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A Survey and Evaluation of High Energy Liquid Chemical Propulsion Systems: Propellant Selection Criteria for Space Missions - Part 1

This report presents the results of a study to develop a procedure for evaluating liquid propellants in order (a) to select the most appropriate propellant (from among those under development) for each of several applications on each of the various missions in the NASA program, or (b) to select new propellants (from among those being proposed) for initiation or continuation of research and development. The analysis begins with a consideration of requirements--either for the specific application or for the various classes of applications. The known characteristics of the propellant or propellants to be evaluated are then put into a convenient form for evaluation. The next step is to determine whether or not there are requirements that simply cannot be met by the propellant. If the propellant passes this test, an optimum vehicle configuration using the propellant (and meeting all requirements) is estimated. (The configuration should be optimized with respect to the total resource consumption for all aspects of the mission, including R&D, production, logistics, and operation.) The total resource consumption for this configuration is then compared with that for similar configurations using other propellants (and meeting all requirements equally well). If all factors have been properly taken into account, this comparison of resource consumption will complete the evaluation. Such an evaluation may be performed several times, in increasing detail and with correspondingly increasing accuracy, as an R&D program proceeds, and the accuracy of the data as well as the cost of the next step in the program increase. The procedure is superior to those in common use in that it minimizes both the amount of analytical work and the number of points at which subjective value judgments are made.

LIQUID PROPELLANT↗

Long-Term Cryogenic Propellant Storage for the TOPS Mission

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LOX) can dramatically enhance NASAs ability to explore the solar system because of their superior specific impulse (Isp) capability. Although these cryogenic propellants can be challenging to manage and store, they allow significant mass advantages over traditional hypergolic propulsion systems and are therefore technically enabling for many planetary science missions. New cryogenic storage techniques such as subcooling and the use of advanced insulation and low thermal conductivity support structures will allow for the long term storage and use of cryogenic propellants for solar system exploration and hence allow NASA to deliver more payloads to targets of interest, launch on smaller and less expensive launch vehicles, or both. Employing cryogenic propellants will allow NASA to perform missions to planetary destinations that would not be possible with the use of traditional hypergolic propellants. These new cryogenic storage technologies were implemented in a design study for the Titan Orbiter Polar Surveyor (TOPS) mission, with LH2 and LOX as propellants, and the resulting spacecraft design was able to achieve a 43 launch mass reduction over a TOPS mission, that utilized a conventional hypergolic propulsion system with mono-methyl hydrazine (MMH) and nitrogen tetroxide (NTO) propellants. This paper describes the cryogenic propellant storage design for the TOPS mission and demonstrates how these cryogenic propellants are stored passively for a decade-long Titan mission.

Cryogenic Propellant Storage↗

Long-Term Cryogenic Propellant Storage for the Titan Orbiter Polar Surveyor (TOPS) Mission

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LOX) can dramatically enhance NASAs ability to explore the solar system because of their superior specific impulse (Isp) capability. Although these cryogenic propellants can be challenging to manage and store, they allow significant mass advantages over traditional hypergolic propulsion systems and are therefore technically enabling for many planetary science missions. New cryogenic storage techniques such as subcooling and the use of advanced insulation and low thermal conductivity support structures will allow for the long term storage and use of cryogenic propellants for solar system exploration and hence allow NASA to deliver more payloads to targets of interest, launch on smaller and less expensive launch vehicles, or both. Employing cryogenic propellants will allow NASA to perform missions to planetary destinations that would not be possible with the use of traditional hypergolic propellants. These new cryogenic storage technologies were implemented in a design study for the Titan Orbiter Polar Surveyor (TOPS) mission, with LH2 and LOX as propellants, and the resulting spacecraft design was able to achieve a 43 launch mass reduction over a TOPS mission, that utilized a conventional hypergolic propulsion system with mono-methyl hydrazine (MMH) and nitrogen tetroxide (NTO) propellants. This paper describes the cryogenic propellant storage design for the TOPS mission and demonstrates how these cryogenic propellants are stored passively for a decade-long Titan mission.

Cryogenic Propellant Storage↗

Green Propellant Test Capabilities of the Altitude Combustion Stand at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC) is committed to providing simulated altitude rocket test capabilities to NASA programs, other government agencies, private industry partners, and academic partners. A primary facility to support those needs is the Altitude Combustion Stand (ACS). ACS provides the capability to test combustion components at a simulated altitude up to 100,000 ft. (approx.0.2 psia/10 Torr) through a nitrogen-driven ejector system. The facility is equipped with an axial thrust stand, gaseous and cryogenic liquid propellant feed systems, data acquisition system with up to 1000 Hz recording, and automated facility control system. Propellant capabilities include gaseous and liquid hydrogen, gaseous and liquid oxygen, and liquid methane. A water-cooled diffuser, exhaust spray cooling chamber, and multi-stage ejector systems can enable run times up to 180 seconds to 16 minutes. The system can accommodate engines up to 2000-lbf thrust, liquid propellant supply pressures up to 1800 psia, and test at the component level. Engines can also be fired at sea level if needed. The NASA GRC is in the process of modifying ACS capabilities to enable the testing of green propellant (GP) thrusters and components. Green propellants are actively being explored throughout government and industry as a non-toxic replacement to hydrazine monopropellants for applications such as reaction control systems or small spacecraft main propulsion systems. These propellants offer increased performance and cost savings over hydrazine. The modification of ACS is intended to enable testing of a wide range of green propellant engines for research and qualification-like testing applications. Once complete, ACS will have the capability to test green propellant engines up to 880 N in thrust, thermally condition the green propellants, provide test durations up to 60 minutes depending on thrust class, provide high speed control and data acquisition, as well as provide advanced imaging and diagnostics such as infrared (IR) imaging.

Testing↗

Robust Exploration and Commercial Missions to the Moon Using NTR LANTR Propulsion and Lunar-Derived Propellants

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable access through cislunar space necessary for commercial development and sustained human presence on the Moon. In his post-Apollo Integrated Space Program Plan (1970-1990), Wernher von Braun, proposed a reusable nuclear thermal propulsion stage (NTPS) to deliver cargo and crew to the Moon to establish a lunar base before undertaking human missions to Mars. The NTR option was selected by von Braun because it was a demonstrated technology capable of generating both high thrust and high specific impulse (Isp 900 s) twice that of todays best chemical rockets. In NASAs Mars Design Reference Architecture (DRA) 5.0 study, the crewed Mars transfer vehicle used three 25 klbf Pewee engines the smallest and highest performing engine tested in the Rover program along with graphite composite fuel. Smaller, lunar transfer vehicles consisting of a NTPS using three approximately 16.5 klbf Small Nuclear Rocket Engines (SNREs), an in-line propellant tank, plus the payload can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong tourism missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing an affordable in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in-situ propellant production used to supply strategically located propellant depots and transportation nodes. The utilization of iron-rich volcanic glass or lunar polar ice (LPI) deposits (each estimated at billions of metric tons) for propellant production can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using liquid oxygen/hydrogen (LOX/LH2) chemical rocket engines. Afterwards, LOX/LH2 propellant depots can be established in lunar equatorial and polar orbits to supply the LTS. At this point a modified version of the conventional NTR called the LOX-augmented NTR, or LANTR would be introduced into the LTS allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an afterburner into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engines choked sonic throat essentially scramjet propulsion in reverse. By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and Isp values while the reactor core power level remains relatively constant. Eventually, a LANTR-based LTS can enable a rapid commuter shuttle with one-way trip times to and from the Moon ranging from 36 to 24 hours. Even if only 1 of the extracted propellant from identified volcanic glass and polar ice deposits were available for use in lunar orbit, such a supply could support daily commuter flights to the Moon for many thousands of years! An evolutionary mission architecture is outlined and a variety of lunar missions and transfer vehicle designs are examined, along with the increasing demands on propellant production as mission complexity increases. A comparison of vehicle features and engine operating characteristics, for both NTR and LANTR engines, is also provided along with a brief discussion on the propellant production issues associated with using volcanic glass and LPI as source material.

Spacecraft design↗

Design of a Propeller with Global Minimum Torque

Academia, industry, and Government are actively working towards a future where dozens of small to large Unmanned Aerial Systems (UAS) are present within urban environments. In this environment, high noise pollution and inefficiencies have the potential to render these new technologies impractical due to public annoyance and nonacceptance. This study aims to design and analyze a novel propeller design for minimum global torque using an optimization algorithm to find the full three dimensional solution of maximum efficiency. This resulted in a 𝐶 𝑙 distribution defining the global minimum torque solution for propeller design which corresponded with moving as much lift inboard as possible and reducing lift rapidly at the blade tip. The novel propeller (dubbed "Prandtl" propeller) was then compared with the current gold standard in propeller design, a minimum induced loss (MIL) propeller, which had all the same geometric properties except for blade twist and produced the same amount of thrust at the same advance ratio. The results of multiple iterations of Prandtl propellers showed an increase in efficiency of 2.0-3.3% for the Prandtl blade when compared to the equivalent MIL blade. A potential added benefit of this blade design is lower noise generation due to the lower lift loading at the tip reducing the large shear layer intensity which is the point source of noise in propellers. Two major breakthroughs for enabling widespread use of UAS in urban environments are noise reduction and vehicle efficiency, and this new propeller design has the potential to provide both.

Propeller↗

Design of a Propeller with Global Minimum Torque

Academia, industry, and Government are actively working towards a future where dozens of small to large Unmanned Aerial Systems (UAS) are present within urban environments. In this environment, high noise pollution and inefficiencies have the potential to render these new technologies impractical due to public annoyance and nonacceptance. This study aims to design and analyze a novel propeller design for minimum global torque using an optimization algorithm to find the full three dimensional solution of maximum efficiency. This resulted in a 𝐶 𝑙 distribution defining the global minimum torque solution for propeller design which corresponded with moving as much lift inboard as possible and reducing lift rapidly at the blade tip. The novel propeller (dubbed "Prandtl" propeller) was then compared with the current gold standard in propeller design, a minimum induced loss (MIL) propeller, which had all the same geometric properties except for blade twist and produced the same amount of thrust at the same advance ratio. The results of multiple iterations of Prandtl propellers showed an increase in efficiency of 2.0-3.3% for the Prandtl blade when compared to the equivalent MIL blade. A potential added benefit of this blade design is lower noise generation due to the lower lift loading at the tip reducing the large shear layer intensity which is the point source of noise in propellers. Two major breakthroughs for enabling widespread use of UAS in urban environments are noise reduction and vehicle efficiency, and this new propeller design has the potential to provide both.

Propeller↗

Propeller modulation effects on a scanning beam microwave landing system

An investigation to assess the modulation effects on microwave signals transmitted through rotating propeller blades. Interruption of the antenna line-of-sight signal by the rotating propeller causes a variation of path loss, which produces essentially an amplitude modulation of the received signal. This interruption or blockage effect is generally only partial because of edge diffraction around the particular interfering propeller blade. Signals reflected from the rotating propeller will also cause Doppler frequency shifts to be present in the received signals. A scanning beam microwave landing system (MLS) known as MODILS (modular instrument landing system) was used to process the received signals for display. The effects of propeller modulation were studied by varying the following parameters: (1) spacing between propeller and receiving antenna, (2) propeller dimensions, (3) propeller speed (rpm), (4) number of propeller blades, (5) system data rate, (6) receiver response time, and (7) receiver antenna aperture.

Pope, J. M.↗

Prediction of a propellant tank pressure history using state space methods

An analysis of the time response of a propellant supply system operating in the blowdown mode is presented. The supply system is part of a pump-fed propulsion system intended for use on interplanetary spacecraft. As such, the supply system must provide the pump with propellant at sufficient pressure to avoid pump cavitation. The system, consisting of the tank, the liquid propellant, the pressurant gas and propellant vapor mixture, and a film layer separating the liquid and vapor phases, is analyzed using the principles of mass and energy conservation. The resulting set of ordinary, coupled, nonlinear differential equations for the thermodynamic state variables is integrated as an initial value problem. The resulting histories of total pressure, propellant vapor pressure, propellant liquid temperature, film layer temperature, propellant vapor/pressurant gas temperature, propellant vapor mass, and propellant liquid mass enable the calculation of the net positive suction head available at the pump which determines the viability of the pump-fed system concept when operated in the blowdown mode.

Estey, P. N.↗

Low-speed wind-tunnel tests of single- and counter-rotation propellers

A low-speed (Mach 0 to 0.3) wind-tunnel investigation was conducted to determine the basic performance, force and moment characteristics, and flow-field velocities of single- and counter-rotation propellers. Compared with the eight-blade single-rotation propeller, a four- by four- (4 x 4) blade counter-rotation propeller with the same blade design produced substantially higher thrust coefficients for the same blade angles and advance ratios. The results further indicated that ingestion of the wake from a supporting pylon for a pusher configuration produced no significant change in the propeller thrust performance for either the single- or counter-rotation propellers. A two-component laser velocimeter (LV) system was used to make detailed measurements of the propeller flow fields. Results show increasing slipstream velocities with increasing blade angle and decreasing advance ratio. Flow-field measurements for the counter-rotation propeller show that the rear propeller turned the flow in the opposite direction from the front propeller and, therefore, could eliminate the swirl component of velocity, as would be expected.

Dunham, D. M.↗

Directivity and trends of noise generated by a propeller in a wake

An experimental study of the effects on far-field propeller noise of a pylon wake interaction was conducted with a scale model of a single-rotation propeller in a low-speed anechoic wind tunnel. A detailed mapping of the noise directivity was obtained at 10 test conditions covering a wide range of propeller power landings at several subsonic tip speeds. Two types of noise penalties were investigated-pulser and spacing. The pusher noise penalty is the difference in the average overall sound pressure level, OASPL, for pusher and tractor installations. (In a pusher installation, the propeller disk is downstream of a pylon or another aerodynamic surface.) The spacing noise penalty is the difference in the average OASPL for different distances between the pylon trailing edge and the propeller. The variations of these noise penalties with axial, or flyover, angle theta and circumferential angle phi are presented, and the trends in these noise penalties with tip Mach number and power loading are given for selected values of theta and phi. The circumferential directivity of the noise from a pusher installation showed that the addition noise due to the interaction of the pylon wake with the propeller had a broad peak over a wide range of circumferential angles approximately perpendicular to the pylon with a sharp minimum 90 deg. to the pylon for the majority of cases tested. The variation of the pusher noise penalty with theta had a minimum occurring near the propeller plane and maximum values of as much as 20 dB occurring toward the propeller axes. The magnitude of the pusher noise penalty generally decreased as propeller tip Mach number or power loading was increased.

Block, P. J. W.↗

Noise of a model high speed counterrotation propeller at simulated takeoff/approach conditions (F7/A7)

A high speed advanced counterrotation propeller, was tested in the NASA-Lewis 9 x 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with fixed floor microphones, an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish the propeller operating conditions. The propeller was run over a range of blade setting angles from 36.4/36.5 to 41.1/39.4 deg, tip speeds from 165 to 259 m/sec, rotor spacings from 1.56 to 3.63 based on forward rotor tip chord to aerodynamic separation, and angles of attack to + or - 16 deg. First order rotor alone tones showed highest directivity levels near the propeller plane, while interaction tone showed high levels throughout sideline directivity, especially toward the propeller rotation axis. Interaction tone levels were sensitive to propeller row spacing while rotor alone tones showed little spacing effect. There is a decreased noise level associated with higher propeller blade numbers for the same overall propeller thrust.

Woodward, Richard P.↗

Analytical determination of propeller performance degradation due to ice accretion

A computer code capable of computing the propeller performance for clean, glaze, or rime ice propeller configurations to determine the performance degradation resulting from a given icing encounter has been developed. The inviscid, incompressible flowfield at each specified propeller radial location is first computed using the Theodorsen method. A droplet trajectory computation then calculates the droplet impingement points and airfoil collection efficiency for each radial location. User-selectable empirical correlations are available for determining the aerodynamic penalties due to ice accretion. Propeller performance is finally computed using strip analysis for either the clean or iced propeller. In the iced mode, the thrust and torque coefficient equations are modified by the drag and lift coefficient increments due to ice to obtain the appropriate iced values. Comparison with available experimental propeller icing data shows generally good agreement. The code's capability of properly predicting the thrust coefficient, power coefficient, and propeller efficiency of an iced propeller is shown to be dependent on the choice of empirical correlation employed as well as on the proper specification of the radial icing extent and propeller blade angle.

Miller, T. L.↗

Noise of a model high speed counterrotation propeller at simulated takeoff/approach conditions (F7/A7)

A high speed advanced counterrotation propeller, was tested in the NASA-Lewis 9 x 15 foot Anechoic Wind Tunnel at simulated takeoff/approach conditions of 0.2 Mach number. Acoustic measurements were taken with fixed floor microphones, an axially translating microphone probe, and with a polar microphone probe which was fixed to the propeller nacelle and could take both sideline and circumferential acoustic surveys. Aerodynamic measurements were also made to establish the propeller operating conditions. The propeller was run over a range of blade setting angles from 36.4/36.5 to 41.1/39.4 deg, tip speeds from 165 to 259 m/sec, rotor spacings from 1.56 to 3.63 based on forward rotor tip chord to aerodynamic separation, and angles of attack to + or - 16 deg. First order rotor alone tones showed highest directivity levels near the propeller plane, while interaction tone showed high levels throughout sideline directivity, especially toward the propeller rotation axis. Interaction tone levels were sensitive to propeller row spacing while rotor alone tones showed little spacing effect. There is a decreased noise level associated with higher propeller blade numbers for the same overall propeller thrust.

Woodward, Richard P.↗

An analysis for high speed propeller-nacelle aerodynamic performance prediction. Volume 1: Theory and application

A computer program, the Propeller Nacelle Aerodynamic Performance Prediction Analysis (PANPER), was developed for the prediction and analysis of the performance and airflow of propeller-nacelle configurations operating over a forward speed range inclusive of high speed flight typical of recent propfan designs. A propeller lifting line, wake program was combined with a compressible, viscous center body interaction program, originally developed for diffusers, to compute the propeller-nacelle flow field, blade loading distribution, propeller performance, and the nacelle forebody pressure and viscous drag distributions. The computer analysis is applicable to single and coaxial counterrotating propellers. The blade geometries can include spanwise variations in sweep, droop, taper, thickness, and airfoil section type. In the coaxial mode of operation the analysis can treat both equal and unequal blade number and rotational speeds on the propeller disks. The nacelle portion of the analysis can treat both free air and tunnel wall configurations including wall bleed. The analysis was applied to many different sets of flight conditions using selected aerodynamic modeling options. The influence of different propeller nacelle-tunnel wall configurations was studied. Comparisons with available test data for both single and coaxial propeller configurations are presented along with a discussion of the results.

Egolf, T. Alan↗

Design issues for propulsion systems using metallized propellants

Metallized propellants are liquid propellants that contain metal particles. These particles are suspended in a gelled fuel or oxidizer. Aluminum is used as the metal additive. The addition of metal to conventional propellants can increase their specific impulse and their density over conventional propellants, and consequently, the payload delivered on Mars and lunar transportation vehicles, Earth-to-Orbit vehicles and upper stages for robotic planetary missions. Gelled fuels also provide increased safety during accidental propellant leakage or spills. To take full advantage of these potential performance increases, there are changes that must be made to the vehicle design. The differences are discussed between metallized propellant and traditional liquid propellants and their effect on the propulsion system design. These differences include the propellant density, mixture ratio, engine performance, and propellant rheology. Missions related to the Space Exploration Initiative are considered as design examples to illustrate these issues.

Palaszewski, Bryan↗

Design issues for propulsion systems using metallized propellants

Metallized propellants are liquid propellants that contain metal particles. These particles are suspended in a gelled fuel or oxidizer. Aluminum is used as the metal additive. The addition of metal to conventional propellants can increase their specific impulse and their density over conventional propellants, and consequently, the payload delivered on Mars and lunar transportation vehicles, Earth-to-Orbit vehicles and upper stages for robotic planetary missions. Gelled fuels also provide increased safety during accidental propellant leakage or spills. To take full advantage of these potential performance increases, there are changes that must be made to the vehicle design. The differences are discussed between metallized propellant and traditional liquid propellants and their effect on the propulsion system design. These differences include the propellant density, mixture ratio, engine performance, and propellant rheology. Missions related to the Space Exploration Initiative are considered as design examples to illustrate these issues.

Palaszewski, Bryan↗

An Investigation of Single- and Dual-Rotation Propellers at Positive and Negative Thrust, and in Combination with an NACA 1-series D-Type Cowling at Mach Numbers up to 0.84

An investigation has been made to determine the aerodynamic characteristics of the NACA 4-(5)(05)-041 four-blade, single-relation propeller and the NACA 4-(5)(05)-037 six- and eight-blade, dual-rotation propellers in combination with various spinners and NACA d-type spinner-cowling combinations at Mach numbers up to 0.84. Propeller force characteristics, local velocity distributions in the propeller planes, inlet pressure recoveries, and static-pressure distributions on the cowling surfaces were measured for a wide range of blade angles, advance ratios, and inlet-velocity ratios. Included are data showing: (a) the effect of extended cylindrical spinners on the characteristics of the single-rotation propeller, (b) the effect of variation of the difference in blade angle setting between the front and rear components of the dual-rotation propellers, (c) the negative- and static-thrust characteristics of the propellers with 1 series spinners, and (d) the effects of ideal- and platform-type propeller-spinner junctures on the pressure-recovery characteristics of the single-rotation propeller-spinner-cowling combination.

Reynolds, Robert M↗