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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1958

The Explorer Rocket Research Program

Since September of 1956, nine Jupiter-C missiles have been launched from the firing pad at Cape Canaveral. The first Jupiter-C firing tested the propulsion system, air frame, and guidance components of the missile, and the second and third firings tested a model of the Jupiter nose cone under realistic re-entry conditions. The remaining six Jupiter-C missiles were used as the launching vehicles for EXPLORER satellites I through VI (Fig. 1). Of the six satellite firings, EXPLORERs I, III, and IV achieved satisfactory orbits. The Jupiter-C missile was designed and developed as a joint program under the technical direction of the Jet Propulsion Laboratory and the Army Ballistic Missile Agency. The Jet Propulsion Laboratory developed the three high-speed stages, and the Army Ballistic Missile Agency handled the development, construction, and operation of the first-stage booster rocket and the guidance system. Many other organizations have contributed to the success of the EXPLORER satellite program, most notably the State University of Iowa, the Air Force Cambridge Research Center, and the satellite tracking teams of the Vanguard organization.

Robillard, G.↗
NASA NTRS1979

Second generation PMR polyimide/fiber composites

A second generation polymerization monomeric reactants (PMR) polyimdes matrix system (PMR 2) was characterized in both neat resin and composite form with two different graphite fiber reinforcements. Three different formulated molecular weight levels of laboratory prepared PMR 2 were examined, in addition to a purchased experimental fully formulated PMR 2 precurser solution. Isothermal aging of graphite fibers, neat resin samples and composite specimens in air at 316 C were investigated. Humidity exposures at 65 C and 97 percent relative humidity were conducted for both neat resin and composites for eight day periods. Anaerobic char of neat resin and fire testing of composites were conducted with PMR 15, PMR 2, and an epoxy system. Composites were fire tested on a burner rig developed for this program. Results indicate that neat PMR 2 resins exhibit excellent isothermal resistance and that PMR 2 composite properties appear to be influenced by the thermo-oxidative stability of the reinforcing fiber.

Cavano, P. J.↗
NASA NTRS1989

Technique for Evaluating the Erosive Properties of Ablative Internal Insulation Materials

A technique for determining the average erosion rate versus Mach number of candidate internal insulation materials was developed for flight motor applications in 12 inch I.D. test firing hardware. The method involved the precision mounting of a mechanical measuring tool within a conical test cartridge fabricated from either a single insulation material or two non-identical materials each of which constituted one half of the test cartridge cone. Comparison of the internal radii measured at nine longitudinal locations and between eight to thirty two azimuths, depending on the regularity of the erosion pattern before and after test firing, permitted calculation of the average erosion rate and Mach number. Systematic criteria were established for identifying erosion anomalies such as the formation of localized ridges and for excluding such anomalies from the calculations. The method is discussed and results presented for several asbestos-free materials developed in-house for the internal motor case insulation in solid propellant rocket motors.

McComb, J. C.↗
NASA NTRS2006

Local Heat Flux Measurements with Single and Small Multi-element Coaxial Element-Injectors

To support NASA's Vision for Space Exploration mission, the NASA Marshall Space Flight Center conducted a program in 2005 to improve the capability to predict local thermal compatibility and heat transfer in liquid propellant rocket engine combustion devices. The ultimate objective was to predict and hence reduce the local peak heat flux due to injector design, resulting in a significant improvement in overall engine reliability and durability. Such analyses are applicable to combustion devices in booster, upper stage, and in-space engines with regeneratively cooled chamber walls, as well as in small thrust chambers with few elements in the injector. In this program, single and three-element injectors were hot-fire tested with liquid oxygen and gaseous hydrogen propellants at The Pennsylvania State University Cryogenic Combustor Laboratory from May to August 2005. Local heat fluxes were measured in a 1-inch internal diameter heat sink combustion chamber using Medtherm coaxial thermocouples and Gardon heat flux gauges, Injector configurations were tested with both shear coaxial elements and swirl coaxial elements. Both a straight and a scarfed single element swirl injector were tested. This paper includes general descriptions of the experimental hardware, instrumentation, and results of the hot-fire testing for three coaxial shear and swirl elements. Detailed geometry and test results the for shear coax elements has already been published. Detailed test result for the remaining 6 swirl coax element for the will be published in a future JANNAF presentation to provide well-defined data sets for development and model validation.

Jones, Gregg↗
NASA NTRS1990

Rocket engine failure detection using system identification techiques

The theoretical foundation and application of two univariate failure detection algorithms to Space Shuttle Main Engine (SSME) test firing data is presented. Both algorithms were applied to data collected during steady state operation of the engine. One algorithm, the time series algorithm, is based on time series techniques and involves the computation of autoregressive models. Times series techniques have been previously applied to SSME data. The second algorithm is based on standard signal processing techniques. It consists of tracking the variations in the average signal power with time. The average signal power algorithm is a newly proposed SSME failure detection algorithm. Seven nominal test firings were used to develop failure indication thresholds for each algorithm. These thresholds were tested using four anomalous firings and one additional nominal firing. Both algorithms provided significantly earlier failure indication times than did the current redline limit system. Neither algorithm gave false failure indications for the nominal firing. The strengths and weaknesses of the two algorithms are discussed and compared. The average signal algorithm was found to have several advantages over the time series algorithm.

Meyer, Claudia M.↗
NASA NTRS1990

Rocket engine failure detection using system identification techniques

The theoretical foundation and application of two univariate failure detection algorithms to Space Shuttle Main Engine (SSME) test firing data is presented. Both algorithms were applied to data collected during steady state operation of the engine. One algorithm, the time series algorithm, is based on time series techniques and involves the computation of autoregressive models. Time series techniques have been previously applied to SSME data. The second algorithm is based on standard signal processing techniques. It consists of tracking the variations in the average signal power with time. The average signal power algorithm is a newly proposed SSME failure detection algorithm. Seven nominal test firings were used to develop failure indication thresholds for each algorithm. These thresholds were tested using four anomalous firings and one additional nominal firing. Both algorithms provided significantly earlier failure indication times than did the current redline limit system. Neither algorithm gave false failure indications for the nominal firing. The strengths and weaknesses of the two algorithms are discussed and compared. The average signal algorithm was found to have several advantages over the time series algorithm.

Meyer, Claudia M.↗
NASA NTRS1992

Space Storable Rocket Technology (SSRT) basic program

The Space Storable Rocket Technology Program (SSRT) was conducted to establish a technology for a new class of high performance and long life bipropellant engines using space storable propellants. The results are described. Task 1 evaluated several characteristics for a number of fuels to determine the best space storable fuel for use with LO2. The results indicated that LO2-N2H4 is the best propellant combination and provides the maximum mission/system capability maximum payload into GEO of satellites. Task 2 developed two models, performance and thermal. The performance model indicated the performance goal of specific impulse greater than or = 340 seconds (sigma = 204) could be achieved. The thermal model was developed and anchored to hot fire test data. Task 3 consisted of design, fabrication, and testing of a 200 lbf thrust test engine operating at a chamber pressure of 200 psia using LO2-N2H4. A total of 76 hot fire tests were conducted demonstrating performance greater than 340 (sigma = 204) which is a 25 second specific impulse improvement over the existing highest performance flight apogee type engines.

Chazen, M. L.↗
NASA NTRSDate not supplied

Thermal Protection System P50 Cork Environments and Response due to Radiative Heating

Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Nonmetallic Materials Branch thermal vacuum chamber (TVC) and investigates the P50 cork heat transfer environments and thermal protection system (TPS) response due to sensitivity changes in radiative heat rates, ambient pressure, air entrainment mass flow rates, test gas and TPS sample types. An SLS ascent ambient pressure profile was also simulated within the TVC facility. This test data enabled the efforts toward the Artemis I SLS post-flight reconstruction and initial assessment of flight TPS performance. A ground test program was developed to gain an in-depth understanding of the cork combustion dynamics and TPS response due to the SLS launch vehicle flight ascent environments.

thermal protection system↗
NASA NTRSDate not supplied

Thermal Protection System P50 Cork Char Response Characterization to Ascent Flight Shear and Heating Environments

NASA’s Space Launch System (SLS) experienced deflagration of the acreage of the Core Stage base heat shield during the Green Run hot-fire test campaigns and Artemis I flight. The burning products from the base heat shield during Green Run hot-fire test operation led to concerns in aerothermal environments and thermal protection system (TPS) performance prior to Artemis I flight. Updated design thermal environments accounting for cork combustion were developed using Green Run measurements and assessed prior to Artemis I, resulting in increased TPS thickness for the base heat shield. This work documents a highly controlled ground test within the NASA Marshall Space Flight Center’s Propulsion Test Branch Hot Gas Facility (HGF) and investigates the P50 cork TPS response due to sensitivity changes in radiative heat rates and surface shear stress. Prior to testing at the HGF, most of the P50 cork panels had a thick layer of char due to the cork combustion process replicated in a thermal vacuum chamber. SLS ascent shear stress and heating rate profile were simulated within the HGF by running the combustion-driven wind tunnel at off-nominal conditions and Mach numbers below 1. This test data provided insight into aerothermal measurements from Artemis I flight as well as informing updated base heating design environments for Artemis II. An in-depth understanding of the TPS P50 cork char response and observations is presented for launch vehicle flight ascent environments.

aerothermodynamics↗
NASA NTRS2011

Taurus II Stage Test Simulations: Using Large-Scale CFD Simulations to Provide Critical Insight into Plume Induced Environments During Design

This paper describes the use of targeted Loci/CHEM CFD simulations to evaluate the effects of a dual-engine first-stage hot-fire test on an evolving integrated launch pad/test article design. This effort was undertaken as a part of the NESC Independent Assessment of the Taurus II Stage Test Series. The underlying conceptual model included development of a series of computational models and simulations to analyze the plume induced environments on the pad, facility structures and test article. A pathfinder simulation was first developed, capable of providing quick-turn around evaluation of plume impingement pressures on the flame deflector. Results from this simulation were available in time to provide data for an ongoing structural assessment of the deflector. The resulting recommendation was available in a timely manner and was incorporated into construction schedule for the new launch stand under construction at Wallops Flight Facility. A series of Reynolds-Averaged Navier-Stokes (RANS) quasi-steady simulations representative of various key elements of the test profile was performed to identify potential concerns with the test configuration and test profile. As required, unsteady Hybrid-RANS/LES simulations were performed, to provide additional insight into critical aspects of the test sequence. Modifications to the test-specific hardware and facility structures thermal protection as well as modifications to the planned hot-fire test profile were implemented based on these simulation results.

Struzenberg, L. L.↗
NASA NTRSDate not supplied

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗
NASA NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗
NASA NTRS2017

NASA's Space Launch System Takes Shape

Major hardware and software for NASA's Space Launch System (SLS) began rolling off assembly lines in 2016, setting the stage for critical testing in 2017 and the launch of a major new capability for deep space human exploration. SLS continues to pursue a 2018 first launch of Exploration Mission 1 (EM-1). At NASA's Michoud Assembly Facility near New Orleans, LA, Boeing completed welding of structural test and flight liquid hydrogen tanks, and engine sections. Test stands for core stage structural tests at NASA's Marshall Space Flight Center, Huntsville, AL. neared completion. The B2 test stand at NASA's Stennis Space Center, MS, completed major structural renovation to support core stage green run testing in 2018. Orbital ATK successfully test fired its second qualification solid rocket motor in the Utah desert and began casting the motor segments for EM-1. Aerojet Rocketdyne completed its series of test firings to adapt the heritage RS-25 engine to SLS performance requirements. Production is under way on the first five new engine controllers. NASA also signed a contract with Aerojet Rocketdyne for propulsion of the RL10 engines for the Exploration Upper Stage. United Launch Alliance delivered the structural test article for the Interim Cryogenic Propulsion Stage to MSFC for tests and construction was under way on the flight stage. Flight software testing at MSFC, including power quality and command and data handling, was completed. Substantial progress is planned for 2017. Liquid oxygen tank production will be completed at Michoud. Structural testing at Marshall will get under way. RS-25 hotfire testing will verify the new engine controllers. Core stage horizontal integration will begin. The core stage pathfinder mockup will arrive at the B2 test stand for fit checks and tests. EUS will complete preliminary design review. This paper will discuss the technical and programmatic successes and challenges of 2016 and look ahead to plans for 2017.

Askins, Bruce↗
NASA NTRS1991

Heavy hydrocarbon main injector technology program

The Heavy Hydrocarbon Main Injector Program was an analytical, design, and test program to demonstrate an injection concept applicable to an Isolated Combustion Compartment of a full-scale, high pressure, LOX/RP-1 engine. Several injector patterns were tested in a 3.4-in. combustor. Based on these results, features of the most promising injector design were incorporated into a 5.7-in. injector which was then hot-fire tested. In turn, a preliminary design of a 5-compartment 2D combustor was based on this pattern. Also the additional subscale injector testing and analysis was performed with an emphasis on improving analytical techniques and acoustic cavity design methodology. Several of the existing 3.5-in. diameter injectors were hot-fire tested with and without acoustic cavities for spontaneous and dynamic stability characteristics.

Arbit, H. A.↗
NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in 2014 with more planned for 2015, including firing tests of both main propulsion elements and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will still deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 metric tons to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware. An RS-25 liquid propellant engine was hotfire-tested at NASA's Stennis Space Center, Miss. for the first time since 2009 exercising and validating the new engine controller, the renovated A-1 test stand, and the test teams. Four RS-25s will power the SLS core stage. A qualification five-segment solid rocket motor incorporating several design, material, and process changes was scheduled to be test-fired in March at the prime contractor's facility in Utah. The booster also successfully completed its Critical Design Review (CDR) validating the planned design. All six major manufacturing tools for the core stage are in place at the Michoud Assembly Facility in Louisiana, and have been used to build numerous pieces of confidence, qualification, and even flight hardware, including barrel sections, domes and rings used to assemble the world's largest rocket stage. SLS Systems Engineering accomplished several key tasks including vehicle avionics software and hardware build and testing, scale model acoustic and base heating tests. Construction of the Interim Cryogenic Propulsion Stage (ICPS) began. Advanced development provided a look into the future of SLS. Shell buckling knockdown factor testing refined decades-old design margins that added thousands of pounds to rocket payloads. Adaptive manufacturing and structured light scanning development promised to cut the cost and time associated with manufacturing and testing. This paper will provide an overview of the progress made over the past year and provide a glimpse of 2015 milestones and beyond on the way to the first launch in 2018.

May, Todd↗
NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in 2014 with more planned for 2015, including firing tests of both main propulsion elements and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will still deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 metric tons to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware. An RS-25 liquid propellant engine was hotfire-tested at NASA's Stennis Space Center, Miss. for the first time since 2009 exercising and validating the new engine controller, the renovated A-1 test stand, and the test teams. Four RS-25s will power the SLS core stage. A qualification five-segment solid rocket motor incorporating several design, material, and process changes was scheduled to be test-fired in March at the prime contractor's facility in Utah. The booster also successfully completed its Critical Design Review (CDR) validating the planned design. All six major manufacturing tools for the core stage are in place at the Michoud Assembly Facility in Louisiana, and have been used to build numerous pieces of confidence, qualification, and even flight hardware, including barrel sections, domes and rings used to assemble the world's largest rocket stage. SLS Systems Engineering accomplished several key tasks including vehicle avionics software and hardware build and testing, scale model acoustic and base heating tests. Construction of the Interim Cryogenic Propulsion Stage (ICPS) began. Advanced development provided a look into the future of SLS. Shell buckling knockdown factor testing refined decades-old design margins that added thousands of pounds to rocket payloads. Adaptive manufacturing and structured light scanning development promised to cut the cost and time associated with manufacturing and testing. This paper will provide an overview of the progress made over the past year and provide a glimpse of 2015 milestones and beyond on the way to the first launch in 2018.

May, Todd↗
NASA NTRS2002

Lightweight, Actively Cooled Ceramic Matrix Composite Thrustcells Successfully Tested in Rocket Combustion Lab

In a joint effort between the NASA Glenn Research Center and the NASA Marshall Space Flight Center, regeneratively cooled ceramic matrix composite (CMC) thrustcells were developed and successfully tested in Glenn's Rocket Combustion Lab. Cooled CMC's offer the potential for substantial weight savings over more traditional metallic parts. Two CMC concepts were investigated. In the first of these concepts, an innovative processing approach utilized by Hyper-Therm, Inc., allowed woven CMC coolant containment tubes to be incorporated into the complex thruster design. In this unique design, the coolant passages had varying cross-sectional shapes but maintained a constant cross-sectional area along the length of the thruster. These thrusters were silicon carbide matrix composites reinforced with silicon carbide fibers. The second concept, which was supplied by Ceramic Composites, Inc., utilized copper cooling coils surrounding a carbon-fiber-reinforced carbon matrix composite. In this design, a protective gradient coating was applied to the inner thruster wall. Ceramic Composites, Inc.'s, method of incorporating the coating into the fiber and matrix eliminated the spallation problem often observed with thermal barrier coatings during hotfire testing. The focus of the testing effort was on screening the CMC material's capabilities as well as evaluating the performance of the thermal barrier or fiber-matrix interfacial coatings. Both concepts were hot-fire tested in gaseous O2/H2 environments. The test matrix included oxygen-to-fuel ratios ranging from 1.5 to 7 with chamber pressures to 400 psi. Steady-state internal wall temperatures in excess of 4300 F were measured in situ for successful 30-sec test runs. Photograph of actively cooled composite thrustcell fabricated by Hyper-Therm is shown. The thrustcell is a silicon-carbide-fiber-reinforced silicon carbide matrix composite with woven cooling channels. The matrix is formed via chemical vapor infiltration. Photograph of hot-fire test of an actively cooled carbon-fiber-reinforced carbon matrix composite thrustcell is also shown. This composite thrustcell, which was fabricated by CCI, Inc., was wound with copper cooling coils to contain the water coolant. The tests were run with oxygen fuel ratios up to seven with chamber pressures of 200 psia.

Jaskowiak, Martha H.↗
NASA NTRS2005

Facility Activation and Characterization for IPD Turbopump Testing at NASA Stennis Space Center

The Integrated Powerhead Demonstrator (IPD) is a 250K lbf (1.1 MN) thrust cryogenic hydrogen/oxygen engine technology demonstrator that utilizes a full flow staged combustion engine cycle. The Integrated Powerhead Demonstrator (IPD) is, in part, supported by NASA. IPD is also supported through the Department of Defense's Integrated High Payoff Rocket Propulsion Technology (IHPRPT) program, which seeks to increase the performance and capability of today's state-of-the-art rocket propulsion systems while decreasing costs associated with military and commercial access to space. The primary industry participants include Boeing-Rocketdyne and GenCorp Aerojet. The IPD Program recently achieved two major milestones. The first was the successful completion of the IPD Oxidizer Turbopump (OTP) hot-fire test project at the NASA John C. Stennis Space Center (SSC) E-1 test facility in June 2003. A total of nine IPD Workhorse Preburner tests were completed, and subsequently 12 IPD OTP hot-fire tests were completed. The second major milestone was the successful completion of the IPD Fuel Turbopump (FTP) cold-flow test project at the NASA SSC E-1 test facility in November 2003. A total of six IPD FTP cold-flow tests were completed. The next phase of development involves IPD integrated engine system testing also at the NASA SSC E-1 test facility scheduled to begin in early 2005. Following and overview of the NASA SSC E-1 test facility, this paper addresses the facility aspects pertaining to the activation and testing of the IPD oxidizer and fuel turbopumps. In addition, some of the facility challenges encountered and the lessons learned during the test projects shall be detailed.

Sass, J. P.↗