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Spacecraft systems (fuel, electrical) are analyzed for performance prior to launch. Systems failures are examined, and safety precautions and safety devices are reviewed. Spacecraft configurations of the command module and docking system are shown.
Cycle studies have shown the benefits of increasing engine pressure ratios and cycle temperatures to decrease engine weight and improve performance in next generation turbine engines. Advanced seals have been identified as critical in meeting engine goals for specific fuel consumption, thrust-to-weight, emissions, durability and operating costs. NASA and the industry are identifying and developing engine and sealing technologies that will result in dramatic improvements and address the goals for engines entering service in the 2005-2007 time frame. This paper provides an overview of advanced seal technology requirements and highlights the results of a preliminary design effort to implement advanced seals into a regional aircraft turbine engine. This study examines in great detail the benefits of applying advanced seals in the high pressure turbine region of the engine. Low leakage film-riding seals can cut in half the estimated 4% cycle air currently used to purge the high pressure turbine cavities. These savings can be applied in one of several ways. Holding rotor inlet temperature (RIT) constant the engine specific fuel consumption can be reduced 0.9%, or thrust could be increased 2.5%, or mission fuel burn could be reduced 1.3%. Alternatively, RIT could be lowered 20 'F resulting in a 50% increase in turbine blade life reducing overall regional aircraft maintenance and fuel bum direct operating costs by nearly 1%. Thermal, structural, secondary-air systems, safety (seal failure and effect), and emissions analyses have shown the proposed design is feasible.
Launching the space shuttle involves an interesting paradox: While the temperatures inside the shuttle s main engines climb higher than 6,000 F hot enough to boil iron for fuel, the engines use liquid hydrogen, the second coldest liquid on Earth after liquid helium. Maintained below 20 K (-423 F), the liquid hydrogen is contained in the shuttle s rust-colored external tank. The external tank also contains liquid oxygen (kept below a somewhat less chilly 90 K or -297 F) that combines with the hydrogen to create an explosive mixture that along with the shuttle s two, powdered aluminum-fueled solid rocket boosters allows the shuttle to escape Earth s gravity. The cryogenic temperatures of the main engines liquid fuel can cause ice, frost, or liquefied air to build up on the external tank and other parts of the numerous launch fueling systems, posing a possible debris risk when the ice breaks off during launch and causing difficulties in the transfer and control of these cryogenic liquid propellants. Keeping the fuel at the necessary ultra-cold temperatures while minimizing ice buildup and other safety hazards, as well as reducing the operational maintenance costs, has required NASA to explore innovative ways for providing superior thermal insulation systems. To address the challenge, the Agency turned to an insulating technology so effective that, even though it is mostly air, a thin sheet can prevent a blowtorch from igniting a match. Aerogels were invented in 1931 and demonstrate properties that make them the most extraordinary insulating materials known; a 1-inch-thick piece of aerogel provides the same insulation as layering 15 panes of glass with air pockets in between. Derived from silica, aluminum oxide, or carbon gels using a supercritical drying process - resulting in a composition of almost 99-percent air - aerogels are the world s lightest solid (among 15 other titles they hold in the Guinness World Records), can float indefinitely on water if treated to be hydrophobic, and can withstand extremely hot temperatures (from 1,100 F to 3,000 F depending on the type of aerogel) down to cryogenic levels, making this "frozen smoke" ideal for use in space. Because of its low weight and ability to withstand temperature extremes, an aerogel was even used as the space-based catcher s mitt to trap comet particles and space dust for NASA s Stardust mission, launched in 1999. All of this remarkable technology s characteristics were ideal for NASA s purposes except one: The aerogels were extremely brittle. Through a long-term partnership between Kennedy Space Center and Aspen Aerogels Inc., of Northborough, Massachusetts, researchers developed a flexible, durable form of aerogel that NASA has since used as cryogenic insulation for space shuttle launch systems. Through Aspen Aerogels, the technology has made oil pipeline insulation, extreme weather clothing, and infrared shielding for combat helicopters.
Robust, miniaturized sensing systems are needed to improve performance, increase efficiency, and track system health status and failure modes of advanced propulsion systems. Because microsensors must operate in extremely harsh environments, there are many technical challenges involved in developing reliable systems. In addition to high temperatures and pressures, sensing systems are exposed to oxidation, corrosion, thermal shock, fatigue, fouling, and abrasive wear. In these harsh conditions, sensors must be able to withstand high flow rates, vibration, jet fuel, and exhaust. In order for existing and future aeropropulsion turbine engines to improve safety and reduce cost and emissions while controlling engine instabilities, more accurate and complete sensor information is necessary. High-temperature (300 to 1,350 C) capacitive pressure sensors are of particular interest due to their high measurement bandwidth and inherent suitability for wireless readout schemes. The objective of this project is to develop a capacitive pressure sensor based on silicon carbon nitride (SiCN), a new class of high-temperature ceramic materials, which possesses excellent mechanical and electric properties at temperatures up to 1,600 C.
Current renewed interest in exploration of the moon, Mars, and other planetary objects is driving technology development in many fields of space system design. In particular, there is a desire to land both robotic and human missions on the moon and elsewhere. The landing guidance system must be able to deliver the vehicle to a desired soft landing while meeting several constraints necessary for the safety of the vehicle. Due to performance limitations of current launch vehicles, it is desired to minimize the amount of fuel used. In addition, the landing site may change in real-time in order to avoid previously undetected hazards which become apparent during the landing maneuver. This complicated maneuver can be broken into simpler subproblems that bound the full problem. One such subproblem is to find a minimum-fuel landing solution that meets constraints on the initial state, final state, and bounded thrust acceleration magnitude. With the assumptions of constant gravity and negligible atmosphere, the form of the optimal steering law is known, and the equations of motion can be integrated analytically, resulting in a system of five equations in five unknowns. It is shown that this system of equations can be reduced analytically to two equations in two unknowns. With an additional assumption of constant thrust acceleration magnitude, this system can be reduced further to one equation in one unknown. It is shown that these unknowns can be bounded analytically. An algorithm is developed to quickly and reliably solve the resulting one-dimensional bounded search, and it is used as a real-time guidance applied to a lunar landing test case.
CERMET fuel materials are being developed at the NASA Marshall Space Flight Center for a Nuclear Cryogenic Propulsion Stage. Recent work has resulted in the development and demonstration of a Compact Fuel Element Environmental Test (CFEET) System that is capable of subjecting depleted uranium fuel material samples to hot hydrogen. A critical obstacle to the development of an NCPS engine is the high-cost and safety concerns associated with developmental testing in nuclear environments. The purpose of this testing capability is to enable low-cost screening of candidate materials, fabrication processes, and further validation of concepts. The CERMET samples consist of depleted uranium dioxide (UO2) fuel particles in a tungsten metal matrix, which has been demonstrated on previous programs to provide improved performance and retention of fission products1. Numerous past programs have utilized hot hydrogen furnace testing to develop and evaluate fuel materials. The testing provides a reasonable simulation of temperature and thermal stress effects in a flowing hydrogen environment. Though no information is gained about radiation damage, the furnace testing is extremely valuable for development and verification of fuel element materials and processes. The current work includes testing of subscale W-UO2 slugs to evaluate fuel loss and stability. The materials are then fabricated into samples with seven cooling channels to test a more representative section of a fuel element. Several iterations of testing are being performed to evaluate fuel mass loss impacts from density, microstructure, fuel particle size and shape, chemistry, claddings, particle coatings, and stabilizers. The fuel materials and forms being evaluated on this effort have all been demonstrated to control fuel migration and loss. The objective is to verify performance improvements of the various materials and process options prior to expensive full scale fabrication and testing. Post test analysis will include weight percent fuel loss, microscopy, dimensional tolerance, and fuel stability.
The objective is to determine the mechanism of gas-phase flame spread over solid fuel surfaces in the absence of any buoyancy or externally imposed gas-phase flow. Such understanding can be used to improve the fire safety aspects of space travel by providing information that will allow judicious selections of spacecraft materials and environments to be made. The planned experiment consists of measuring the flame spread rate over thermally thin and thermally thick fuels in a closed container in the low-gravity environment of the Space Shuttle. Measurements consist of flame spread rate and shape obtained from two views of the process as recorded on movie film and surface and gas-phase temperatures obtained from fine-wire thermocouples. The temperature measurements along with appropriate modeling provide information about the gas-to-solid heat flux. Environmental parameters to be varied are the oxygen concentration and pressure.
The use of a liquid oxidizer-solid fuel hybrid propellant combination in booster rocket motors appears extremely attractive due to the integration of the best features of liquid and solid propulsion systems. The hybrid rocket combines the high performance, clean exhaust, and safety of liquid propellant engines with the low cost and simplicity of solid propellant motors. Additionally, the hybrid rocket has unique advantages such as an inert fuel grain and a relative insensitivity to fuel grain and oxidizer injection anomalies. The advantages mark the hybrid rocket as a potential replacement or alternative for current and future solid propellant booster systems. The issues are addressed and recommendations are made concerning oxidizer feed systems, injectors, and ignition systems as related to hybrid rocket propulsion. Early in the program a baseline hybrid configuration was established in which liquid oxygen would be injected through ports in a solid fuel whose composition is based on hydroxyl terminated polybutadiene (HTPB). Liquid oxygen remained the recommended oxidizer and thus all of the injector concepts which were evaluated assumed only liquid would be used as the oxidizer.
The spread and growth of flames over large solid fuel samples and their effect on the pressurized spacecraft were studied inside the Cygnus spacecraft while in orbit after departing the International Space Station. These experiments were developed by NASA’s Advanced Exploration Systems Division in the Human Exploration and Operations Mission Directorate. The ignited materials consisted of poly-methyl methacrylate (PMMA), cotton fabric and a cotton/fiberglass fabric blend. The samples were all 40 cm wide and with various lengths ranging from 18 cm for the PMMA samples to 50 cm for the fabrics. The overall results from these tests and their impact on the spacecraft are presented with emphasis on the fire safety implications of the results. The experiments included, a post-fire cleanup system, vehicle internal volume measurements, and transport of acid gases (HCl and HF). Measurements included video images, flame spread rate, flame temperatures and radiant heat output; energy release through oxygen calorimetry; distributed measurements of CO2 concentration and temperature at six locations in the spacecraft; CO2, CO, O2, HF and HCl concentrations; vehicle pressurized volume; and aerosol concentrations. Details of the flame growth and spread are discussed in other papers as are details of the post-fire cleanup system performance. The fire events had a measurable impact on the vehicle pressure, temperature, and carbon dioxide concentration. However, despite having heat release rates up to 10 kW, the average vehicle conditions did not rise to unacceptable levels. The combined results of the experiments provide significant new understanding of the impact of sample and flow duct height on flame spread and growth in addition to an improved perspective of the impact of a fire event on a spacecraft.
The spread and growth of flames over large solid fuel samples and their effect on the pressurized spacecraft were studied inside the Cygnus spacecraft while in orbit after departing the International Space Station. These experiments were developed by NASA’s Advanced Exploration Systems Division in the Human Exploration and Operations Mission Directorate. The ignited materials consisted of poly-methyl methacrylate (PMMA), cotton fabric and a cotton/fiberglass fabric blend. The samples were all 40 cm wide and with various lengths ranging from 18 cm for the PMMA samples to 50 cm for the fabrics. The overall results from these tests and their impact on the spacecraft are presented with emphasis on the fire safety implications of the results. The experiments included, a post-fire cleanup system, vehicle internal volume measurements, and transport of acid gases (HCl and HF). Measurements included video images, flame spread rate, flame temperatures and radiant heat output; energy release through oxygen calorimetry; distributed measurements of CO2 concentration and temperature at six locations in the spacecraft; CO2, CO, O2, HF and HCl concentrations; vehicle pressurized volume; and aerosol concentrations. Details of the flame growth and spread are discussed in other papers as are details of the post-fire cleanup system performance. The fire events had a measurable impact on the vehicle pressure, temperature, and carbon dioxide concentration. However, despite having heat release rates up to 10 kW, the average vehicle conditions did not rise to unacceptable levels. The combined results of the experiments provide significant new understanding of the impact of sample and flow duct height on flame spread and growth in addition to an improved perspective of the impact of a fire event on a spacecraft.
The feasibility, practicability, and potential advantages/disadvantages of using liquid hydrogen as fuel in long range, subsonic transport aircraft of advanced design were studied. Both passenger and cargo-type aircraft were investigated. To provide a valid basis for comparison, conventional hydrocarbon (Jet A) fueled aircraft were designed to perform identical missions using the same advanced technology and meeting the same operational constraints. The liquid hydrogen and Jet A fueled aircraft were compared on the basis of weight, size, energy utilization, cost, noise, emissions, safety, and operational characteristics. A program of technology development was formulated.
Reusable space propulsion hot gas-path components are required to operate under severe thermal and mechanical loading conditions. These operating conditions produce elevated temperature and thermal transients which results in significant thermally induced inelastic strains, particularly, in the turbopump turbine blades. An inelastic analysis for this component may therefore be necessary. Anisotropic alloys such as MAR M-247 or PWA-1480 are being considered to meet the safety and durability requirements of this component. An anisotropic inelastic structural analysis for an SSME fuel turbopump turbine blade was performed. The thermal loads used resulted from a transient heat transfer analysis of a turbine blade. A comparison of preliminary results from the elastic and inelastic analyses is presented.
Powering missions to the outer solar system is a significant challenge. These missions are typically powered by a Radioisotope Thermoelectric Generator (RTG). Though these sources provide stable power regardless of location in space, they are expensive to produce, difficult to integrate, and have both safety concerns as well as negative sociopolitical connotations. Perhaps most importantly, the availability of their fuel, plutonium-238, is scarce. Solar power is often considered a more attractive option. However, photovoltaic generation falls off at the distance from the sun squared. This drives the size of traditional solar generators to infeasible levels for deep space and their utilization at locations deeper the Jupiter is currently non-existent. Herein, a hypothetical solution, the PowerSail, and its application to a non-nuclear Uranus mission is presented. The PowerSail is a marriage of solar sails and thin-film solar cell assemblies. Herein the application of PowerSail spacecraft to a high priority science mission, the Applied Physics Laboratory’s Uranus Probe and Explorer, is studied. The overall mission design along with key subsystems design changes are discussed, ultimately showing that a PowerSail could be utilized as a non-nuclear option to reach destinations very deep in our solar system. Key needed technology developments to make the PowerSail and such a mission a reality are given.
The launch of a space shuttle is a complex and lengthy procedure. There are many places and components to look at and prepare. The components are the orbiter, solid rocket boosters, external tank, and ground equipment. Some of the places are the launch pad, fuel locations, and surrounding structures. Preparations for a launch include equipment checks, system checks, sniff checks for hazardous commodities, and countless walkdowns. Throughout these preparations, pad safety personnel must always be on call. This requires three shifts of multiple people to be ready when needed. Also, the pad safety personnel must be available for the non-launch tasks that are always present for both launch pads
General Aviation will benefit from turbine engines that are both fuel-efficient and reliable. Current engines fall short of their potential to achieve these attributes. The reason is compressor surge, which is a flow stability problem that develops when the compressor is subjected to conditions that are outside of its operating range. Compressor surge can occur when fuel flow to the engine is increased, temporarily back pressuring the compressor and pushing it past its stability limit, or when the compressor is subjected to inlet flow-field distortions that may occur during takeoff and landing. Compressor surge can result in the loss of an aircraft. As a result, engine designers include a margin of safety between the operating line of the engine and the stability limit line of the compressor. Unfortunately, the most efficient operating line for the compressor is usually closer to its stability limit line than it is to the line that provides an adequate margin of safety. A wider stable flow range will permit operation along the most efficient operating line of the compressor, improving the specific fuel consumption of the engine and reducing emissions. The NASA Glenn Research Center is working to extend the stable flow range of the compressor. Significant extension has been achieved in axial compressors by injecting air upstream of the compressor blade rows. Recently, the technique was successfully applied to a 4:1 pressure ratio centrifugal compressor by injecting streams of air into the diffuser. Both steady and controlled unsteady injection were used to inject air through the diffuser shroud surface and extend the range. Future work will evaluate the effect of air injection through the diffuser hub surface and diffuser vanes with the goal of maximizing the range extension while minimizing the amount of injected air that is required.
This investigation consists of a short-term feasibility study to determine whether or not an alternate electrical power source would trade favorably from a performance, reliability, safety, operation, and weight standpoint in replacing the current auxiliary power unit subsystems with its attendant components (water spray boiler, hydrazine fuel and tanks, feed and vent lines, controls, etc.), operating under current flight rules. Results of this feasibility study are used to develop recommendations for the next step (e.g., to determine if such an alternate electrical power source would show an advantage given that the current operational flight mode of the system could be modified in such a way as not to constrain the operational capability and safety of the vehicle). However, this next step is not within the scope of this investigation. This study does not include a cost analysis, nor does it include investigation of the integration aspects involved in such a trade, except in a qualitative sense for the determination of concept feasibility.
Impact-survivable postcrash fire accidents were surveyed. The data base developed includes foreign and domestic accidents involving airlines and jet aircraft. The emphasis was placed on domestic accidents, airlines, and jet aircraft due principally to availability of information. Only transport category aircraft in commercial service designed under FAR Part 25 were considered. A matrix was prepared to show the relationships between the accident characteristics and the fire fatalities. Typical postcrash fire scenaries were identified. Safety concepts were developed for three engineering categories: cabin interiors - cabin subsystems; power plant - engines and fuel systems; and structural mechanics - primary and secondary structures. The parameters identified for concept evaluation are cost, effectiveness, and societal concerns. Three concepts were selected for design definition and cost and effectiveness analysis: improved fire-resistant seat materials; anti-misting kerosene; and additional cabin emergency exits.
An overview is given of the plans for a program in nuclear electric propulsion (NEP) technology for outer space applications being considered by NASA, DOE, and DOD. Possible missions using NEP are examined, and NEP technology plans are addressed regarding concept development, systems engineering, nuclear fuels, power conversion, thermal management, power management and distribution, electric thrusters, facilities, and issues related to safety and environment. The programmatic characteristics are considered.