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Segregation Evolution and Diffusion of Titanium in Directed Energy Deposited NASA HR-1

Titanium segregation in single-pass directed energy deposited (DED) NASA HR-1 is very difficult to control because grain size varies considerably and many large grains (>100 μm) are present. Therefore, homogenization kinetic analysis was performed to see how the homogenization process should be adjusted to mitigate titanium segregation. A basic model for titanium diffusion in NASA HR-1 was developed to project titanium segregation as a function of homogenization temperature, time, and grain size. The homogenization kinetic analysis provides a valuable reference on how the homogenization treatment should be adjusted to reduce titanium segregation to a very low level for DED NASA HR-1.

liquid rocket engine↗

Initial Criticality Assessments to Guide FMEAs on Rocket Engine Hot Fire Testing

Presented is an explanation of the use of the Initial Criticality Assessment (ICA) technique, a triage process for prioritizing required Failure Modes and Effects Analysis (FMEAs), for the European Service Module's main propulsion system's hot-fire test bed at White Sands New Mexico. Rather than instinctively performing many FMEAs of subsystems, or one large system level FMEA where every subcomponent is analyzed, the ICA guided an informed analysis of only the hardware that had a large impact to hazards. The low criticality hardware was documented via the ICA and no FMEA was performed; the work could then focus on the high criticality hardware. Thus a savings of Program resources was achieved. The experiences gained in creating these ICAs for this international collaborative project confirmed that the need for continuous communication across the technical teams is one of the greatest areas of emphasis. The European Space Agency (ESA) is developing the European Service Module (ESM), with its primary contractor, Airbus Defence and Space in Germany, for delivery to the National Aeronautics and Space Administration (NASA). The module will be equipped with a total of 21 engines to support NASA’s Orion spacecraft: one U.S. Space Shuttle Orbital Maneuvering System-Engine (OMS-E), eight auxiliary thrusters and 12 smaller RCS (Reaction Control System) thrusters. The main ESM propulsion system, used for large translational maneuvers, consists of one OMS-E... To qualify the design of the ESM propulsion subsystem (PSS) an all-steel Propulsion Qualification Module (PQM) structure is used to test the propulsion systems on Orion, including “hot firing” of the OMS engine, thrusters, and RCS. The PQM has been developed as a hot-fire test bed to be tested at the NASA White Sands Test Facility (WSTF). One of the objectives of the testing is to assure that the OMS-E can be safely operated with the PQM. Testing will also demonstrate that the PQM can set the proper upstream pressures and temperatures for the OMS-E to operate nominally given the PQM has never been tested in hot-fire operation with OMS-E before. In order to safely conduct the test campaign, hardware such as the engine subassembly, fluid feed lines, valves, electrical power lines, instrumentation, stiff links, installation Ground Support Equipment (GSE), and diffuser [whose objectives are to collect the exhaust of the OMS-E to actively cool down the exhaust gases, reduce thermal exchanges, and create a vacuum at OMS-E level before igniting], had to be analyzed for any hazards and failure modes.

Fault Tolerance↗

Force limited vibration testing

A new method of conducting lab vibration tests of spacecraft equipment was developed to more closely simulate the vibration environment experienced when the spacecraft is launched on a rocket. The improved tests are tailored to identify equipment design and workmanship problems without inducing artificial failures that would not have occurred at launch. These new, less destructive types of vibration tests are essential to JPL's protoflight test approach in which lab testing is conducted using the flight equipment, often one of a kind, to save time and money. In conventional vibration tests, only the input vibratory motion is specified; the feedback, or reaction force, between the test item and the vibration machine is ignored. Most test failures occur when the test item goes into resonance, and the reaction force becomes very large. It has long been recognized that the large reaction force is a test artifact which does not occur with the lightweight, flexible mounting structures characteristic of spacecraft and space vehicles. In new vibration tests, both the motion and the force provided to the test item by the vibration machine are controlled, so that the vibration ride experienced by the test item is as in flight.

Scharton, Terry D.↗

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗

A Finite Volume Procedure for Thermo-Fluid System Analysis in a Flow Network

This paper describes a finite volume procedure for network flow analysis in a thermofluid system. A flow network is defined as a group of inter-connected control volumes called “nodes” that are connected by “branches”. The mass and energy conservation equations are solved at the nodes and momentum conservation equations are solved at the branches. The flow network also includes solid nodes to account for fluid to solid heat transfer. The heat conduction equation is solved at the solid nodes in conjunction with the flow equations. The properties of a real fluid are calculated using a thermodynamic property program and used in the conservation equations. The system of equations describing the fluid-solid network is solved by a hybrid numerical method that is a combination of the Newton-Raphson and successive substitution method. This procedure has been incorporated into a general-purpose computer program, the Generalized Fluid System Simulation Program, GFSSP. This paper also presents the application and verification of the method by comparison with test data for several applications that include (a) internal flow in a rocket engine turbo-pump, (b) pressurization and loading of a cryogenic propellant tank, (c) fluid transient during sudden opening of valve for priming of an evacuated feed line, and (d) chill down of a cryogenic transfer line with phase change and two phase flows.

Majumdar, Alok↗

J-2X Abort System Development

The J-2X is an expendable liquid hydrogen (LH2)/liquid oxygen (LOX) gas generator cycle rocket engine that is currently being designed as the primary upper stage propulsion element for the new NASA Ares vehicle family. The J-2X engine will contain abort logic that functions as an integral component of the Ares vehicle abort system. This system is responsible for detecting and responding to conditions indicative of impending Loss of Mission (LOM), Loss of Vehicle (LOV), and/or catastrophic Loss of Crew (LOC) failure events. As an earth orbit ascent phase engine, the J-2X is a high power density propulsion element with non-negligible risk of fast propagation rate failures that can quickly lead to LOM, LOV, and/or LOC events. Aggressive reliability requirements for manned Ares missions and the risk of fast propagating J-2X failures dictate the need for on-engine abort condition monitoring and autonomous response capability as well as traditional abort agents such as the vehicle computer, flight crew, and ground control not located on the engine. This paper describes the baseline J-2X abort subsystem concept of operations, as well as the development process for this subsystem. A strategy that leverages heritage system experience and responds to an evolving engine design as well as J-2X specific test data to support abort system development is described. The utilization of performance and failure simulation models to support abort system sensor selection, failure detectability and discrimination studies, decision threshold definition, and abort system performance verification and validation is outlined. The basis for abort false positive and false negative performance constraints is described. Development challenges associated with information shortfalls in the design cycle, abort condition coverage and response assessment, engine-vehicle interface definition, and abort system performance verification and validation are also discussed.

Santi, Louis M.↗

Technical Evaluation Motor 3 (TEM-3)

A primary objective of the technical evaluation motor program is to recover the case, igniter and nozzle hardware for use on the redesigned solid rocket motor flight program. Two qualification objectives were addressed and met on TEM-3. The Nylok thread locking device of the 1U100269-03 leak check port plug and the 1U52295-04 safe and arm utilizing Krytox grease on the barrier-booster shaft O-rings were both certified. All inspection and instrumentation data indicate that the TEM-3 static test firing conducted 23 May 1989 was successful. The test was conducted at ambient conditions with the exception of the field joints (set point of 121 F, with a minimum of 87 F at the sensors), igniter joint (set point at 122 F with a minimum of 87 F at sensors) and case-to-nozzle joint (set point at 114 F with a minimum of 87 F at sensors). Ballistics performance values were within specification requirements. Nozzle performance was nominal with typical erosion. The nozzle and the case joint temperatures were maintained at the heaters controlling set points while electrical power was supplied. The water and the CO2 quench systems prevented damage to the metal hardware. All other test equipment performed as planned, contributing to a successful motor firing. All indications are that the test was a success, and all expected hardware will be refurbished for the RSRM program.

Garecht, Diane↗

Study of SRM Critical Surfaces Using Near Infrared Optical Fiber Spectrometry

The measurement and control of cleanliness for critical surfaces during manufacturing and in service operations provides a unique challenge in the current thrust for environmentally benign processes. Of particular interest has been work performed in maintaining quality in the production of bondline surfaces in propulsion systems and the identification of possible contaminants which are detrimental to the integrity of the bondline. This work requires an in-depth study of the possible sources of contamination, methodologies to identify contaminants, discrimination between contaminants and chemical species caused by environment, and the effect of particular contaminants on the bondline integrity of the critical surfaces. This paper will provide an introduction to the use of Near Infrared (NIR) optical fiber spectrometry in a nondestructive measurement system for process monitoring and how it can be used to help clarify issues concerning surface chemistry. In a previous conference, experimental results for quantitative measurement of silicone and Conoco HD2 greases, and tape residues on solid rocket motor surfaces were presented. This paper will present data for metal hydroxides and discuss the use of the integrating sphere to minimize the effects of physical properties of the surfaces (such as surface roughness) on the results obtained from the chemometric methods used for quantitative analysis.

Workman, G. L.↗

Real-time thickness measurement of MCC ablator material

One of the most favorable characteristics of the Space Shuttle Program is the reusability of two of its primary components: the orbiter itself and the Solid Rocket Boosters (SRB). The SRB's provide the primary source of propulsion for the Space Shuttle during take-off after which they are recovered for refurbishment and reuse. During refurbishment, the SRB's are stripped of all remaining ablative (heat resistant) coating. A new layer is applied to the appropriate sections (nose cone, frustum, forward skirt, and aft skirt). It is the process of applying the ablative coating which provided the impetus for this project. The thickness of this protective layer is considered to be of primary importance to the level of thermal protection provided. The objectives of this effort are to investigate possible techniques for measuring the thickness of MCC, and if possible to test the specific capabilities of those considered good candidates for implementation. The system would be able to take measurements in real-time as close to the spray gun as possible. This will allow the information to be used in the control of the process without an inordinate time delay between a measurement and its appropriate response. The thickness of the deposited material is to be measured with less than 0.100 in if uncertainty. This is the defined tolerance window for the ablator thickness. Finally, it must operate within the confines of the chamber which encloses the turntable, robot, and spray system, and therefore is required to be insensitive to, or at least maintainable in, that environment.

Greenway, R. Bryan, Jr.↗

Report of the Panel on Propulsion

Propulsion, while conventionally included on the list of important aeronautical disciplines along with aerodynamics, structures, etc., is in itself a systems endeavor, analogous to the engineering of the entire vehicle; indeed propulsion encompasses important aspects of all the other disciplines. In recognition of this fact, the panel focused its discussion on those aspects of the key disciplines that are especially or uniquely important to propulsion. From the initial development of the airplane, the propulsion system has been recognized as one of the pacing technologies. It is perhaps because of the technological disparity between the reciprocating engine and the primitive airframe that the two remained relatively and separate, were developed somewhat independently, usually by different organizations. In recent years, the maturing of the gas turbine power plant and the advance in high-speed airframes have rendered this separation somewhat artificial. The power plant and the airframe now share common structural and aerodynamic elements; as the flight Mach number rises, the degree of interaction increases. By the year 2000, this interdependence will have increased in many respects to a point where independent design may not be practical or possible. During the period since the initiation of the aircraft gas turbine, the solid propellant rocket and the liquid propellant rocket, a vast array of other novel engines have been studied, covering the full spectrum of flight conditions from low subsonic to hypersonic and transatmospheric flight. In each instance, performance limits have been investigated under the assumption that current technology or reasonably foreseeable technology would be available for their development. Among the extensive list of advanced, high-performance concepts and cycles examined are the hypersonic ramjet, the variable cycle, runway-to-orbit airbreathing engine, the ram rocket (airbreathing and rich solid propellant rocket), and the air turborocket. At various times, these systems have come relatively close to meriting development and application. In many instances, limitations of materials and technologies curtailed development. As important and with almost equal frequency, the lack of commercial or military utility of the concept precluded the necessary funding. It is instructive to note that two former items on this list, the turbofan (bypass engine) and the high-speed turboprop, are respectively a mainstay engine and a promising development. In the case of the turbofan, its full potential could not be realized until turbine cooling technology had been developed and new materials developed to permit the construction of transonic fans. In the case of the highspeed turbopropeller engine, not only were the material and turbine technologies needed, but, in addition, the rise in fuel costs provided the impetus to take advantage of its favorable fuel consumption characteristic. As the basic technologies progress and as new missions become attractive, the engines in the foregoing list become candidates for new feasibility studies and further technology development. At the present time, the ram rocket is the prime contender to augment the range of small missiles. Of interest also is the hypersonic ram jet and its logical extension, the runway-to-orbit airbreathing engine. Much of this report deals with the development of current or near-future power plant concepts. First, the motivating factors for aeronautical propulsion research are reviewed as a reminder of the importance of continued effort in a field that has often been characterized as mature. Next, technical areas are discussed in which the panel feels additional research effort is warranted and would lead to the realization of the technological potentials between now and the year 2000. Under these guidelines, new cycles (e.g., isothermal energy exchange) were not considered by the panel. Finally, although facility requirements were not a prime consideration in the current projections, the panel believes that the increasing complexity of propulsion systems; the need for more refined interaction between propulsion system, airframe, and controls; and increasing operation in adverse weather will require test capabilities beyond those now available (see appendix). Enhanced test capability is needed in the areas of propulsion airframe integration and in largescale icing research with proper concurrent treatment of altitude, temperature, and speed.

Kerrebrock, Jack L.↗

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗

Propellant Delivery via VDC Driven Pump

The SMART (Scalable Mobile Autonomous Rocket engine Test) testbed system initiative at SSC was conceived to attempt to address many of the principal cost drivers in developing and maintaining a rocket engine test facility. The system (optimized to test engines and components generating up to 10K lbf nominal thrust) is serving as a testbed for innovative technologies and processes to provide lower cost test services with a rapid test cadence and expedient turnaround times. The system can also potentially be used as a testbed to test other related technologies relevant to surface situations (e.g., moon, Mars associated with crogenic fluid management, engine/component testing, autonomous operations, etc.). This FY20 CIF project, being conducted as part of the SMART testbed system, is developing and testing a propellant delivery system via electrically driven centrifugal pumps (obviating dependence upon Multi-Layer Pressure Vessels) with configuration and operation by a minimal number of personnel. During FY20 the team identified the requirements and worked with P3 and Masten Space Systems to develop the long lead (9 months after receipt of order) items, the 400 VDC pumps, for delivery in mid FY21. Since control of the 400 VDC pump motor is not well developed the team has established heuristics to control flows in LN2 at off nominal shaft speeds to allow deep throttling of the pump in flow test scenarios. Various test scenarios including nominal i.e. high flow high pressure, high flow low pressure, low flow high pressure, low flow low pressure, minimum throttle step change, and low inlet pressure cavitation testing were developed ahead of the anticipated hardware delivery and test. FY20 COVID Stage 3 conditions restricted access to the center and hindered lab work, so efforts focused on the system design and testing plans along with the project procurement paperwork for the hardware... now with its anticipated delivery in spring FY21. Some limited access to the center is expected by spring/summer FY21 for the continuing second year (FY21) CIF project effort meant to be focused upon system integration and initial testing.

Aaron Head↗

CECE: Expanding the Envelope of Deep Throttling Technology in Liquid Oxygen/Liquid Hydrogen Rocket Engines for NASA Exploration Missions

As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in high-energy, cryogenic, in-space propulsion. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Four series of demonstrator engine tests have been successfully completed between April 2006 and April 2010, accumulating 7,436 seconds of hot fire time over 47 separate tests. While the first two test series explored low power combustion (chug) and system instabilities, the third test series investigated and was ultimately successful in demonstrating several mitigating technologies for these instabilities and achieved a stable throttling ratio of 13:1. The fourth test series significantly expanded the engine s operability envelope by successfully demonstrating a closed-loop control system and extensive transient modeling to enable lower power engine starting, faster throttle ramp rates, and mission-specific ignition testing. The final hot fire test demonstrated a chug-free, minimum power level of 5.9%, corresponding to an overall 17.6:1 throttling ratio achieved. In total, these tests have provided an early technology demonstration of an enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for future lander descent main engines.

Giuliano, Victor J.↗

NASA Tech Briefs, January 2011

The topics include: 1) Distributed Aerodynamic Sensing and Processing Toolbox; 2) Collaborative Supervised Learning for Sensor Networks; 3) Hazard Detection Software for Lunar Landing; 4) Onboard Nonlinear Engine Sensor and Component Fault Diagnosis and Isolation Scheme; 5) Network-Capable Application Process and Wireless Intelligent Sensors for ISHM; 6) Interface Supports Multiple Broadcast Transceivers for Flight Applications; 7) FPGA Sequencer for Radar Altimeter Applications; 8) Miniature Sapphire Acoustic Resonator - MSAR; 9) Process-Hardened, Multi-Analyte Sensor for Characterizing Rocket Plume Constituents; 10) SAD5 Stereo Correlation Line-Striping in an FPGA; 11) Hybrid Composite Cryogenic Tank Structure; 12) Nanoscale Deformable Optics; 13) Reliability-Based Design Optimization of a Composite Airframe Component; 14) Zinc Oxide Nanowire Interphase for Enhanced Lightweight Polymer Fiber Composites; 15) Plasma Igniter for Reliable Ignition of Combustion in Rocket Engines; 16) Wire Test Grip Fixture; 17) A Sub-Hertz, Low-Frequency Vibration Isolation Platform; 18) Carbon Nanofibers Synthesized on Selective Substrates for Nonvolatile Memory and 3D Electronics; 19) Nanoparticle/Polymer Nanocomposite Bond Coat or Coating; 20) High-Resolution Wind Measurements for Offshore Wind Energy Development; 21) Spring Tire; 22) Marsviewer 2008; 23) Mission Services Evolution Center Message Bus; 24) Major Constituents Analysis for the Vehicle Cabin Atmosphere Monitor; 25) Astronaut Health Participant Summary Application; 26) Adaption of the AMDIS Method to Flight Status on the VCAM Instrument; 27) Natural Language Interface for Safety Certification of Safety-Critical Software; 28) Cryogenic Caging for Science Instrumentation; 29) Wide-Range Neutron Detector for Space Nuclear Applications; 30) In Situ Guided Wave Structural Health Monitoring System; 31) Multiplexed Energy Coupler for Rotating Equipment; 32) Attitude Estimation in Fractionated Spacecraft Cluster Systems; 33) Full Piezoelectric Multilayer-Stacked Hybrid Actuation/Transduction Systems; 34) Active Flow Effectors for Noise and Separation Control; 35) Method and System for Temporal Filtering in Video Compression Systems; 36) Apparatus for Measuring Total Emissivity of Small, Low-Emissivity Samples; 37) Multiple-Zone Diffractive Optic Element for Laser Ranging Applications; 38) Simplified Architecture for Precise Aiming of a Deep-Space Communication Laser Transceiver; 39) Two-Photon-Absorption Scheme for Optical Beam Tracking; 40) High-Sensitivity, Broad-Range Vacuum Gauge Using Nanotubes for Micromachined Cavities; 41) Wide-Field Optic for Autonomous Acquisition of Laser Link; 42) Extracting Zero-Gravity Surface Figure of a Mirror; 43) Modeling Electromagnetic Scattering From Complex Inhomogeneous Objects; 44) Visual Object Recognition and Tracking of Tools; 45) Method for Implementing Optical Phase Adjustment; 46) Visual SLAM Using Variance Grid Maps; 47) Rapid Calculation of Spacecraft Trajectories Using Efficient Taylor Series Integration; 48) Efficient Kriging Algorithms; 49) Predicting Spacecraft Trajectories by the WeavEncke Method; 50) An Augmentation of G-Guidance Algorithms; 51) Comparison of Aircraft Icing Growth Assessment Software; 52) Silicon-Germanium Voltage-Controlled Oscillator at 105 GHz; 53) Estimation of Coriolis Force and Torque Acting on Ares-1; 54) Null Lens Assembly for X-Ray Mirror Segments; and 55) High-Precision Pulse Generator.

Source record↗

Combustion of Metals in Carbon Dioxide and Reduced-Gravity Environments

Ongoing exploration and future mission2001110444 s to Mars have given impetus to research on the use of natural resources of the planet. Since carbon dioxide (CO2) constitutes approximately 95% of the Mars atmosphere and since it reacts directly and vigorously with several metals, this investigation focuses on metal-CO2 reactions as a possible combination for rocket-propellant production and energy generation. Magnesium (Mg) has been initially selected as the metal fuel owing to its low ignition temperature and high specific impulse and burning rate in CO2. Our studies in this field started with low gravity (g) combustion tests of Mg in O2, CO2, and CO. Reduced gravity provided a clear picture of the burning phenomena by eliminating the intrusive buoyant flows in high-temperature metal reactions and by removing the destructive effect of gravity on the shape of molten metal samples. Suspended cylindrical metal samples of 2, 3, and 4-mm in diameter and length were radiatively ignited in low-g to generate free-floating samples exhibiting a spherically symmetric flame with increasing metal-oxide accumulation in an outer shell. For the Mg-CO2 combination, burning times twice as long as in normal-g and five times longer than in Mg-O2 flames were observed, revealing a diffusion-controlled reaction. The burning time is proportional to the square of the sample diameter. In tests conducted with pure CO, combustion was not possible without constant heating of the sample due to the formation of a thick carbon-containing coating around the Mg sample generated by surface reactions. The following work presents two new studies that attempt to explain some of the low-g experimental observations. First, a simplified one-dimensional, quasi-steady numerical model is developed to obtain temperature, species concentrations, and burning rates of the spherically symmetric diffusion flame around the Mg sample burning in O2 and CO2. Second, a Planar Laser Induced Fluorescence (PLIF) technique is implemented to provide spatially resolved measurements of magnesium oxide (MgO) in the reaction zone of Mg samples burning in O2 and CO2. These experiments reveal fundamental differences between the two combustion systems.

Branch, M. C.↗

Orbit transfer rocket engine technology program

An advanced near term (1990's) space-based Orbit Transfer Vehicle Engine (OTVE) system was designed, and the technologies applicable to its construction, maintenance, and operations were developed under Tasks A through F of the Orbit Transfer Rocket Engine Technology Program. Task A was a reporting task. In Task B, promising OTV turbomachinery technologies were explored: two stage partial admission turbines, high velocity ratio diffusing crossovers, soft wear ring seals, advanced bearing concepts, and a rotordynamic analysis. In Task C, a ribbed combustor design was developed. Possible rib and channel geometries were chosen analytically. Rib candidates were hot air tested and laser velocimeter boundary layer analyses were conducted. A channel geometry was also chosen on the basis of laser velocimeter data. To verify the predicted heat enhancement effects, a ribbed calorimeter spool was hot fire tested. Under Task D, the optimum expander cycle engine thrust, performance and envelope were established for a set of OTV missions. Optimal nozzle contours and quick disconnects for modularity were developed. Failure Modes and Effects Analyses, maintenance and reliability studies and component study results were incorporated into the engine system. Parametric trades on engine thrust, mixture ratio, and area ratio were also generated. A control system and the health monitoring and maintenance operations necessary for a space-based engine were outlined in Task E. In addition, combustor wall thickness measuring devices and a fiberoptic shaft monitor were developed. These monitoring devices were incorporated into preflight engine readiness checkout procedures. In Task F, the Integrated Component Evaluator (I.C.E.) was used to demonstrate performance and operational characteristics of an advanced expander cycle engine system and its component technologies. Sub-system checkouts and a system blowdown were performed. Short transitions were then made into main combustor ignition and main stage operation.

Gustafson, N. B.↗

Investigation of Advanced Processed Single-Crystal Turbine Blade Alloys

This investigation studied the influence of thermal processing and microstructure on the mechanical properties of the single-crystal, nickel-based superalloys PWA 1482 and PWA 1484. The objective of the program was to develop an improved single-crystal turbine blade alloy that is specifically tailored for use in hydrogen fueled rocket engine turbopumps. High-gradient casting, hot isostatic pressing (HIP), and alternate heat treatment (HT) processing parameters were developed to produce pore-free, eutectic-free microstructures with different (gamma)' precipitate morphologies. Test materials were cast in high thermal gradient solidification (greater than 30 C/cm (137 F/in.)) casting furnaces for reduced dendrite arm spacing, improved chemical homogeneity, and reduced interdendritic pore size. The HIP processing was conducted in 40 cm (15.7 in.) diameter production furnaces using a set of parameters selected from a trial matrix study. Metallography was conducted on test samples taken from each respective trial run to characterize the as-HIP microstructure. Post-HIP alternate HT processes were developed for each of the two alloys. The goal of the alternate HT processing was to fully solution the eutectic gamma/(gamma)' phase islands and to develop a series of modified (gamma)' morphologies for subsequent characterization testing. This was accomplished by slow cooling through the (gamma)' solvus at controlled rates to precipitate volume fractions of large (gamma)'. Post-solution alternate HT parameters were established for each alloy providing additional volume fractions of finer precipitates. Screening tests included tensile, high-cycle fatigue (HCF), smooth and notched low-cycle fatigue (LCF), creep, and fatigue crack growth evaluations performed in air and high pressure (34.5 MPa (5 ksi)) hydrogen at room and elevated temperature. Under the most severe embrittling conditions (HCF and smooth and notched LCF in 34.5 MPa (5 ksi) hydrogen at 20 C (68 F), screening test results showed increases in fatigue life typically on the order of 1OX, when compared to the current Space Shuttle Main Engine (SSME) Alternate Turbopump (AT) blade alloy (PWA 1480).

Peters, B. J.↗

Operational Lessons Learned from the Ares I-X Flight Test

The Ares I-X flight test, launched in 2009, is the first test of the Ares I crew launch vehicle. This development flight test evaluated the flight dynamics, roll control, and separation events, but also provided early insights into logistical, stacking, launch, and recovery operations for Ares I. Operational lessons will be especially important for NASA as the agency makes the transition from the Space Shuttle to the Constellation Program, which is designed to be less labor-intensive. The mission team itself comprised only 700 individuals over the life of the project compared to the thousands involved in Shuttle and Apollo missions; while missions to and beyond low-Earth orbit obviously will require additional personnel, this lean approach will serve as a model for future Constellation missions. To prepare for Ares I-X, vehicle stacking and launch infrastructure had to be modified at Kennedy Space Center's Vehicle Assembly Building (VAB) as well as Launch Complex (LC) 39B. In the VAB, several platforms and other structures designed for the Shuttle s configuration had to be removed to accommodate the in-line, much taller Ares I-X. Vehicle preparation activities resulted in delays, but also in lessons learned for ground operations personnel, including hardware deliveries, cable routing, transferred work and custodial paperwork. Ares I-X also proved to be a resource challenge, as individuals and ground service equipment (GSE) supporting the mission also were required for Shuttle or Atlas V operations at LC 40/41 at Cape Canaveral Air Force Station. At LC 39B, several Shuttle-specific access arms were removed and others were added to accommodate the in-line Ares vehicle. Ground command, control, and communication (GC3) hardware was incorporated into the Mobile Launcher Platform (MLP). The lightning protection system at LC 39B was replaced by a trio of 600-foot-tall towers connected by a catenary wire to account for the much greater height of the vehicle. Like Shuttle, Ares I-X will be stacked on a MLP and rolled out to the pad on a Saturn-era crawler-transporter. While Ares I-X was only held in place by the four hold-down posts on its aft skirt during rollout, a new vehicle stabilization system (VSS) attached to the vertical service structure kept the vehicle from undue swaying prior to launch at the pad, LC 39B. Following the launch, the flight test vehicle first stage was recovered with the aid of new parachutes resized to accommodate the five-segment-long first stage, which had a much greater length and mass than the Shuttle s reusable solid rocket boosters. After splashdown, recovery divers exercised extra care when handling the first stage to ensure that the flight data recorders in the fifth segment simulator were not damaged by exposure to sea water. The data recovered from the Ares I-X flight test will be very valuable in verifying the predicted environments and models used to design the vehicle. Lessons learned from Ares I-X will be shared with the Ares Projects through written and verbal reports and through integration of mission team members into the Project workforce.

Davis, Stephan R.↗