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Morehead, Robert L.

Publications and source records attributed to Morehead, Robert L..

12 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Cold Helium Gas Pressurization For Spacecraft Cryogenic Propulsion Systems

To reduce the dry mass of a spacecraft pressurization system, helium pressurant may be stored at low temperature and high pressure to increase mass in a given tank volume. Warming this gas through an engine heat exchanger prior to tank pressurization both increases the system efficiency and simplifies the designs of intermediate hardware such as regulators, valves, etc. since the gas is no longer cryogenic. If this type of cold helium pressurization system is used in conjunction with a cryogenic propellant, though, a loss in overall system efficiency can be expected due to heat transfer from the warm ullage gas to the cryogenic propellant which results in a specific volume loss for the pressurant, interpreted as the Collapse Factor. Future spacecraft with cryogenic propellants will likely have a cold helium system, with increasing collapse factor effects as vehicle sizes decrease. To determine the collapse factor effects and overall implementation strategies for a representative design point, a cold helium system was hotfire tested on the Integrated Cryogenic Propulsion Test Article (ICPTA) in a thermal vacuum environment at the NASA Glenn Research Center Plum Brook Station. The ICPTA vehicle is a small lander-sized spacecraft prototype built at NASA Johnson Space Center utilizing cryogenic liquid oxygen/liquid methane propellants and cryogenic helium gas as a pressurant to operate one 2,800lbf 5:1 throttling main engine, two 28lbf Reaction Control Engines (RCE), and two 7lbf RCEs (Figure 1). This vehicle was hotfire tested at a variety of environmental conditions at NASA Plum Brook, ranging from ambient temperature/simulated high altitude, deep thermal/high altitude, and deep thermal/high vacuum conditions. A detailed summary of the vehicle design and testing campaign may be found in Integrated Cryogenic Propulsion Test Article Thermal Vacuum Hotfire Testing, AIAA JPC 2017.

Morehead, Robert L.↗
NASA NTRS2017

Integrated Cryogenic Propulsion Test Article Thermal Vacuum Hotfire Testing

In support of a facility characterization test, the Integrated Cryogenic Propulsion Test Article (ICPTA) was hotfire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). The ICPTA utilizes liquid oxygen and liquid methane propellants for its main engine and four reaction control engines, and uses a cold helium system for tank pressurization. The hotfire test series included high altitude, high vacuum, ambient temperature, and deep cryogenic environments, and several hundred sensors on the vehicle collected a range of system level data useful to characterize the operation of an integrated LOX/Methane spacecraft in the space environment - a unique data set for this propellant combination.

Morehead, Robert L.↗
NASA NTRS2017

Pressure-Fed LOX/LCH4 Reaction Control System for Spacecraft: Transient Modeling and Thermal Vacuum Hotfire Test Results

An integrated cryogenic liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA), a pressure-fed LOX/LCH4 propulsion system composed of a single 2,800 lbf main engine, two 28 lbf RCS engines, and two 7 lbf RCS engines. Propellants are stored in four 48 inch diameter 5083 aluminum tanks that feed both the main engine and RCS engines in parallel. Helium stored cryogenically in a composite overwrapped pressure vessel (COPV) flows through a heat exchanger on the main engine before being used to pressurize the propellant tanks to a design operating pressure of 325 psi. The ICPTA is capable of simultaneous main engine and RCS operation. The RCS engines utilize a coil-on-plug (COP) ignition system designed for operation in a vacuum environment, eliminating corona discharge issues associated with a high voltage lead. There are two RCS pods on the ICPTA, with two engines on each pod. One of these two engines is a heritage flight engine from Project Morpheus. Its sea level nozzle was removed and replaced by an 85:1 nozzle machined using Inconel 718, resulting in a maximum thrust of 28 lbf under altitude conditions. The other engine is a scaled down version of the 28 lbf engine, designed to match the core and overall mixture ratios as well as other injector characteristics. This engine can produce a maximum thrust of 7 lbf with an 85:1 nozzle that was additively manufactured using Inconel 718. Both engines are film-cooled and capable of limited duration gas-gas and gas-liquid operation, as well as steady-state liquid-liquid operation. Each pod contains one of each version, such that two engines of the same thrust level can be fired as a couple on opposite pods. The RCS feed system is composed of symmetrical 3/8 inch lines that tap off of the main propellant manifold to send LOX and LCH4 outboard to the RCS pods. A Thermodynamic Vent System (TVS) is used to condition propellants at each pod by venting through an orifice and then routing the cold expansion products back through tubing that is welded along a large portion of the main RCS feed lines. Prior to final installation on the ICPTA, the RCS engines were tested in a small vacuum chamber at the Johnson Space Center (JSC) Energy Systems Test Area (ESTA) to verify functionality of the new COP ignition system and check out operation of the vacuum nozzles. After engine-level testing, the RCS engines were installed on the vehicle and a series of integrated hot-fire tests were performed at JSC consisting of various pulsing and steady-state firings as well as integrated main engine/RCS operation. The ICPTA was then integrated into the Plum Brook B-2 facility for vacuum and thermal/vacuum testing. Testing in the B-2 facility was composed of multiple thermal and pressure environments. The first set of tests were performed under ambient temperature and altitude pressure conditions. These tests consisted of a range of minimum impulse bit (MIB) pulsing sequences with low duty cycle, analogous to a coast phase in which the RCS is primarily used for station keeping. The primary goal of this sequence is to understand how propellant conditions were effected without an active TVS. In this scenario, consistent gas-gas operation is desirable since it results in a smaller MIB and more efficient propellant consumption. Multiple skin thermocouples are mounted on the feedlines, in addition to a submerged thermocouple on each commodity, in order to gather thermal data on the system. Higher duty cycle pulsing tests were then performed, analogous to an ascent or landing mission phase. The primary goal of this sequence was to examine how well the engines self-conditioned without active TVS when starting from a quiescent state. The TVS was then activated during some tests to demonstrate the capability to quickly condition the engines for higher pulsing demand scenarios. A thermocouple at the TVS outlet allows for the calculation of energy absorbed by the vented propellant. Lastly, tests with longer pulses and multiple engines firing either in sequence or simultaneously were run in order to gather transient system response data on waterhammer. Six total high-speed pressure transducers are installed on the RCS system, one sensor at the end of each propellant manifold line on the pods, and one at the tap-off location for each commodity. This will allow for the accurate characterization of waterhammer in the system under various propellant conditions and firing sequences. Other instrumentation for this test series includes nozzle throat thermocouples, chamber pressure measurement, heat soakback measurement, and tank wall plume impingement temperature measurement. The next set of tests were performed to demonstrate simultaneous main engine and RCS operation. Data from this test will be used to examine if there is any change to nominal operation of the RCS as a result of feed system interaction or other phenomenon. Some of these tests began under high vacuum conditions (target ambient pressure less than 1x10(exp -3) torr) and others began at altitude conditions. The last set of tests were performed with the B-2 cold wall active. Under these tests, many of the same low duty cycle MIB tests were repeated in order to characterize how propellant conditions changed with the lower heat leak. In this scenario the RCS manifold experiences much less heat leak, resulting in a change to how well the engines self-condition. As a result, an increase in maximum waterhammer pressures and a change in natural frequency of the system was expected due to higher density propellants. The lower heat leak should also result in a change to the MIB pulse profile, and data will be examined to understand how MIB repeatability is affected in the different operating environments. Parallel to the test efforts, a set of transient model development efforts were made to predict RCS performance. The primary effort was aimed at producing a SINDA/FLUINT model to predict propellant conditioning up to the engine inlet as a function of different environmental and operating parameters, with the goal of predicting chamber pressure, TVS performance, and propellant consumption over time. Preliminary results for this effort will be presented in comparison with test data. Additional modeling efforts were made using SINDA/FLUINT to predict waterhammer in the system since the software is capable of handling multiphase transient fluid dynamics. These results will be compared with the high-speed pressure transducer test data for validation purposes.

Atwell, Matthew J.↗
NASA NTRS2017

Coil-On-Plug Ignition for LOX/Methane Liquid Rocket Engines in Thermal Vacuum Environments

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX) / liquid methane rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/methane propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. In order to successfully demonstrate ignition reliability in the vacuum conditions and eliminate corona discharge issues, a coil-on-plug ignition system has been developed. The ICPTA uses spark-plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark-plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp.-2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, Plum Brook testing demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/methane propulsion systems in future spacecraft.

Melcher, John C.↗
NASA NTRS2017

Characterization of a Pressure-Fed LOX/LCH4 Reaction Control System Under Simulated Altitude and Thermal Vacuum Conditions

A liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under simulated altitude and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA) and was initially developed under Project Morpheus. Composed of two 28 lbf-thrust and two 7 lbf-thrust engines, the RCS is fed in parallel with the ICPTA main engine from four propellant tanks. 40 tests consisting of 1,010 individual thruster pulses were performed across 6 different test days. Major test objectives were focused on system dynamics, and included characterization of fluid transients, manifold priming, manifold thermal conditioning, thermodynamic vent system (TVS) performance, and main engine/RCS interaction. Peak surge pressures from valve opening and closing events were examined. It was determined that these events were impacted significantly by vapor cavity formation and collapse. In most cases the valve opening transient was more severe than the valve closing. Under thermal vacuum conditions it was shown that TVS operation is unnecessary to maintain liquid conditions at the thruster inlets. However, under higher heat leak environments the RCS can still be operated in a self-conditioning mode without overboard TVS venting, contingent upon the engines managing a range of potentially severe thermal transients. Lastly, during testing under cold thermal conditions the engines experienced significant ignition problems. Only after warming the thruster bodies with a gaseous nitrogen purge to an intermediate temperature was successful ignition demonstrated.

Atwell, Matthew J.↗
NASA NTRS2017

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗
NASA NTRS2017

Coil-On-Plug Ignition for Oxygen/Methane Liquid Rocket Engines in Thermal-Vacuum Environments

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX)/liquid methane (LCH4) rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/LCH4 propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. A coil-on-plug ignition system has been developed to successfully demonstrate ignition reliability at these conditions while preventing corona discharge issues. The ICPTA uses spark plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp -2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, hot-fire testing at Plum Brook demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/LCH4 propulsion systems in future spacecraft.

Melcher, John C.↗
NASA NTRS2015

Design and Test of a Liquid Oxygen / Liquid Methane Thruster with Cold Helium Pressurization Heat Exchanger

A liquid oxygen / liquid methane 2,000 lbf thruster was designed and tested in conjuction with a nozzle heat exchanger for cold helium pressurization. Cold helium pressurization systems offer significant spacecraft vehicle dry mass savings since the pressurant tank size can be reduced as the pressurant density is increased. A heat exchanger can be incorporated into the main engine design to provide expansion of the pressurant supply to the propellant tanks. In order to study the systems integration of a cold-helium pressurization system, a 2,000 lbf thruster with a nozzle heat exchanger was designed for integration into the Project Morpheus vehicle at NASA Johnson Space Center. The testing goals were to demonstrate helium loading and initial conditioning to low temperatures, high-pressure/low temperature storage, expansion through the main engine heat exchanger, and propellant tank injection/pressurization. The helium pressurant tank was an existing 19 inch diameter composite-overwrap tank, and the targert conditions were 4500 psi and -250 F, providing a 2:1 density advantage compared to room tempatrue storage. The thruster design uses like-on-like doublets in the injector pattern largely based on Project Morpheus main engine hertiage data, and the combustion chamber was designed for an ablative chamber. The heat exchanger was installed at the ablative nozzle exit plane. Stand-alone engine testing was conducted at NASA Stennis Space Center, including copper heat-sink chambers and highly-instrumented spoolpieces in order to study engine performance, stability, and wall heat flux. A one-dimensional thermal model of the integrated system was completed. System integration into the Project Morpheus vehicle is complete, and systems demonstrations will follow.

Melcher, John C.↗
NASA NTRS2014

Combustion Stability Characteristics of the Project Morpheus Liquid Oxygen/Liquid Methane Main Engine

The Project Morpheus liquid oxygen (LOX) / liquid methane rocket engines demonstrated acousticcoupled combustion instabilities during sea‐level ground‐based testing at the NASA Johnson Space Center (JSC) and Stennis Space Center (SSC). High‐amplitude, 1T, 1R, 1T1R (and higher order) modes appear to be triggered by injector conditions. The instability occurred during the Morpheus‐specific engine ignition/start sequence, and did demonstrate the capability to propagate into mainstage. However, the instability was never observed to initiate during mainstage, even at low power levels. The Morpheus main engine is a JSC‐designed ~5,000 lbf‐thrust, 4:1 throttling, pressure‐fed cryogenic engine using an impinging element injector design. Two different engine designs, named HD4 and HD5, and two different builds of the HD4 engine all demonstrated similar instability characteristics. Through the analysis of more than 200 hot fire tests on the Morpheus vehicle and SSC test stand, a relationship between ignition stability and injector/chamber pressure was developed. The instability has the distinct characteristic of initiating at high relative injection pressure drop (dP) at low chamber pressure (Pc); i.e., instabilities initiated at high dP/Pc at low Pc during the start sequence. The high dP/Pc during start results during the injector /chamber chill‐in, and is enhanced by hydraulic flip in the injector orifice elements. Because of the fixed mixture ratio of the existing engine design (the main valves share a common actuator), it is not currently possible to determine if LOX or methane injector dP/Pc were individual contributors (i.e., LOX and methane dP/Pc typically trend in the same direction within a given test). The instability demonstrated initiation characteristic of starting at or shortly after methane injector chillin. Colder methane (e.g., sub‐cooled) at the injector inlet prior to engine start was much more likely to result in an instability. A secondary effect of LOX sub‐cooling was also possibly observed; greater LOX sub‐ cooling improved stability. Some tests demonstrated a low‐amplitude 1L‐1T instability prior to LOX injector chill‐in. The Morpheus main engine also demonstrated chug instabilities during some engine shutdown sequences on the flight vehicle and SSC test stand. The chug instability was also infrequently observed during the startup sequence. The chug instabilities predictably initiated at low dP/Pc at low Pc. The chug instabilities were always self‐limiting; startup chug instabilities terminated during throttle‐up and shutdown chug instabilities decayed by shutdown termination.

Melcher, J. C.↗
NASA NTRS2014

Combustion Stability Characteristics of the Project Morpheus Liquid Oxygen / Liquid Methane Main Engine

The project Morpheus liquid oxygen (LOX) / liquid methane (LCH4) main engine is a Johnson Space Center (JSC) designed ~5,000 lbf-thrust, 4:1 throttling, pressure-fed cryogenic engine using an impinging element injector design. The engine met or exceeded all performance requirements without experiencing any in- ight failures, but the engine exhibited acoustic-coupled combustion instabilities during sea-level ground-based testing. First tangential (1T), rst radial (1R), 1T1R, and higher order modes were triggered by conditions during the Morpheus vehicle derived low chamber pressure startup sequence. The instability was never observed to initiate during mainstage, even at low power levels. Ground-interaction acoustics aggravated the instability in vehicle tests. Analysis of more than 200 hot re tests on the Morpheus vehicle and Stennis Space Center (SSC) test stand showed a relationship between ignition stability and injector/chamber pressure. The instability had the distinct characteristic of initiating at high relative injection pressure drop at low chamber pressure during the start sequence. Data analysis suggests that the two-phase density during engine start results in a high injection velocity, possibly triggering the instabilities predicted by the Hewitt stability curves. Engine ignition instability was successfully mitigated via a higher-chamber pressure start sequence (e.g., ~50% power level vs ~30%) and operational propellant start temperature limits that maintained \cold LOX" and \warm methane" at the engine inlet. The main engine successfully demonstrated 4:1 throttling without chugging during mainstage, but chug instabilities were observed during some engine shutdown sequences at low injector pressure drop, especially during vehicle landing.

Melcher, John C.↗
NASA NTRS2011

Project Morpheus Main Engine Development and Preliminary Flight Testing

A LOX/Methane rocket engine was developed for a prototype terrestrial lander and then used to fly the lander at Johnson Space Center. The development path of this engine is outlined, including unique items such as variable acoustic damping and variable film cooling.

Morehead, Robert L.↗