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At least 217 records · Page 12

The Space Shuttle Main Engine

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

Sanchini, D. J.↗

Status of NASA In-Space Propulsion Technologies and Their Infusion Potential

Since 2001, the In-Space Propulsion Technology (ISPT) program has been developing in-space propulsion technologies that will enable or enhance NASA robotic science missions. These in-space propulsion technologies have broad applicability to future competed Discovery and New Frontiers mission solicitations, and are potentially enabling for future NASA flagship and sample return missions currently being considered. This paper provides status of the technology development of several in-space propulsion technologies that are ready for infusion into future missions. The technologies that are ready for flight infusion are: 1) the high-temperature Advanced Material Bipropellant Rocket (AMBR) engine providing higher performance; 2) NASA s Evolutionary Xenon Thruster (NEXT) ion propulsion system, a 0.6-7 kW throttle-able gridded ion system; and 3) Aerocapture technology development with investments in a family of thermal protection system (TPS) materials and structures; guidance, navigation, and control (GN&C) models of blunt-body rigid aeroshells; and aerothermal effect models. Two component technologies that will be ready for flight infusion in FY12/13 are 1) Advanced Xenon Flow Control System, and 2) ultra-lightweight propellant tank technology advancements and their infusion potential will be also discussed. The paper will also describe the ISPT project s future focus on propulsion for sample return missions: 1) Mars Ascent Vehicles (MAV); 2) multi-mission technologies for Earth Entry Vehicles (MMEEV) needed for sample return missions from many different destinations; and 3) electric propulsion for sample return and low cost missions. These technologies are more vehicle-focused, and present a different set of technology infusion challenges. Systems/Mission Analysis focused on developing tools and assessing the application of propulsion technologies to a wide variety of mission concepts.

Anderson, David↗

NASA's Space Launch System Advanced Booster Development

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. NASA is executing this development within flat budgetary guidelines by using existing engines assets and heritage technology to ready an initial 70 metric ton (t) lift capability for launch in 2017, and then employing a block upgrade approach to evolve a 130-t capability after 2021. A key component of the SLS acquisition plan is a three-phased approach for the first-stage boosters. The first phase is to expedite the 70-t configuration by completing development of the Space Shuttle heritage 5-segment solid rocket boosters (SRBs) for the initial flights of SLS. Since no existing boosters can meet the performance requirements for the 130-t class SLS, the next phases of the strategy focus on the eventual development of advanced boosters with an expected thrust class potentially double the current 5-segment solid rocket booster capability of 3.88 million pounds of thrust each. The second phase in the booster acquisition plan is the Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) effort, for which contracts were awarded beginning in 2012 after a full and open competition, with a stated intent to reduce risks leading to an affordable advanced booster. NASA has awarded ABEDRR contracts to four industry teams, which are looking into new options for liquid-fuel booster engines, solid-fuel-motor propellants, and composite booster structures. Demonstrations and/or risk reduction efforts were required to be related to a proposed booster concept directly applicable to fielding an advanced booster. This paper will discuss the status of this acquisition strategy and its results toward readying both the 70 t and 130 t configurations of SLS. The third and final phase will be a full and open competition for Design, Development, Test, and Evaluation (DDT&E) of the advanced boosters. These new boosters will enable the flexible path approach to deep space exploration, opening up vast opportunities for human missions to near-Earth asteroids and Mars. This evolved capability will offer large volume for science missions and payloads, will be modular and flexible, and will be right-sized for mission requirements.

Robinson, Kimberly F.↗

Propulsion/ASME Rocket-Based Combined Cycle Activities in the Advanced Space Transportation Program Office

NASA's Office Of Aeronautics and Space Transportation Technology (OASTT) has establish three major coals. "The Three Pillars for Success". The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville,Ala. focuses on future space transportation technologies under the "Access to Space" pillar. The Advanced Reusable Technologies (ART) Project, part of ASTP, focuses on the reusable technologies beyond those being pursued by X-33. The main activity over the past two and a half years has been on advancing the rocket-based combined cycle (RBCC) technologies. In June of last year, activities for reusable launch vehicle (RLV) airframe and propulsion technologies were initiated. These activities focus primarily on those technologies that support the year 2000 decision to determine the path this country will take for Space Shuttle and RLV. In February of this year, additional technology efforts in the reusable technologies were awarded. The RBCC effort that was completed early this year was the initial step leading to flight demonstrations of the technology for space launch vehicle propulsion. Aerojet, Boeing-Rocketdyne and Pratt & Whitney were selected for a two-year period to design, build and ground test their RBCC engine concepts. In addition, ASTROX, Pennsylvania State University (PSU) and University of Alabama in Huntsville also conducted supporting activities. The activity included ground testing of components (e.g., injectors, thrusters, ejectors and inlets) and integrated flowpaths. An area that has caused a large amount of difficulty in the testing efforts is the means of initiating the rocket combustion process. All three of the prime contractors above were using silane (SiH4) for ignition of the thrusters. This follows from the successful use of silane in the NASP program for scramjet ignition. However, difficulties were immediately encountered when silane (an 80/20 mixture of hydrogen/silane) was used for rocket ignition.

Hueter, Uwe↗

Kennedy Space Center: Creating a Spaceport Reality from the Dreams of Many

On December 17, 1903, Orville Wright piloted the first powered airplane only 20 feet above the ground near Kitty Hawk, North Carolina. The flight lasted 12 seconds and covered 120 feet. Who would have guessed that the bizarre looking contraption developed by brothers in the bicycle business would lay the ground work eventually resulting in over a million passengers moved daily in a sky filled with the contrails of jets flying at over 30,000 feet in elevation and over 500 miles per hour. Similarly, who would have guessed that the destructive nature of V-2 rockets of Germany would spark the genesis of spaceflight to explore our solar system and beyond? Yet the interest in using the Kennedy Space Center (KSC) continues to grow. Potential customers have expressed interest in KSC as a location for testing new rocket engines, servicing the world's largest airborne launching platform for drop-launch rockets, developing multi-use launch platforms that permit diverse customers to use the same launch platform, developing new spacecraft, and implementing advanced modifications for lifting 150 metric ton payloads to low earth orbit. The multitude of customers has grown and with this growth comes a need to provide a command, control, communication, and range infrastructure that maximizes flexibility and reconfigurability to address a much more frequent launch rate of diverse vehicles and spacecraft. The Ground Systems Development and Operations (GSDO) Program Office at KSC is embarking upon these developments to realize the dream of a robust spaceport. Many unique technical trade studies have been completed or are underway to successfully transition KSC into a multi-user customer focused spaceport. Like the evolution of the airplane, GSDO is working to transform KSC infrastructures that will turn once unthinkable space opportunities into a reality for today.

Gray, James A.↗

Application of powder metallurgy techniques to produce improved bearing elements for liquid rocket engines

The objective was to apply powder metallurgy techniques for the production of improved bearing elements, specifically balls and races, for advanced cryogenic turbopump bearings. The materials and fabrication techniques evaluated were judged on the basis of their ability to improve fatigue life, wear resistance, and corrosion resistance of Space Shuttle Main Engine (SSME) propellant bearings over the currently used 440C. An extensive list of candidate bearing alloys in five different categories was considered: tool/die steels, through hardened stainless steels, cobalt-base alloys, and gear steels. Testing of alloys for final consideration included hardness, rolling contact fatigue, cross cylinder wear, elevated temperature wear, room and cryogenic fracture toughness, stress corrosion cracking, and five-ball (rolling-sliding element) testing. Results of the program indicated two alloys that showed promise for improved bearing elements. These alloys were MRC-2001 and X-405. 57mm bearings were fabricated from the MRC-2001 alloy for further actual hardware rig testing by NASA-MSFC.

Moracz, D. J.↗

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

The National Aeronautics and Space Administration (NASA) continues to evolve the human exploration approach for beyond low-Earth orbit and in a manner involving international, academic, and industry partners. The center of this approach is NASA’s Gateway program that will establish a permanent human presence in lunar orbit for human cislunar science, operations, and lunar surface access to eventually land the next American astronauts on the south pole of the Moon. In support of the effort, NASA’s Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall-effect thruster in support of the Gateway program. The project is managed by the NASA Glenn Research Center (GRC), supported by the NASA Jet Propulsion Laboratory (JPL) with development, qualification & flight hardware all supplied by L3 Harris Aerojet Rocketdyne (AR). Development of the 12-kW Hall thruster electric propulsion system began with maturation of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Units (TDUs). The technology development was then transitioned to AR via the AEPS contract, which built and tested two Engineering Test Unit (ETU) thrusters and multiple critical components. The project transitioned to the production of the three flight thrusters and entered qualification testing at the component and thruster levels.

Electric Propulsion↗

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.

Holmes, Richard↗

From Earth to Orbit: An assessment of transportation options

The report assesses the requirements, benefits, technological feasibility, and roles of Earth-to-Orbit transportation systems and options that could be developed in support of future national space programs. Transportation requirements, including those for Mission-to-Planet Earth, Space Station Freedom assembly and operation, human exploration of space, space science missions, and other major civil space missions are examined. These requirements are compared with existing, planned, and potential launch capabilities, including expendable launch vehicles (ELV's), the Space Shuttle, the National Launch System (NLS), and new launch options. In addition, the report examines propulsion systems in the context of various launch vehicles. These include the Advanced Solid Rocket Motor (ASRM), the Redesigned Solid Rocket Motor (RSRM), the Solid Rocket Motor Upgrade (SRMU), the Space Shuttle Main Engine (SSME), the Space Transportation Main Engine (STME), existing expendable launch vehicle engines, and liquid-oxygen/hydrocarbon engines. Consideration is given to systems that have been proposed to accomplish the national interests in relatively cost effective ways, with the recognition that safety and reliability contribute to cost-effectiveness. Related resources, including technology, propulsion test facilities, and manufacturing capabilities are also discussed.

Gavin, Joseph G., Jr.↗

SSME Investment in Turbomachinery Inducer Impeller Design Tools and Methodology

Within the rocket engine industry, SSME turbomachines are the de facto standards of success with regard to meeting aggressive performance requirements under challenging operational environments. Over the Shuttle era, SSME has invested heavily in our national inducer impeller design infrastructure. While both low and high pressure turbopump failures/anomaly resolution efforts spurred some of these investments, the SSME program was a major benefactor of key areas of turbomachinery inducer-impeller research outside of flight manifest pressures. Over the past several decades, key turbopump internal environments have been interrogated via highly instrumented hot-fire and cold-flow testing. Likewise, SSME has sponsored the advancement of time accurate and cavitating inducer impeller computation fluid dynamics (CFD) tools. These investments together have led to a better understanding of the complex internal flow fields within aggressive high performing inducers and impellers. New design tools and methodologies have evolved which intend to provide confident blade designs which strike an appropriate balance between performance and self induced load management.

Zoladz, Thomas↗

Affordable Development and Demonstration of a Small NTR Engine and Stage: A Preliminary NASA, DOE, and Industry Assessment

In FY11, NASA formulated a plan for Nuclear Thermal Propulsion (NTP) development that included Foundational Technology Development followed by system-level Technology Demonstrations. The ongoing NTP project, funded by NASA's Advanced Exploration Systems (AES) program, is focused on Foundational Technology Development and includes 5 key task activities: (1) Fuel element fabrication and non-nuclear validation testing of heritage fuel options; (2) Engine conceptual design; (3) Mission analysis and engine requirements definition; (4) Identification of affordable options for ground testing; and (5) Formulation of an affordable and sustainable NTP development program. Performance parameters for Point of Departure designs for a small criticality-limited and full size 25 klb (sub f) (kip, or 1000 pound-force)-class engine were developed during FYs 13-14 using heritage fuel element designs for both Rover NERVA (Nuclear Engine for Rocket Vehicle Applications) Graphite Composite (GC) and Ceramic Metal (Cermet) fuel forms. To focus the fuel development effort and maximize use of its resources, the AES program decided, in FY14, that a leader-follower down-selection between GC and cermet fuel was required. An Independent Review Panel (IRP) was convened by NASA and tasked with reviewing the available fuel data and making a recommendation to NASA. In February 2015, the IRP recommended and the AES program endorsed GC as the leader fuel In FY14, a preliminary development schedule DDTE (Design Development Test and Evaluation) plan was produced by GRC (Glenn Research Center), DOE (Department of Energy) and industry for the AES program. Assumptions, considerations and key task activities are presented here. At the direction of NASA HQ (32515), NASA and DOE are to work together to formulate a detailed development plan and schedule allowing the affordable development of a small (7.5-16.5 klbf) GC engine for possible flight technology demonstration (FTD) mission within a 10-year timeframe.

Lunar Flyby Mission↗

Rocketdyne Development of RBCC Engine for Low Cost Access to Space

Rocketdyne is pursuing the conceptual design and development of a Rocket Based Combined Cycle (RBCC) engine for booster and SSTO, advanced reusable space transportation ARTT systems under contract with NASA Marshall Space Flight Center. The Rocketdyne concept is fixed geometry integrated Rocket, Ram Scramjet which is Hydrogen fueled and uses Hydrogen regenerative cooling. Vision vehicle integration studies have determined that scramjet operation to Mach 12 has high payoff for low cost reusable space transportation. Rocketdyne is internally developing versions of the concept for other applications in high speed aircraft and missiles with Hydrocarbon fuel systems. Subscale engine ground testing is underway for all modes of operation from takeoff to Mach 8. High altitude Rocket only mode tests will be completed as part of the ground test program to validate high expansion ratio performance. A unique feature of the ground test series is the inclusion of dynamic trajectory simulation with real time Mach number, altitude, engine throttling, and RBCC mode changes in a specially modified freejet test facility at GASL. Preliminary cold flow Air Augmented Rocket mode test results and Short Combustor tests have met program goals and have been used to integrate all modes of operation in a single combustor design with a fixed geometry inlet for design confirmation tests. A water cooled subscale engine is being fabricated and installed for test beginning the last quarter of 1997.

Ortwerth, P.↗

Testing of a Liquid Oxygen/Liquid Methane Reaction Control Thruster in a New Altitude Rocket Engine Test Facility

A relocated rocket engine test facility, the Altitude Combustion Stand (ACS), was activated in 2009 at the NASA Glenn Research Center. This facility has the capability to test with a variety of propellants and up to a thrust level of 2000 lbf (8.9 kN) with precise measurement of propellant conditions, propellant flow rates, thrust and altitude conditions. These measurements enable accurate determination of a thruster and/or nozzle s altitude performance for both technology development and flight qualification purposes. In addition the facility was designed to enable efficient test operations to control costs for technology and advanced development projects. A liquid oxygen-liquid methane technology development test program was conducted in the ACS from the fall of 2009 to the fall of 2010. Three test phases were conducted investigating different operational modes and in addition, the project required the complexity of controlling propellant inlet temperatures over an extremely wide range. Despite the challenges of a unique propellant (liquid methane) and wide operating conditions, the facility performed well and delivered up to 24 hot fire tests in a single test day. The resulting data validated the feasibility of utilizing this propellant combination for future deep space applications.

Meyer, Michael L.↗

NASA Space Launch System Operations Strategy

The National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is charged with delivering a new capability for human and scientific exploration beyond Earth orbit. The SLS also will provide backup crew and cargo services to the International Space Station, where astronauts have been training for long-duration voyages to destinations such as asteroids and Mars. For context, the SLS will be larger than the Saturn V, providing 10 percent more thrust at liftoff in its initial 70 metric ton (t) configuration and 20 percent more in its evolved 130 t configuration. The SLS Program knows that affordability is the key to sustainability. This paper will provide an overview of its operations strategy, which includes initiatives to reduce both development and fixed costs by using existing hardware and infrastructure assets to meet a first launch by 2017 within the projected budget. It also has a long-range plan to keep the budget flat using competitively selected advanced technologies that offer appropriate return on investment. To arrive at the launch vehicle concept, the SLS Program conducted internal engineering and business studies that have been externally validated by industry and reviewed by independent assessment panels. A series of design reference missions has informed the SLS operations concept, including launching the Orion Multi-Purpose Crew Vehicle on an autonomous demonstration mission in a lunar flyby scenario in 2017, and the first flight of a crew on Orion for a lunar flyby in 2021. Additional concepts address the processing of very large payloads, using a series of modular fairings and adapters to flexibly configure the rocket for the mission. This paper will describe how the SLS, Orion, and 21st Century Ground Systems programs are working together to create streamlined, affordable operations for sustainable exploration.

Singer, Joan A.↗

NASA Space Launch System Operations Strategy

The National Aeronautics and Space Administration s (NASA) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center (MSFC), is charged with delivering a new capability for human and scientific exploration beyond Earth orbit (BEO). The SLS may also provide backup crew and cargo services to the International Space Station, where astronauts have been training for long-duration voyages to destinations such as asteroids and Mars. For context, the SLS will be larger than the Saturn V, providing 10 percent more thrust at liftoff in its initial 70 metric ton (t) configuration and 20 percent more in its evolved 130-t configuration. The SLS Program knows that affordability is the key to sustainability. This paper will provide an overview of its operations strategy, which includes initiatives to reduce both development and fixed costs by using existing hardware and infrastructure assets to meet a first launch by 2017 within the projected budget. It also has a long-range plan to keep the budget flat using competitively selected advanced technologies that offer appropriate return on investment. To arrive at the launch vehicle concept, the SLS Program conducted internal engineering and business studies that have been externally validated by industry and reviewed by independent assessment panels. A series of design reference missions has informed the SLS operations concept, including launching the Orion Multi-Purpose Crew Vehicle (MPCV) on an autonomous demonstration mission in a lunar flyby scenario in 2017, and the first flight of a crew on Orion for a lunar flyby in 2021. Additional concepts address the processing of very large payloads, using a series of modular fairings and adapters to flexibly configure the rocket for the mission. This paper will describe how the SLS, Orion, and Ground Systems Development and Operations (GSDO) programs are working together to create streamlined, affordable operations for sustainable exploration for decades to come.

Singer, Joan A.↗

An Overview: NASA LeRC Structures Programs

A workshop on National Structures Programs was held, jointly sponsored by the AIAA Structures Technical Committee, the University of Virginia's Center for Advanced Computational Technology and NASA. The Objectives of the Workshop were to: provide a forum for discussion of current Government-sponsored programs in the structures area; identify high potential research areas for future aerospace systems; and initiate suitable interaction mechanisms with the managers of structures programs. The presentations covered structures programs at NASA, DOD (AFOSR, ONR, ARO and DARPA), and DOE. This publication is the presentation of the Structures and Acoustics Division of the NASA Lewis Research Center. The Structures and Acoustics Division has its genesis dating back to 1943. It is responsible for NASA research related to rotating structures and structural hot sections of both airbreathing and rocket engines. The work of the division encompasses but is not limited to aeroelasticity, structural life prediction and reliability, fatigue and fracture, mechanical components such as bearings, gears, and seals, and aeroacoustics. These programs are discussed and the names of responsible individuals are provided for future reference.

Zaretsky, Erwin V.↗

Control of Propellant Lead/Lag to the LAE in the AXAF Propulsion System

Control of the rate at which hypergolic propellants are supplied to a rocket engine prior to ignition is critically important. Potentially damaging explosions may result from excessive lead of either propellant into the combustion chamber. Because the injector fill process is governed by the engine as well as the propellant feed system design, proper management of this issue must take both into consideration. This was recognized early in the development of TRW's Advanced Columbium-Liquid Apogee Engine (LAE), which was flight-qualified in 1996 to maneuver the Advanced X-Ray Astrophysics Facility (AXAF) spacecraft into orbit. The LAE runs on hydrazine and nitrogen tetroxide (MON-3) at a nominal mixture ratio of 1.0. This paper describes the comprehensive test program conducted to ensure reliable startup operation of the LAE in the AYAF propulsion system. The most significant factors affecting chamber fuel lead were found to be: (1) engine location, (2) propellant saturation level, (3) amount of undissolved gas in the lines, and (4) off- nominal tank pressures. Hot-fire tests at a chamber fuel lead range over and above that expected for the LAEs in AXAF demonstrated extremely tolerant behavior of the engine. AY-AF is scheduled for launch on NASA's STS-93 in December 1998.

Casillas, A. R.↗