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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 235 records · Page 13
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NASA NTRS1994

Charge efficiency of Ni/H2 cells during transfer orbit of Telstar 4 satellites

The TELSTAR 4 communication satellites being manufactured by Martin Marietta Astro Space (Astro Space) for AT&T are three axis stabilized spacecraft scheduled to be launched on expendable vehicles such as the Atlas or Ariane rockets. Typically, these spacecraft consist of a box that holds the electronics and supports the antenna reflectors and the solar array wings. The wings and reflectors are folded against the sides of the box during launch and the spacecraft is spun for attitude control in that phase; they are then deployed after achieving the final orbit. The launch phase and transfer orbits required to achieve the final geosynchronous orbit typically take 4 to 5 days during which time the power required for command, telemetry, attitude control, heaters, etc., is provided by two 50 AH nickel hydrogen batteries augmented by the exposed outboard solar panels. In the past, this situation has presented no problem since there was a considerable excess of power available from the array. In the case of large high powered spacecraft such as TELSTAR 4, however, the design power levels in transfer orbit approach the time-averaged power available from the exposed surface area of the solar arrays, resulting in a very tight power margin. To compound the difficulty, the array output of the spinning spacecraft in transfer orbit is shaped like a full wave rectified sine function and provides very low charging rates to the batteries during portions of the rotation. In view of the typically low charging efficiency of alkaline nickel batteries at low rates, it was decided to measure the efficiency during a simulation of the TELSTAR 4 conditions at the expected power levels and temperatures on three nickel hydrogen cells of similar design. The unique feature of nickel hydrogen cells that makes the continuous measurement of efficiency possible is that hydrogen is one of the active materials and thus, cell pressure is a direct measure of the state of charge or available capacity. The pressure is measured with a calibrated strain gage mounted on the outside of the pressurized cell.

Fang, W. C.↗
NASA NTRS2000

Mission Design Overview for Mars 2003/2005 Sample Return Mission

In May 2003, a new and exciting chapter in Mars exploration will begin with the launch of the first of three spacecraft that will collectively contribute toward the goal of delivering samples from the Red Planet to Earth. This mission is called Mars Sample Return (MSR) and will utilize both the 2003 and 2005 launch opportunities with an expected sample return in October 2008. NASA and CNES are major partners in this mission. The baseline mission mode selected for MSR is Mars orbit rendezvous (MOR), analogous in concept to the lunar orbit rendezvous (LOR) mode used for Apollo in the 1960s. Specifically, MSR will employ two NASA-provided landers of nearly identical design and one CNES-provided orbiter carrying a NASA payload of rendezvous sensors, orbital capture mechanisms, and an Earth entry vehicle (EEV). The high-level concept is that the landers will launch surface samples into Mars orbit, and the orbiter will retrieve the samples in orbit and then carry them back to Earth. The first element to depart for Mars will be one of the two landers. Currently, it is proposed that an intermediate class launch vehicle, such as the Boeing Delta 3 or Lockheed Martin Atlas 3A, will launch this 1800-kg lander from Cape Canaveral during the May 2003 opportunity. The lander will utilize a Type-1 transfer trajectory with an arrival at Mars in mid-December 2003. Landing will be aided by precision approach navigation and a guided hypersonic entry to achieve a touchdown accuracy of 10 km or better. Although the exact landing site has not yet been determined, it is estimated that lander resource constraints will limit the site to between 15 degrees north and south latitudes. Following touchdown, the lander will deploy a six-wheeled, 60-kg rover carrying an extensive suite of instruments designed to aid in the analysis of the local terrain and collection of core samples from selected rocks. The surface mission is currently designed around a concept called the surface traverse. Each traverse will involve the rover exploring a selected area of terrain up to 100 meters from the lander, the collection of rock core samples, and the delivery of the samples from the traverse back to a sample canister on the lander. Planning estimates indicate that up to three traverses may be possible during the expected 90-sol lifetime of the lander. The canister that will receive the samples from the rover will be attached to the top stage of a small solid-fueled rocket mounted to the deck of the lander. This rocket is called the Mars Ascent Vehicle (MAV) and consists of three stages weighing a total of about 140 kg. After the conclusion of the surface mission, the MAV will lift-off and insert the sample canister into a near-circular orbit with an altitude of about 600 km and inclination of 45 degrees. The sample canister will wait in this orbit until it is retrieved by the orbiter sometime in early 2007. In August 2005, the second lander and a CNES-provided orbiter weighing 2700 kg will depart for Mars. Currently, it is proposed that a single Ariane 5 provided by CNES will launch both of these two elements onto a Type-2 transfer trajectory. Although the orbiter and lander will be launched together, they will separate shortly after injection and will fly to Mars as two independent spacecraft. However, both spacecraft will perform a maneuver between 10 and 15 days after launch so that their arrival times at Mars differ by between 12 and 24 hours. This scheme will reduce the operational complexity at the encounter date. A set of four 60-kg surface probes will ride piggyback on the orbiter to Mars. These CNES-provided probes are called Netlanders and will serve as surface stations for scientific investigations independent of the Mars Sample Return goals. Starting approximately one month prior to arrival at Mars, the orbiter will begin to release the Netlanders one at a time. Each release cycle will take several days, and will include time for precision navigation to execute one or two maneuvers that will target the Netlanders to their proper landing site. All four deployment cycles will be completed prior to 10 days before arrival. Both the orbiter and lander will arrive in late-July 2006. Upon arrival, the lander will perform a precision landing and surface mission similar in concept to the one that was executed during the 2003 opportunity. Although the landing site for the 2005 opportunity has not been selected, it is expected to be different from the 2003 site to enhance the diversity of the collected samples. The orbiter's arrival at Mars will be highlighted by the first use of aerocapture to insert a spacecraft into a capture orbit around another planet. The choice of aerocapture, as opposed to a propulsive orbit insertion, was considered mission enabling due to a reduction of over 2000 m/s in mission AV. Aerocapture will be targeted to produce a 250 km x 1400 km capture orbit with an inclination of 45 degrees. Current analysis indicates that achieving this goal will require approximately six minutes of flight deep in the atmosphere with a targeted periapsis of approach of about 43 km. After factoring into account the penalty for carrying a heat shield to survive aerocapture, the net savings compared to a propulsive orbital insertion amounts to several hundred kilograms.

Lee, Wayne J.↗
NASA NTRS2012

Space Transportation Infrastructure Supported By Propellant Depots

A space transportation infrastructure is described that utilizes propellant depot servicing platforms to support all foreseeable missions in the Earth-Moon vicinity and deep space out to Mars. The infrastructure utilizes current expendable launch vehicle (ELV) systems such as the Delta IV Heavy, Atlas V, and Falcon 9, for all crew, cargo, and propellant launches to orbit. Propellant launches are made to Low-Earth-Orbit (LEO) Depot and an Earth-Moon Lagrange Point 1 (L1) Depot to support a new reusable in-space transportation vehicles. The LEO Depot supports missions to Geosynchronous Earth Orbit (GEO) for satellite servicing and to L1 for L1 Depot missions. The L1 Depot supports Lunar, Earth-Sun L2 (ESL2), Asteroid and Mars Missions. New vehicle design concepts are presented that can be launched on current 5 meter diameter ELV systems. These new reusable vehicle concepts include a Crew Transfer Vehicle (CTV) for crew transportation between the LEO Depot, L1 Depot and missions beyond L1; a new reusable lunar lander for crew transportation between the L1 Depot and the lunar surface; and Mars orbital Depot are based on International Space Station (ISS) heritage hardware. Data provided includes the number of launches required for each mission utilizing current ELV systems (Delta IV Heavy or equivalent) and the approximate vehicle masses and propellant requirements. Also included is a discussion on affordability with ideas on technologies that could reduce the number of launches required and thoughts on how this infrastructure include competitive bidding for ELV flights and propellant services, developments of new reusable in-space vehicles and development of a multiuse infrastructure that can support many government and commercial missions simultaneously.

Smitherman, David↗
NASA NTRS1996

Launch vehicle and power level impacts on electric GEO insertion

Solar Electric Propulsion (SEP) has been shown to increase net geosynchronous spacecraft mass when used for station keeping and final orbit insertion. The impact of launch vehicle selection and power level on the benefits of this approach were examined for 20 and 25 kW systems launched using the Ariane 5, Atlas IIAR, Long March, Proton, and Sea Launch vehicles. Two advanced on-board propulsion technologies, 5 kW ion and Hall thruster systems, were used to establish the relative merits of the technologies and launch vehicles. GaAs solar arrays were assumed. The analysis identifies the optimal starting orbits for the SEP orbit raising/plane changing while considering the impacts of radiation degradation in the Van Allen belts, shading, power degradation, and oblateness. This use of SEP to provide part of the orbit insertion results in net mass increases of 15 - 38% and 18 - 46% for one to two month trip times, respectively, over just using SEP for 15 years of north/south station keeping. SEP technology was shown to have a greater impact on net masses of launch vehicles with higher launch latitudes when avoidance of solar array and payload degradation is desired. This greater impact of SEP could help reduce the plane changing disadvantage of high latitude launch sites. Comparison with results for 10 and 15 kW systems show clear benefits of incremental increases in SEP power level, suggesting that an evolutionary approach to high power SEP for geosynchronous spacecraft is possible.

Oleson, Steven R.↗
NASA NTRS2012

Future Concepts for Integrating the Space Launch System and the Multi-Purpose Crew Vehicle into a Reusable Space Transportation Infrastructure

A space transportation infrastructure is described that utilizes the Space Launch System (SLS), the Mulit-Purpose Crew Vehicle (MPCV), the International Space Station (ISS), and propellant depot servicing platforms to support all foreseeable missions in the Earth-Moon vicinity and deep space out to Mars. The infrastructure utilizes current expendable launch vehicle (ELV) systems such as the Delta IV Heavy, Atlas V, and Falcon 9, for commercial crew, cargo, and propellant launches to a Low-Earth-Orbit (LEO) Depot and/or the ISS. The SLS provides all payload and propellant launches to the Earth-Moon Langrange Point 1 (EML1) Depot to support new reusable in-space transportation vehicles. The ISS or follow-on LEO Depot supports missions to Geosynchronous Earth Orbit (GEO) for satellite servicing and to Earth-Moon L1 for EML1 Depot missions. The EML1 Depot supports Lunar, Earth-Sun L2 (ESL2), Asteroid, and Mars missions. New vehicle design concepts are presented that can be launched utilizing the SLS and current ELV systems. These new reusable vehicle concepts include a Crew Transfer Vehicle (CTV) derived from the MPCV and a reusable Cryogenic Propulsion Stage (CPS) for crew transportation between the LEO Depot, EML1 Depot and missions beyond the Earth-Moon vicinity; a new reusable Lunar Lander for crew transportation between the EML1 Depot and the lunar surface; and a new reusable Deep Space Habitat (DSH) with a CTV to support crew missions from the EML1 Depot to ESL2, Asteroids, and a Mars Orbital Depot. The LEO Depot, EML1 Depot, and Mars Orbital Depot are based on International Space Station (ISS) heritage hardware. Data provided includes the number of launches required for each mission utilizing SLS and current ELV systems (Delta IV Heavy or equivalent) and the approximate vehicle masses and propellant requirements. Also included is a discussion on affordability with ideas on technologies that could reduce the number of launches required and thoughts on how this infrastructure might be implemented incrementally over the next few decades. The potential benefits of this infrastructure include competitive bidding for ELV flights and propellant services, development of new reusable in-space vehicles, and development of a robust multiuse infrastructure that can support many government and commercial missions simultaneously.

Smitherman, David↗
NASA NTRSDate not supplied

NASA Support for Commercial Crew Launch Capabilities

Since the earliest days of U.S. human spaceflight, NASA’s Marshall Space Flight Center in Huntsville, Alabama, has played a key role in American crew launch capability, from engineering support for the first Mercury-Redstone launches, to the Saturn launches to the Moon, through Shuttle and now Artemis. Today, Marshall brings that expertise gained through decades of crewed space launches to NASA’s Commercial Crew Program (CCP), providing launch vehicle engineering and programmatic support. The team’s responsibilities have included human certification of commercial launch systems for the CCP missions, including Atlas V and Falcon 9, and verifying each launch vehicle complies with flight certification. MSFC provides expertise in nearly all aspects of launch vehicle design and performance including solid motors and liquid engines, stage propulsion, thrust vector control, structural and dynamics, safety and mission assurance. During each commercial crew launch, an engineering support team is on console at Marshall’s Huntsville Operations Support Center, which has provided launch operations support since Apollo, providing real-time oversight to safety standards for the vehicle and verifying data. Launch vehicle support for Commercial Crew has come as a paradigm shift for the MSFC team, inspiring new approaches that leverage expertise and best practices from past NASA-developed launch vehicle missions, while at the same time providing new synergies from work with commercial partners on CCP. This paper will explore the role that the Marshall launch vehicle services team plays in the Commercial Crew Program, as well as lessons learned from the program that will continue to benefit a new era of spaceflight partnerships.

Commercial Crew↗
NASA NTRS1976

SEATSAT programs option analysis

A preliminary analysis of the costs of SEASAT follow-on options is presented. All the options assume the existence of SEASAT-A as currently defined in the SEASAT Economic Assessment. It is assumed that each option will continue through the year 2000 and approach operational system status in the 1983-1986 period, depending upon the sensor package selected. The launch vehicle assumed through 1983 is the Atlas Agena. After 1983, it is assumed SEASAT-A will switch to the use of the Space Shuttle. All cost estimates are 1976 dollars for fiscal year cost accounting, with no inflation rate included.

Luckl, L.↗
NASA NTRS1991

Geostationary Operational Environmental Satellite (GOES I-M) METSAT project

The primary objective of the METSAT project is to provide a satellite system that meets the National Environmental Satellite Data and Information Service (NESDIS) requirements as specified by NOAA. For the GOES I-M spacecraft, these requirements include an imager and sounder system, a data collection system, and a search and rescue system. The Space Transportation System and GOES I-M development philosophy and the satellite transfer orbit philosophy are explained. The spacecraft will be launched from the Kennedy Space Center using Atlas G/Centaur D-1A expendable launch vehicles. The coverage required for launch and the support of transfer and drift orbits will consist of the 26-m antenna as prime and the TBD antenna as backup for 11 days at all complexes. There will be contingency support 15 days for on-station spacecraft checkout. After the initial 30 to 45 days, the Deep Space Network (DSN) is committed for emergency support. Contingency and emergency support will be provided by Goldstone only. Information is given in tabular form for DSN support, frequency assignments, telemetry, command, and tracking support responsibility.

Blaney, K.↗
NASA NTRS2018

Interplanetary Trajectory Design for NASA's Common Probe Study

The Galileo Probe, Pioneer-Venus probes, and SPRITE concept all share a number of common characteristics. They all follow a similar entry and descent sequence, using an aeroshell to protect against entry environments, and parachutes to aid in extrusion and descent speed control of the descent vehicle containing the science instruments. The descent vehicles all contained similar instruments (e.g. mass spectrometers and atmosphere structure sensors), and data was either relayed back to a carrier spacecraft (Galileo Probe, SPRITE) or transmitted direct to Earth (Pioneer-Venus). Based on these similar characteristics, NASA initiated a study to investigate a “common probe' that might be designed to perform similar science in a variety of planetary environments. This concept would leverage a common aeroshell design, and descent vehicle designs that could be made as similar as possible (the primary exception being that Venus will require a pressure vessel due to the extreme pressures and temperatures seen in the lower portion of the descent). To support the Common Probe study, GSFC and JPL performed a series of interplanetary trajectory analyses to help develop the mission designs for Venus, Jupiter, Saturn, Uranus, and Neptune. Primary considerations in the trajectory modeling included: a maximum of 12-year time of flight (for outer planet destinations), generation of both steep and shallow entry trajectories to each destination (where steep and shallow resulted in approximately 150 g and 50 g peak deceleration during entry at each location), and consideration of the data relay. Gravity assists and trajectories with low delta-V requirements (typically much less than 500 m/s) were also incorporated into the design process to enable launch on existing vehicles such as the Atlas V.

Hughes, Kyle M.↗
NASA NTRS2008

Design and Development of an In-Space Deployable Sun Shield for the Atlas Centaur

The Centaur, by virtue of its use of high specific-impulse (Isp) LO2/LH2 propellants, has initial mass-to-orbit launch requirements less than half of those upper stages using storable propellants. That is, for Earth escape or GSO missions the Centaur is half the launch weight of a storable propellant upper stage. A drawback to the use of Liquid oxygen and liquid hydrogen, at 90 K and 20 K respectively, over storable propellants is the necessity of efficient cryogen storage techniques that minimize boil-off from thermal radiation in space. Thermal blankets have been used successfully to shield both the Atlas Centaur and Titan Centaur. These blankets are protected from atmospheric air loads during launch by virtue of the fact that the Centaur is enclosed within the payload fairing. The smaller Atlas V vehicle, the Atlas 400, has the Centaur exposed to the atmosphere during launch, and therefore, to date has not flown with thermal blankets shielding the Centaur. A design and development effort is underway to fly a thermal shield on the Atlas V 400 vehicle that is not put in place until after the payload fairing jettisons. This can be accomplished by the use of an inflatable and deployable thermal blanket referred to as the Centaur Sun Shield (CSS). The CSS design is also scalable for use on a Delta upper stage, and the technology potentially could be used for telescope shades, re-entry shields, solar sails and propellant depots. A Phase I effort took place during 2007 in a partnership between ULA and ILC Dover which resulted in a deployable proof-of-concept Sun Shield being demonstrated at a test facility in Denver. A Phase H effort is underway during 2008 with a partnership between ULA, ILC, NASA Glenn Research Center (GRC) and NASA Kennedy Space Center (KSC) to define requirements, determine materials and fabrication techniques, and to test components in a vacuum chamber at cold temperatures. This paper describes the Sun Shield development work to date, and the future plans leading up to a flight test in the 2011 time frame.

Dew, Michael↗
NASA NTRS1984

Assessment of candidate-expendable launch vehicles for large payloads

In recent years the U.S. Air Force and NASA conducted design studies of 3 expendable launch vehicle configurations that could serve as a backup to the space shuttle--the Titan 34D7/Centaur, the Atlas II/Centaur, and the shuttle-derived SRB-X--as well as studies of advanced shuttle-derived launch vehicles with much larger payload capabilities than the shuttle. The 3 candidate complementary launch vehicles are judged to be roughly equivalent in cost, development time, reliability, and payload-to-orbit performance. Advanced shuttle-derived vehicles are considered viable candidates to meet future heavy lift launch requirements; however, they do not appear likely to result in significant reduction in cost-per-pound to orbit.

Source record↗
NASA NTRS2016

Aerocapture Design Study for a Titan Polar Orbiter

In 2014 a team at NASA Goddard Space Flight Center (GSFC) studied the feasibility of using active aerocapture to reduce the chemical Delta V requirements for inserting a small scientific satellite into Titan polar orbit. The scientific goals of the mission would be multi-spectral imaging and active radar mapping of Titan's surface and subsurface. The study objectives were to: (i) identify and select from launch window opportunities and refine the trajectory to Titan; (ii) study the aerocapture flight path and refine the entry corridor; (iii) design a carrier spacecraft and systems architecture; (iv) develop a scientific and engineering plan for the orbital portion of the mission. Study results include: (i) a launch in October 2021 on an Atlas V vehicle, using gravity assists from Earth and Venus to arrive at Titan in January 2031; (ii) initial aerocapture via an 8-km wide entry corridor to reach an initial 350X6000 km orbit, followed by aerobraking to reach a 350X1500 km orbit, and a periapse raise maneuver to reach a final 1500 km circular orbit; (iii) a three-part spacecraft system consisting of a cruise stage, radiator module, and orbiter inside a heat shield; (iv) a 22-month mission including station keeping to prevent orbital decay due to Saturn perturbations, with 240 Gb of compressed data returned. High-level issues identified include: (i) downlink capability - realistic downlink rates preclude the desired multi-spectral, global coverage of Titan's surface; (ii) power - demise of the NASA ASRG (Advanced Stirling Radioisotope Generator) program, and limited availability at present of MMRTGs (Multi-Mission Radioisotope Generators) needed for competed outer planet missions; (iii) thermal - external radiators must be carried to remove 4 kW of waste heat from MMRTGs inside the aeroshell, requiring heat pipes that pass through the aeroshell lid, compromising shielding ability; (iv) optical navigation to reach the entry corridor; (v) the NASA requirement of continuous critical event coverage for the orbiter, especially during the peak heating of the aerocapture when the radio link will be broken. In conclusion, although Titan aerocapture allows for considerable savings in propellant mass, this comes at a cost of increased mission complexity. Further architecture study and refinement is required to reduce high-level mission risks and to elucidate the optimum architecture.

Nixon, Conor A.↗
NASA NTRSDate not supplied

Development of an Ejectable Data Recorder Ejection Mechanism for the Low Earth Orbit Flight Test of an Inflatable Decelerator

On November 10, 2022, the 1100kg (2,425 lbs.) LOFTID Reentry Vehicle (RV) was launched on a United Launch Alliance Atlas V as a secondary payload with the Joint Polar Surveyor System-2. The 6-meter diameter (~20 ft.) aeroshell (a type of heat shield) entered the atmosphere at 8 kilometers per second (18,000 miles per hour), and flew nominally, enduring the intended heat pulse that saw temperatures exceeding 1371˚C (2500˚F) on the front side while the payload skin remained only about 38˚C (100˚F). The RV exceeded Mach 30 and the heat-affected aeroshell withstood a pressure pulse that exerted 9g’s deceleration maintaining stable flight through the hypersonic, supersonic, transonic, and subsonic regimes to the parachute deployment. As part of the Agency’s strategic goal “to extend human presence deeper into space and to the moon for sustainable long-term exploration and utilization”, the LOFTID inflatable aerodynamic decelerator or aeroshell technology could one day help land humans on Mars. As with any flight test, data collection is of utmost importance. Without a data downlink and a possibility of the RV sinking before the recovery crew got to it, a secondary data collection method was introduced. The RV would eject a data recorder, which would have a duplicate copy of the on-board flight date, before splashdown and be retrieved separately. This paper discusses the development of the ejection mechanism used to eject the data recorder from the RV during the test flight. The development includes discussions of design constraints, a design overview, the testing program, and lessons learned throughout the process all the way through successful data recorder recovery.

mechanism↗
NASA NTRS2020

An Initial Concept for a JUMP Mating Mechanism

Lunar landers currently under development for crew and cargo missions to the Moon are limited by the available boosters to launch them from Earth. Most landers are being developed for commercial launch vehicles (CLVs) in the Falcon Heavy / Vulcan / New Glenn / Atlas V class, limiting their performance with many lunar surface studies consequently restricted to 5-10 metric ton payloads. The JUMP Lander (Joinable Undercarriage to Maximize Payload) attempts to overcome this limitation by performing an in-space mating, linking multiple landers together. This research provides an initial proof of concept demonstration that two or more CLV-launched lunar landers can be mated in-space to produce a larger lander with greater payload capacity. Multiple rockets have been connected hundreds if not thousands of times in spaceflight history. An example is the space shuttle. The External Tank-Orbiter interface is an example where the 100-ton Orbiter is bolted to the side of the External Tank. This example serves as a concept metaphor for JUMP where a system of bolts is used as the mating system. This paper performs a high-level sizing analysis of the bolt, including the structural connection to each lander and the physical dimensions of the bolt, given the projected lander and payload masses. It sizes the necessary motors to perform the in-space mating and describes the motor to bolt integration. It describes the mounting and translation for the bolt-motor assembly, including structural supports, physical stops, and range of travel. It discusses active-active and active-passive implementations for the mating system and post-mating options to jettison no-longer-needed components of the assembly, including a discussion of benefits of jettisoning or not jettisoning. Finally, forward work for the mating mechanism and overall JUMP Lander concept is described.

Lunar Lander↗
NASA NTRS2019

Extreme-Temperature Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

The United States (US) National Aeronautics and Space Administration (NASA) and its US industry partners are developing extreme-temperature composite nozzle extensions for a variety of cryogenic liquid rocket engine propulsion systems. Applications under consideration at the NASA Marshall Space Flight Center (MSFC) include launch vehicle (upper stage), in-space, and lunar lander descent/ascent propulsion systems. Composite material systems of interest include carbon-carbon (C-C) and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Missions addressed include access to low Earth orbit, the lunar surface, and more distant destinations. Cryogenic upper-stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. As a result of the large size of such nozzles, and the related engine performance requirements, composite nozzle extensions are being considered to reduce mass impacts. Currently, metallic and foreign composite nozzle extensions used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles represent the state-of-the-art. Such extensions are limited to use at or slightly above 2000°F (1093°C). Materials under development by MSFC and its industry partners have the potential to operate at temperatures up to (or above) 4250°F (2343°C). Marshall Space Flight Center efforts are aimed at (a) further developing the technology and databases needed to enable the use of composite nozzle extensions on cryogenic liquid rocket engines, (b) developing and demonstrating low-cost capabilities for testing and qualifying such nozzle extensions, and (c) advancing the US domestic supply chain for nozzle extensions. Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs, low-level internal MSFC research projects, and teaming arrangements with domestic industry partners, composite material design, development, hot-fire test, and evaluation efforts are progressing. Hot- fire engine tests of subscale hardware have been conducted using oxygen/hydrogen (LOX/H2), oxygen/methane (LOX/CH4), and oxygen/kerosene (LOX/RP-1) propellants. These engine tests at MSFC have enabled the evaluation of both heritage and state-of-the-art material systems, demonstrating the initial capabilities of the extreme temperature materials and their fabrication methods. Recent, ongoing, and potential future work supporting cryogenic propulsion systems development will be presented. The composite nozzle extension technology and test capabilities being developed are intended to support both NASA and US Department of Defense requirements, as well as those of the broader Commercial Space industry.

Valentine, Peter G.↗