SEARCH · Search NASA
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Engineering details are presented for a magnetized target fusion (MTF) propulsion system designed to support crewed missions to the outer solar system. Structural, thermal and radiation-management design details are presented. Propellant storage and supply options are also discussed and a propulsion system mass estimate is given.
As NASA begins exploration of other planets, a method of non-propulsively slowing vehicles at the planet, aerobraking, may become a valuable technique for managing vehicle design mass and propellant. An example of this is Mars Reconnaissance Orbiter (MRO), which will launch in late 2005 and reach Mars in March of 2006. In order to save propellant, MRO will use aerobraking to modify the initial orbit at Mars. The spacecraft will dip into the atmosphere briefly on each orbit, and during the drag pass, the atmospheric drag on the spacecraft will slow it, thus lowering the orbit apoapsis. The largest area on the spacecraft, and that most affected by the heat generated during the aerobraking process, is the solar arrays. A thermal analysis of the solar arrays was conducted at NASA Langley, to simulate their performance throughout the entire roughly 6-month period of aerobraking. Several interesting methods were used to make this analysis more rapid and robust. Two separate models were built for this analysis, one in Thermal Desktop for radiation and orbital heating analysis, and one in MSC.Patran for thermal analysis. The results from the radiation model were mapped in an automated fashion to the Patran thermal model that was used to analyze the thermal behavior during the drag pass. A high degree of automation in file manipulation as well as other methods for reducing run time were employed, since toward the end of the aerobraking period the orbit period is short, and in order to support flight operations the runs must be computed rapidly. All heating within the Patran Thermal model was combined in one section of logic, such that data mapped from the radiation model and aeroheating model, as well as skin temperature effects on the aeroheating and surface radiation, could be incorporated easily. This approach calculates the aeroheating at any given node, based on its position and temperature as well as the density and velocity at that trajectory point. Run times on several different processors, computer hard drives, and operating systems (Windows versus Linux) were evaluated.
In order to support long duration cryogenic propellant storage, the Cryogenic Fluid Management (CFM) Project of the Exploration Technology Development Program (ETDP) is investigating the long duration storage propertie$ of liquid methane on the lunar surface. The Methane Lunar Surface Thermal Control (MLSTC) testing is using a tank of the approximate dimensions of the Altair ascent tanks inside of a vacuum chamber to simulate the environment in low earth orbit and on the lunar surface. The thermal performance testing of multilayer insulation (MLI) coupons that are fabricated identically to the tank applied insulation is necessary to understand the performance of the blankets and to be able to predict the performance of the insulation prior to testing. This coupon testing was completed in Cryostat-100 at the Cryogenics Test Laboratory. The results showed the properties of the insulation as a function of layer density, number of layers, and warm boundary temperature. These results aid in the understanding of the performance parameters o fMLI and help to complete the body of literature on the topic.
Human missions to Mars will require next generation solar electric propulsion (SEP) systems that can operate at power levels of 300 kW or higher to efficiently transport crew and cargo. In the mid-2020s, NASA is planning to launch the Deep Space Gateway (DSG), which is a crew-tended habitat that will be placed in orbit around the Moon. NASA is developing 12.5 kW Hall thrusters for the DSG. In the late 2020s, the DSG will be followed by a second vehicle, called the Deep Space Transport (DST), which will simulate a crewed Mars mission in cislunar space. In parallel with the 12.5 kW thrusters for the DSG, NASA is initiating development of 100 kW thrusters for potential demonstration on the DST. In 2016, NASA issued a Next Space Technologies for Exploration Partnerships (NextSTEP) Broad Agency Announcement to solicit proposals for development of high-power electric thrusters. The partnerships require at least 50 percent cost sharing by the companies. Three companies were selected for development activities lasting up to three years: Ad Astra, Aerojet Rocketdyne, and MSNW. Ad Astra is developing a Variable Specific Impulse Magnetoplasma Rocket (VASIMR), Aerojet Rocketdyne is developing a Nested Hall Thruster (NHT), and MSNW is developing an Electrodeless Lorentz Force (ELF) plasma thruster. The primary goal of these activities is to operate the thrusters at 100 kW for 100 continuous hours in a vacuum chamber. In addition to the thrusters, the companies are developing Power Processing Units (PPUs), propellant feed systems, and thermal management systems. This presentation will describe the three activities, the progress they have made in achieving the primary testing goal, the technical challenges they have encountered, and discuss the importance of extensibility.
Traditional in-space propulsion systems use storable propellants, such as MMH/NTO, for applications beyond Low Earth Orbit (LEO). Modern advancements in Cryogenic Fluid Management (CFM) technologies opens the door for use of more efficient cryogenic propellants, such as LOX/LCH4 or LOX/LH2, in these long-duration missions beyond LEO. As these Main Propulsion Systems (MPS) transition to cryogenic propellants, a cryogenic solution for Reaction Control Systems (RCS) becomes attractive for several reasons. A mixed-fluid vehicle solution with cryogenic (cool) MPS and storable (warm) RCS complicates thermal management. Additionally, a vehicle with common cryogenic propellant across the MPS and RCS could take advantage of shared hardware such as tanks, thermal management equipment, and pressurization system, reducing mass and development time. The fluid system design proposed in this presentation features shared hardware, leading to the designation of Cryogenic Integrated Reaction Control System (iRCS). The iRCS design stores cryogenic propellant in the low-pressure (10’s psia) MPS tanks, creates steady high-pressure (100’s psia) flow through an electric pump (e-pump), feeds pulse-firing RCS thrusters, and returns any excess flow to the tank through a pressure control device on a recirculation line. This iRCS design is inspired by the automotive fuel-rail, where similar elevated-pressure and pulse-firing requirements are levied. This design has several inherent advantages. Because this design is pump-fed rather than pressure-fed, heavy, high-pressure propellant storage is not required. The RCS propellant can therefore be stored by increasing MPS tank volume. Furthermore, by increasing the pressure of the circulated fluid through an e-pump, the propellant quality moves further into the sub-cooled regime. Sub-cooled liquid is desirable for accurate pressure and flow control at the thruster inlet. Lastly, the iRCS allows the distribution system hardware to maintain cryogenic temperatures by slowly recirculating liquid in a low-energy “Idle Mode”. Altogether, the iRCS concept enables a more efficient cryogenic vehicle design.
Traditional in-space propulsion systems use storable propellants, such as MMH/NTO, for applications beyond Low Earth Orbit (LEO). Modern advancements in Cryogenic Fluid Management (CFM) technologies opens the door for use of more efficient cryogenic propellants, such as LOX/LCH4 or LOX/LH2, in these long-duration missions beyond LEO. As these Main Propulsion Systems (MPS) transition to cryogenic propellants, a cryogenic solution for Reaction Control Systems (RCS) becomes attractive for several reasons. A mixed-fluid vehicle solution with cryogenic (cool) MPS and storable (warm) RCS complicates thermal management. Additionally, a vehicle with common cryogenic propellant across the MPS and RCS could take advantage of shared hardware such as tanks, thermal management equipment, and pressurization system, reducing mass and development time. The fluid system design proposed in this presentation features shared hardware, leading to the designation of Cryogenic Integrated Reaction Control System (iRCS). The iRCS design stores cryogenic propellant in the low-pressure (10’s psia) MPS tanks, creates steady high-pressure (100’s psia) flow through an electric pump (e-pump), feeds pulse-firing RCS thrusters, and returns any excess flow to the tank through a pressure control device on a recirculation line. This iRCS design is inspired by the automotive fuel-rail, where similar elevated-pressure and pulse-firing requirements are levied. This design has several inherent advantages. Because this design is pump-fed rather than pressure-fed, heavy, high-pressure propellant storage is not required. The RCS propellant can therefore be stored by increasing MPS tank volume. Furthermore, by increasing the pressure of the circulated fluid through an e-pump, the propellant quality moves further into the sub-cooled regime. Sub-cooled liquid is desirable for accurate pressure and flow control at the thruster inlet. Lastly, the iRCS allows the distribution system hardware to maintain cryogenic temperatures by slowly recirculating liquid in a low-energy “Idle Mode”. Altogether, the iRCS concept enables a more efficient cryogenic vehicle design.
To test and validate key capabilities and technologies required for future exploration elements such as large cryogenic propulsion stages and propellant depots, NASA is leading the efforts to develop and design the Cryogenic Propellant Storage and Transfer (CPST) Cryogenic Fluid Management (CFM) payload. The primary objectives of CPST payload are to demonstrate: 1) in-space storage of cryogenic propellants for long duration applications; and 2) in-space transfer of cryogenic propellants. The Ground Test Article (GTA) is a technology development version of the CPST payload. The GTA consists of flight-sized and flight-like storage and transfer tanks, liquid acquisition devices, transfer, and pressurization systems with all of the CPST functionality. The GTA is designed to perform integrated passive and active thermal storage and transfer performance testing with liquid hydrogen (LH2) in a vacuum environment. The GTA storage tank is designed to store liquid hydrogen and the transfer tank is designed to be 5% of the storage tank volume. The LH2 transfer subsystem is designed to transfer propellant from one tank to the other utilizing pressure or a pump. The LH2 vent subsystem is designed to prevent over-pressurization of the storage and transfer tanks. An in-house general-purpose computer program was utilized to model and simulate the vent subsystem operation. The modeling, analysis, and the results will be presented in the final paper.
In support of its goal to find an innovative path for human space exploration, NASA embarked on the Cryogenic Propellant Storage and Transfer (CPST) Project, a Technology Demonstration Mission (TDM) to test and validate key cryogenic capabilities and technologies required for future exploration elements, opening up the architecture for large in-space cryogenic propulsion stages and propellant depots. Recognizing that key Cryogenic Fluid Management (CFM) technologies anticipated for on-orbit (flight) demonstration would benefit from additional maturation to a readiness level appropriate for infusion into the design of the flight demonstration, the NASA Headquarters Space Technology Mission Directorate (STMD) authorized funding for a one-year technology maturation phase of the CPST project. The strategy, proposed by the CPST Project Manager, focused on maturation through modeling, concept studies, and ground tests of the storage and fluid transfer of CFM technology sub-elements and components that were lower than a Technology Readiness Level (TRL) of 5. A technology maturation plan (TMP) was subsequently approved which described: the CFM technologies selected for maturation, the ground testing approach to be used, quantified success criteria of the technologies, hardware and data deliverables, and a deliverable to provide an assessment of the technology readiness after completion of the test, study or modeling activity. The specific technologies selected were grouped into five major categories: thick multilayer insulation, tank applied active thermal control, cryogenic fluid transfer, propellant gauging, and analytical tool development. Based on the success of the technology maturation efforts, the CPST project was approved to proceed to flight system development.
The NASA Advanced Exploration Systems (AES) program has a three year project to develop and demonstrate technologies to fundamentally change the way ground servicing activities support future access to space architectures. The AES Integrated Ground Operation Demonstration Units (IGODU) project has created two test beds for investigating and maturing two key elements of spaceport processing activities. The first is the GODU Integrated Refrigeration and Storage test bed that is demonstrating zero-loss storage of liquid hydrogen propellants and studying the storage and transfer of densified propellants. The second activity is the GODU Autonomous Control test bed that is implementing health management technologies and autonomous control capability of the propellant loading process to reduce the standing army of experts historically needed to ensure safe propellant loading operations. This presentation will give an overview of the activities at the Kennedy Space Center on these two test beds and its potential impact on future access to space programs.
A Technology Plan for Enabling Commercial Space Business was presented at the 48th International Astronautical Congress in Turin, Italy. This paper presents a status of the program's accomplishments. Technology demonstrations have progressed in each of the four elements of the program; (1) Low Cost Technology, (2) Advanced Reusable Technology, (3) Space Transfer Technology and (4) Space Transportation Research. The Low Cost Technology program element is primarily focused at reducing development and acquisition costs of aerospace hardware using a "design to cost" philosophy with robust margins, adapting commercial manufacturing processes and commercial off-the-shelf hardware. The attributes of this philosophy for small payload launch are being demonstrated at the component, sub-system, and system level. The X-34 "Fastrac" engine has progressed through major component and subsystem demonstrations. A propulsion system test bed has been implemented for system-level demonstration of component and subsystem technologies; including propellant tankage and feedlines, controls, pressurization, and engine systems. Low cost turbopump designs, commercial valves and a controller are demonstrating the potential for a ten-fold reduction in engine and propulsion system costs. The Advanced Reusable Technology program element is focused on increasing life through high strength-to-weight structures and propulsion components, highly integrated propellant tanks, automated checkout and health management and increased propulsion system performance. The validation of rocket based combined cycle (RBCC) propulsion is pro,-,ressing through component and subsystem testing. RBCC propulsion has the potential to provide performance margin over an all rocket system that could result in lower gross liftoff weight, a lower propellant mass fraction or a higher payload mass fraction. The Space Transfer Technology element of the program is pursuing technology that can improve performance and dramatically reduce the propellant and structural mass of orbit transfer and deep space systems. Flight demonstration of ion propulsion is progressing towards launch. Ion propulsion is the primary propulsion for Deep Space 1; a flyby of comet West-kohoutek-lkemura and asteroid 3352 McAuliffe. Testing of critical solar-thermal propulsion subsystems have been accomplished and planning is continuing for the flight demonstration of an electrodynamic tether orbit transfer system. The forth and final element of the program, Space Transportation Research, has progressed in several areas of propulsion research. This element of the program is focused at long-term (25 years) breakthrough concepts that could bring launch costs to a factor of one hundred below today's cost or dramatically expand planetary travel and enable interstellar travel.
In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.
Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.
NASA's near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center's (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC's Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA's CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.
Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.
NASA is designing an unmanned submarine to explore the depths of the hydrocarbon-rich seas on Saturn's moon Titan. Data from Cassini indicates that the Titan north polar environment sustains stable seas of variable concentrations of ethane, methane, and nitrogen, with a surface temperature near 93 K. The submarine must operate autonomously, study atmosphere/sea exchange, interact with the seabed, hover at the surface or any depth within the sea, and be capable of tolerating variable hydrocarbon compositions. Currently, the main thermal design concern is the effect of effervescence on submarine operation, which affects the ballast system, science instruments, and propellers. Twelve effervescence measurements on various liquid methane-ethane compositions with dissolved gaseous nitrogen are thus presented from 1.5 bar to 4.5 bar at temperatures from 92 K to 96 K to simulate the conditions of the seas. After conducting effervescence measurements, two freezing point depression measurements were conducted. The freezing liquid line was depressed more than 15 K below the triple point temperatures of pure ethane (90.4 K) and pure methane (90.7 K). Experimental effervescence measurements will be used to compare directly with effervescence modeling to determine if changes are required in the design of the thermal management system as well as the propellers.
The Green Propellant Loading Demonstration (GPLD) was conducted December 2015 at Wallops Flight Facility (WFF), leveraging work performed over recent years to bring lower toxicity hydrazine replacement green propellants to flight missions. The objective of this collaboration between NASA Goddard Space Flight Center (GSFC), WFF, the Swedish National Space Board (SNSB), and Ecological Advanced Propulsion Systems (ECAPS) was to successfully accept LMP-103S propellant at a U.S. Range, store the propellant, and perform a simulated flight vehicle propellant loading. NASA GSFC Propulsion (Code 597) managed all aspects of the operation, handling logistics, preparing the procedures, and implementing the demonstration. In addition to the partnership described above, Moog Inc. developed an LMP-103S propellant-compatible titanium rolling diaphragm flight development tank and loaned it to GSFC to act as the GPLD flight vessel. The flight development tank offered the GPLD an additional level of flight-like propellant handling process and procedures. Moog Inc. also provided a compatible latching isolation valve for remote propellant expulsion. The GPLD operation, in concert with Moog Inc. executed a flight development tank expulsion efficiency performance test using LMP-103S propellant. As part of the demonstration work, GSFC and WFF documented Range safety analyses and practices including all elements of shipping, storage, handling, operations, decontamination, and disposal. LMP-103S has not been previously handled at a U.S. Launch Range. Requisite for this activity was an LMP-103S Risk Analysis Report and Ground Safety Plan. GSFC and WFF safety offices jointly developed safety documentation for application into the GPLD operation. The GPLD along with the GSFC Propulsion historical hydrazine loading experiences offer direct comparison between handling green propellant versus safety intensive, highly toxic hydrazine propellant. These described motives initiated the GPLD operation in order to investigate the handling and process safety variances in project resources between LMP-103S and typical in-space propellants. The GPLD risk reduction operation proved successful for many reasons including handling the green propellant at a U.S. Range, loading and pressurizing a flight-like tank, expelling the propellant, measuring the tank expulsion efficiency, and most significantly, GSFC propulsion personnel's new insight into the LMP-103S propellant handling details.
The Green Propellant Loading Demonstration (GPLD) was conducted December 2015 at Wallops Flight Facility (WFF), leveraging work performed over recent years to bring lower toxicity hydrazine replacement green propellants to flight missions. The objective of this collaboration between NASA Goddard Space Flight Center (GSFC), WFF, the Swedish National Space Board (SNSB), and Ecological Advanced Propulsion Systems (ECAPS) was to successfully accept LMP-103S propellant at a U.S. Range, store the propellant, and perform a simulated flight vehicle propellant loading. NASA GSFC Propulsion (Code 597) managed all aspects of the operation, handling logistics, preparing the procedures, and implementing the demonstration. In addition to the partnership described above, Moog Inc. developed an LMP-103S propellant-compatible titanium rolling diaphragm flight development tank and loaned it to GSFC to act as the GPLD flight vessel. The flight development tank offered the GPLD an additional level of flight-like propellant handling process and procedures. Moog Inc. also provided a compatible latching isolation valve for remote propellant expulsion. The GPLD operation, in concert with Moog Inc. executed a flight development tank expulsion efficiency performance test using LMP-103S propellant. As part of the demonstration work, GSFC and WFF documented Range safety analyses and practices including all elements of shipping, storage, handling, operations, decontamination, and disposal. LMP-103S has not been previously handled at a U.S. Launch Range. Requisite for this activity was an LMP-103S Risk Analysis Report and Ground Safety Plan. GSFC and WFF safety offices jointly developed safety documentation for application into the GPLD operation. The GPLD along with the GSFC Propulsion historical hydrazine loading experiences offer direct comparison between handling green propellant versus safety intensive, highly toxic hydrazine propellant. These described motives initiated the GPLD operation in order to investigate the handling and process safety variances in project resources between LMP-103S and typical in-space propellants. The GPLD risk reduction operation proved successful for many reasons including handling the green propellant at a U.S. Range, loading and pressurizing a flight-like tank, expelling the propellant, measuring the tank expulsion efficiency, and most significantly, GSFC propulsion personnel's new insight into the LMP-103S propellant handling details.
NASA’s near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center’s (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC’s Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA’s CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.