight data, including the start and shut-down transient characteristics.

Binder, Michael P.↗

NASA NTRS2016

NASA's Space Launch Transitions: From Design to Production

NASA's Space Launch System (SLS) successfully completed its Critical Design Review (CDR) in 2015, a major milestone on the journey to an unprecedented era of exploration for humanity. CDR formally marked the program's transition from design to production phase just four years after the program's inception and the first such milestone for a human launch vehicle in 40 years. While challenges typical of a complex development program lie ahead, CDR evaluators concluded that the design is technically and programmatically sound and ready to press forward to Design Certification Review (DCR) and readiness for launch of Exploration Mission 1 (EM-1) in the 2018 timeframe. SLS is prudently based on existing propulsion systems, infrastructure and knowledge with a clear, evolutionary path as required by mission needs. In its initial configuration, designated Block I, SLS will a minimum of 70 metric tons (t) of payload to low Earth orbit (LEO). It can evolve to a 130 t payload capacity by upgrading its engines, boosters, and upper stage, dramatically increasing the mass and volume of human and robotic exploration while decreasing mission risk, increasing safety, and simplifying ground and mission operations. CDR was the central programmatic accomplishment among many technical accomplishments that will be described in this paper. The government/industry SLS team successfully test fired a flight-like five-segment solid rocket motor, as well as seven hotfire development tests of the RS-25 core stage engine. The majority of the major test article and flight barrels, rings, and domes for the core stage liquid oxygen, liquid hydrogen, engine section, intertank, and forward skirt were manufactured at NASA's Michoud Assembly Facility. Renovations to the B-2 test stand for stage green run testing were completed at NASA Stennis Space Center. Core stage test stands are rising at NASA Marshall Space Flight Center. The modified Pegasus barge for core stage transportation from manufacturing to testing and launch sites was delivered. The Interim Cryogenic Propulsion System test article was also completed. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Askins, Bruce↗

NASA NTRS1989

NASA/USRA advanced space design program: The laser powered interorbital vehicle

A preliminary design is presented for a low-thrust Laser Powered Interorbital Vehicle (LPIV) intended for cargo transportation between an earth space station and a lunar base. The LPIV receives its power from two iodide laser stations, one orbiting the earth and the other located on the surface of the moon. The selected mission utilizes a spiral trajectory, characteristic of a low-thrust spacecraft, requiring 8 days for a lunar rendezvous and an additional 9 days for return. The ship's configuration consists primarily of an optical train, two hydrogen plasma engines, a 37.1 m box beam truss, a payload module, and fuel tanks. The total mass of the vehicle fully loaded is 63300 kg. A single plasma, regeneratively cooled engine design is incorporated into the two 500 N engines. These are connected to the spacecraft by turntables which allow the vehicle to thrust tangentially to the flight path. Proper collection and transmission of the laser beam to the thrust chambers is provided through the optical train. This system consists of the 23 m diameter primary mirror, a convex parabolic secondary mirror, a beam splitter and two concave parabolic tertiary mirrors. The payload bay is capable of carrying 18000 kg of cargo. The module is located opposite the primary mirror on the main truss. Fuel tanks carrying a maximum of 35000 kg of liquid hydrogen are fastened to tracks which allow the tanks to be moved perpendicular to the main truss. This capability is required to prevent the center of mass from moving out of the thrust vector line. The laser beam is located and tracked by means of an acquisition, pointing and tracking system which can be locked onto the space-based laser station. Correct orientation of the spacecraft with the laser beam is maintained by control moment gyros and reaction control rockets. Additionally an aerobrake configuration was designed to provide the option of using the atmospheric drag in place of propulsion for a return trajectory.

Source record↗

NASA NTRS2011

Modeling and Simulation of a Nuclear Fuel Element Test Section

"The Nuclear Thermal Rocket Element Environmental Simulator" test section closely simulates the internal operating conditions of a thermal nuclear rocket. The purpose of testing is to determine the ideal fuel rod characteristics for optimum thermal heat transfer to their hydrogen cooling/working fluid while still maintaining fuel rod structural integrity. Working fluid exhaust temperatures of up to 5,000 degrees Fahrenheit can be encountered. The exhaust gas is rendered inert and massively reduced in temperature for analysis using a combination of water cooling channels and cool N2 gas injectors in the H2-N2 mixer portion of the test section. An extensive thermal fluid analysis was performed in support of the engineering design of the H2-N2 mixer in order to determine the maximum "mass flow rate"-"operating temperature" curve of the fuel elements hydrogen exhaust gas based on the test facilities available cooling N2 mass flow rate as the limiting factor.

Moran, Robert P.↗

NASA NTRS2013

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Developed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown, via an upgrade approach that will provide building blocks for future space exploration and development. NASA is working to develop this new capability in an austere economic climate, a fact which has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS program has made in the 2 years since the Agency formally announced its architecture in September 2011, and the path the program is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen which combines the use and enhancement of legacy systems and technology with strategic new development projects that will evolve the capabilities of the launch vehicle. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved version of the vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware and the record-breaking testing of the J-2X engine, to life-cycle milestones such as the vehicle's Preliminary Design Review. The paper will also discuss the remaining challenges in both delivering the 70 t vehicle and in evolving its capabilities to the 130 t vehicle, and how the program plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration

Creech, Stephen D.↗