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NASA NTRS2019

Thermal, Avionics, and Power Considerations for Designing a Nuclear Thermal Propulsion Flight Demonstrator

As part of the Appropriations Bill passed by the US Congress in February 2019, NASA was instructed to develop a nuclear thermal propulsion (NTP) flight demonstrator by 2024. [4] In response to this directive, the Advanced Concepts Office (ACO) at Marshall Space Flight Center (MSFC) was tasked with beginning concept studies for the flight demonstration (FD) mission. During the NTP study formulation, two philoso- phies emerged with regards to FD concept design. The first, Flight Demo 1 (FD1), strictly observes the 2024 schedule requirement at the expense of lower engine performance than expected of theoretical NTP engines. The second concept, Flight Demo 2 (FD2), relaxes the schedule requirement to allow for higher engine performance and more traceability to future operational systems. Both the FD1 and FD2 concepts present considerable challenges for subsystem design, specifically in the areas of thermal control, avionics, and power. To guard against undesired graveyard orbits, a requirement to keep the NTP engine and the reaction control system (RCS) separate was put in place. As a result of this requirement, the avionics subsystem must provide separate command and data handling (CDH) and instrumentation for each propulsion system. In-space instrumentation and monitoring of a NTP system has never been done before, necessitating the development of novel strategies and unique hardware. The heating rates produced by the NTP engine are extremely high, leading to difficulties with thermal control. The FD1 concept utilizes high-pressure gaseous hydrogen (GH2), which is largely insensitive to temperature fluctuations. The FD2 concept, however, utilizes cryogenic liquid hydrogen (LH2) which must be kept stable near 20 Kelvin. A high-performance thermal control system (TCS) will be required to ensure all components and subsystems are maintained within their operational temperature ranges. This paper will highlight the thermal, avionics, and power solutions required for the full scope of challenges for a NTP flight demonstrator.

Johnson, W. E.↗
NASA NTRS2019

Commercialization and Human Settlement of the Moon and Cislunar Space Using ISRU, Fission Surface Power, and Advanced In-Space Propulsion Systems

Over 50 years have passed since themovie 2001: A Space Odyssey debuted in April 1968. In the film, Dr. Heywood Floyd flies to a large artificial gravity space station orbiting Earth aboard a commercial space plane. He then embarks on a commuter flight to the Moon arriving there 25 hours later. Today, on the 50th anniversary of the Apollo 11lunar landing, the images portrayed in 2001 remain well beyond our capabilities and 2100: A Space Odyssey seems a more appropriate title for Kubrick and Clarke's film. This paper looks at the key technologies, systems, and supporting infrastructure (in-situ resource utilization (ISRU), fission surface power (FSP), nuclear thermal propulsion (NTP), andorbiting propellant depots), that could be developed by NASA and the private sector over the next 30years allowing the operational capabilities presented in 2001 to be achieved, albeit on a more spartan scale.

Borowski, Stan↗
NASA NTRS2020

Enabling Deep Space Science Missions with Nuclear Thermal Propulsion

Nuclear thermal propulsion (NTP) enables entirely new classes of deep-space science missions to yield scientific returns that, in most cases, are simply not possible with traditional architectures. NTP systems can yield dramatically reduced interplanetary travel times, deliver roughly 2- 3 times (or more) the mass that can be delivered by conventional chemical propulsion systems, or provide a combination of these advantages to further enhance scientific return. Present NASA and DoD-sponsored plans for NTP systems will mature the technology using prototype and flight demonstration engines to prove the designs. These prototype engines will have performance in the correct thrust range so as to permit use as a low-risk propulsion stage in support of high-payoff deep space science missions. Additionally, the use of low-enriched Uranium (LEU) fuels over highly-enriched Uranium (HEU) fuels reduce the costs of engine development, qualification, acceptance and launch, and lowers the risks associated with proliferation management.

Kurt A Polzin↗
NASA NTRSDate not supplied

Design Reference Mission Development for Nuclear Thermal Propulsion Enabled Science Missions

Nuclear thermal propulsion (NTP) presents a distinct alternative in the advanced propulsion landscape, providing “medium” efficiencies relative to the “high” efficiency of electric propulsion and the “low” efficiency of chemical propulsion. In exchange for this medium efficiency, NTP provides high acceleration, enabling much shorter operating times than the higher efficiency alternatives, often resulting in shorter trip times. This compromise has led to NTP’s frequent consideration in human missions, where crew health and logistics benefit significantly from the schedule advantages provided by NTP. However, the logistics and timeliness of science return from science missions also potentially stand to benefit from reduced schedules, as many of the high energy missions exceed a decade in trip time. Presented here are the results of analysis looking at three missions: A mission to Neptune’s moon, Triton, a solar polar orbiter, and a mission to interstellar space. Comparisons to results found in literature for conventional, and future propulsion technologies are presented.

Stephen Edwards↗
NASA NTRSDate not supplied

Space Exploration Applications for Development of High Capacity Cryocoolers

Long term storage of cryogens is necessary to enable NASAs long duration crewed missions to both the lunar and Martian surfaces. Such missions require in-space transport systems such as Nuclear Thermal Propulsion (NTP), and descent/ascent vehicles for transportation to and from the lunar and Martian surfaces. NTP systems and Lunar/Martian landers utilize cryogenic fluids to minimize architectural volume and mass. To further enhance the capability of these cryogenic systems, the Agency is putting emphasis on reusability, which requires the NTP and ascent/descent elements be replenished on-orbit via tankers or propellant depots, or on the lunar or Martian surface using liquefied in-situ produced propellants. NTP is one of the leading propulsion option for human Mars missions and requires liquid hydrogen to be stored on-orbit for over four years. For such a long duration mission, near “Zero Boil-Off” (ZBO) must be achieved which requires an optimized suite of passive Cryogenic Fluid Management technologies and active cooling (cryocoolers). Tens of Watts of 20K cooling is required to achieve ZBO conditions for NTP, however two-stage cooling using both 20K and 90K systems can lead to a significant reduction in both active cooling mass and power. The use of in-situ resources for lunar and Martian missions will require 150 Watts of 90K cooling for oxygen liquefaction and 300 Watts of 20K cooling for hydrogen liquefaction (lunar only). Descent/Ascent vehicles, propellant depots, and tankers will also require the use of cryocoolers to achieve ZBO conditions. To support these programs, NASA is developing high capacity 20K and 90K reverse turbo-Brayton cycle cryocoolers which offer a scalable, high efficiency, low vibration solution.

cryocooler↗
NASA NTRSDate not supplied

Fuel and Moderator Development Strategy for NEP Systems

Nuclear electric propulsion (NEP)-powered vehicles have been contemplated for human Mars missions. The nuclear power system contemplates using a high temperature light-weight nuclear reactor for the production of electrical power in the range of 2-5 MWe with a 3-10 year service life. There are several reactor and moderator options that exist for an NEP reactor with these operational needs. One option under consideration is a hydride moderated reactor using a fuel comprised of high assay low enriched uranium (HALEU) compounds. The NEP fuel-moderator mixtures share development challenges with NASA’s Nuclear Thermal Propulsion (NTP) and Fission Surface Power (FSP) projects. The operational requirements also align well with development and investments in commercial microreactorsolutions. This paper will describe a structured approach for developing a multi-year strategy for maturing NEP fuel and moderator materials. Touchpoints where NASA could benefit from and be of benefit to the ongoing commercial investments are also described and discussed.

Dasari V Rao↗
NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Zirconium Carbide Additive Manufacture↗
NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Zirconium Carbide Additive Manufacture↗
NASA NTRSDate not supplied

Establishing the Feasibility of the Centrifugal Nuclear Thermal Rocket

The Centrifugal Nuclear Thermal Rocket (CNTR) is a Nuclear Thermal Propulsion (NTP) concept designed to heat propellant directly by the reactor fuel. The primary difference between the CNTR concept and traditional NTP systems is that rather than using traditional solid fuel elements, the CNTR uses liquid fuel with the liquid contained in rotating cylinders by centrifugal force. If the concept can be successfully realized, the CNTR would have a high specific impulse (~1800 s) at high thrust, which may enable viable near-term human Mars exploration by reducing round-trip times to ~420 days. The CNTR could also use storable propellants such as ammonia, methane, or hydrazine at an Isp of ~900 s, enabling long-term in-space storage of a dormant system. Significant engineering challenges must be addressed to establish the technical viability of the CNTR, and the plan for addressing these engineering challenges is the subject of this paper.

Dale Thomas↗
NASA NTRSDate not supplied

20 Watt 20 Kelvin Reverse Turbo-Brayton Cycle Cryocooler Testing and Applications

Long-term storage of cryogens is an essential capability required to enable NASA’s anticipated missions to both the Lunar and Martian surfaces. A key component to furthering these capabilities is the development of a high capacity, low temperature cryocooler to allow for zero-boil-off storage of liquid hydrogen propellant. The technology being developed by NASA to meet this objective is a reverse turbo-Brayton cycle cryocooler capable of removing 20 Watts (W) of heat at 20 Kelvin (K). This hardware was recently tested at Creare LLC in a vacuum chamber to simulate a relevant mission environment. This testing demonstrated the hardware’s functionality and established a baseline for the cryocooler’s capabilities. Additional NASA led characterization testing is underway and will provide a broader picture of the operational capability of the cryocooler. This paper will discuss the results of this recent testing, along with highlighting the applications for high capacity cryocoolers on future NASA missions, such as Nuclear Thermal Propulsion (NTP) and a sustainable lunar architecture.

Cryocooler↗
NASA NTRSDate not supplied

Low Leakage Valves for Long Duration Missions

I.Nomenclaturemtypical_mission=internal mass of propellant lost over the course of a mission with Qtypicalmmission_goal=mass of propellant loss over the course of a mission with Qgoaltmission=theoretical mission durationQtypical=internal leakage rate found in commercially available valvesQgoal=internal leakage rate design goalρH2_STP=density of hydrogen at standard temperature and pressure.1NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)2NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)3NASA AST, Liquid Propulsion Valve Engineer (Retired).Valves, Actuators, and Ducts Design and Development Branch (ER14)4JSEG ESSCA, Engineering Specialist.Valves Actuators and Ducts Design and Development Branch (ER14)5NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)6JSEG ESSCA, Valve Design and Development Engineer.Valves Actuators and Ducts Design and Development Branch (ER14) II.IntroductionCurrent aerospace cryogenic valves present challenges to potential long duration missions that utilize cryogenic propellants. Small interplanetary and long-life communication satellites typically utilize hypergolic propellants that operate at higher temperatures, making it easier to achieve very low internal leakage rates. Larger vehicles for long duration missions will likely need to utilize cryogenic-based chemical and nuclear systems to achieve mission requirements. Some early propulsion concepts are projected to require valves with a nominal size ranging from 3” to 10”.Currently available cryogenic aerospace valves typically have internal leakage rates which can range from 100 to 300 SCIM for 3” valves, or upwards of 2,000 SCIM for 10” valves. With just a few of these valves in a system, internal leakage could account for multiple tons of propellant loss over the course of a potential Mars mission, as shown in Figure 1.Figure 1 - Potential Propellant Loss Over the Course of a Long Duration MissionMost internal leakage rates can be attributed to inherent imperfections and misalignments, which result in imperfect contact between sealing surfaces, as shown in Figure 2.Figure 2 - Imperfections and Misalignments Between Sealing Surfaces The ER14 Branch at Marshall Space Flight Center (MSFC) has created a self-aligning seat and poppet design (shown in Figure 3) that allows a valve to be more tolerant of imperfect contacts. This design utilizes a metallic poppet head with five degrees of freedom that allows the poppet toself-align with the seat, reducing the need for tight tolerances.Figure 3 - Self-Aligning Seat and Poppet DesignIII.Test Valve DescriptionA series of development tasks have been conducted to study potential improvements to internal leakage rates. These tasks include 3 test valves (shown in Figure 4) to demonstrate the potential application to various configurations and sizes:A 3” isolation valve for liquid flows (similar to a fill and drain valve)A 3” relief valve for low temperature gas flows.An 8” pre-valve (similar to the engine isolation valve needed on a Nuclear Thermal Propulsion (NTP) engine).Figure 4 - Low Leakage Development Test ValvesThese valves have been developed and are currently being tested at liquid nitrogen (LN2) temperatures, and are anticipated to undergo testing at liquid hydrogen (LH2) temperatures in late 2022

Cody L Gilliland↗
NASA NTRSDate not supplied

Coupled Reactor and Engine Nuclear Thermal Propulsion Modeling Methodology

The design and development process of a Nuclear Thermal Propulsion (NTP) system requires extensive multiphysics modeling to couple the neutron physics and thermal feedback effects to determine the reactor’s power shape. Propulsion system performance codes utilize this power shape to determine NTP key performance parameters. While the power shape is heavily dependent on the temperature profile and geometry of the reactor, many analyses either assume a constant power shape, or use neutronics analysis to determine a power shape for a specific reactor configuration. The development of a coupling interface for a propulsion system performance code and a Monte Carlo neutron transport code (OpenMC) allows for the reactor power shape to be calculated in a Picard iteration.

Jacob Stonehill↗
NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

Cryogenic Propellant Transfer↗
NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

cryogenic propellant transfer↗
NASA NTRSDate not supplied

Coupled Reactor and Engine Nuclear Thermal Propulsion Modeling Methodology

The design and development process of a Nuclear Thermal Propulsion (NTP) system requires extensive multiphysics modeling to couple the neutron physics and thermal feedback effects to determine the reactor’s power shape. Propulsion system performance codes utilize this power shape to determine NTP key performance parameters. While the power shape is heavily dependent on the temperature profile and geometry of the reactor, many analyses either assume a constant power shape, or use neutronics analysis to determine a power shape for a specific reactor configuration. The development of a coupling interface for a propulsion system performance code and a Monte Carlo neutron transport code (OpenMC) allows for the reactor power shape to be calculated in an iteration loop. The interface utilizes a file share system to transfer geometry dimensions, temperatures, and material identifiers to OpenMC, which is used to perform a neutron transport simulation of a design like the government Testing Reference Design reactor. The interface is then able to post-process the results from OpenMC and use the same file share system to share a power shape and other important neutron transport parameters to the system performance code. Initial results show that neglecting the changes to power shape when comparing reactor configurations can yield inaccurate results. Furthermore, utilizing propellants other than hydrogen gas can cause significant changes to the power shape, and thus, the thermal performance of a specific reactor design. This methodology is being expanded to allow for multiple families of NTP reactors to be analyzed, including block moderator, particle bed, and NERVA-derived reactors.

multiphysics coupling↗
NASA NTRSDate not supplied

Coupled Reactor and Engine Nuclear Thermal Propulsion Modeling Methodology

The design and development process of a Nuclear Thermal Propulsion (NTP) system requires extensive multiphysics modeling to couple the neutron physics and thermal feedback effects to determine the reactor’s power shape. Propulsion system performance codes utilize this power shape to determine NTP key performance parameters. While the power shape is heavily dependent on the temperature profile and geometry of the reactor, many analyses either assume a constant power shape, or use neutronics analysis to determine a power shape for a specific reactor configuration. The development of a coupling interface for a propulsion system performance code and a Monte Carlo neutron transport code (OpenMC) allows for the reactor power shape to be calculated in an iteration loop. The interface utilizes a file share system to transfer geometry dimensions, temperatures, and material identifiers to OpenMC, which is used to perform a neutron transport simulation of a design like the government Testing Reference Design reactor. The interface is then able to post-process the results from OpenMC and use the same file share system to share a power shape and other important neutron transport parameters to the system performance code. Initial results show that neglecting the changes to power shape when comparing reactor configurations can yield inaccurate results. Furthermore, utilizing propellants other than hydrogen gas can cause significant changes to the power shape, and thus, the thermal performance of a specific reactor design. This methodology is being expanded to allow for multiple families of NTP reactors to be analyzed, including block moderator, particle bed, and NERVA-derived reactors.

multiphysics coupling↗
NASA NTRSDate not supplied

Sensitivity Analysis of Heat Rejection and Propellant Management Technologies for Nuclear Thermal Propulsion Architectures

Cryogenic fluid management (CFM) technologies are very important for enabling a wider range of missions to utilize space nuclear propulsion (SNP) concepts such as nuclear thermal propulsion (NTP). Technologies for thermal and cryogenic propellant management allow for vehicles to take full advantage of the higher efficiency NTP systems for longer duration human interplanetary and deep space robotic missions. Currently, the CFM Portfolio Project at NASA’s Marshall Space Flight Center (MSFC) is developing thermal and propellant management technologies needed for SNP. When developing these technologies, it is important to understand the sensitivities of key performance parameters (KPPs) at the system and overall mission level due to the ways the technologies interact with each other, other subsystems, and influence the overall vehicle. The Advanced Concepts Office (ACO) at NASA-MSFC was tasked with building an integrated system model of a human Mars NTP mission to evaluate the impacts and sensitivities of CFM technologies on the overall vehicle and mission. This paper will cover the buildup of the model and highlight major sensitivities and breakpoints encountered, as well as future work in improving the existing models and sensitivities being evaluated.

Robert J. Hetterich↗
NASA NTRS2024

Parahydrogen Thermophysical Properties V05 Final Report

The NASA Space Nuclear Propulsion (SNP) Program works to mature both nuclear electric and nuclear thermal propulsion capabilities. The nuclear thermal propulsion (NTP) sub-effort focuses on development of technologies enabling human exploration of Mars – with a nominal performance target of 900 second vacuum specific impulse (Ivac). This Ivac target demands a hydrogen (molecular hydrogen, or dihydrogen) monopropellant NTP engine system, as other propellant choices fall well short of this target for realistically attainable reactor system temperatures (< 3000 K).

Parahydrogen↗