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Mars Ascent Vehicle Study Summary: Potential Mars Sample Return Campaign; Assumptions; Motor Sizing; Propellant Selection; Nozzle and Controls; Development and Qualification Testing; Future Work.
The present study, based on a NASA technology assessment, examines the effect of new technologies on trends in crew-systems design and their implications from the vantage point of man-vehicle systems research. Those technologies that are most relevant to future trends in crew-systems design are considered along with problems associated with the introduction of rapidly changing technologies and systems concepts from a human-factors point of view. The technologies discussed include information processing, displays and controls, flight and propulsion control, flight and systems management, air traffic control, training and simulation, and flight and resource management. The historical evolution of cockpit systems design is used to illustrate past and possible future trends in man-vehicle systems research.
The testing of a rocket engine oxygen turbopump using high pressure ambient temperature nitrogen and oxygen as the turbine drive gas in separate test series is discussed. The pumped fluid was liquid nitrogen or liquid oxygen. The turbopump (TPA) is designed to operate with 400 F oxygen turbine drive gas which will be demonstrated in a subsequent test series. Following bearing tests, the TPA was finish machined (impeller blading and inlet/outlet ports). Testing started on 15 February 1989 and was successfully concluded on 21 March 1989. Testing started using nitrogen to reduce the ignition hazard during initial TPA checkout. The Hydrostatic Bearing System requires a Bearing Pressurization System. Initial testing used a separate bearing supply to prevent a rubbing start. Two test series were successfully completed with the bearing assist supplied only by the pump second stage output which entailed a rubbing start until pump pressure builds up. The final test series used ambient oxygen drive and no external bearing assist. Total operating time was 2268 seconds. There were 14 starts without bearing assist and operating speeds up to 80,000 rpm were logged. Teardown examination showed some smearing of silverplated bearing surfaces but no exposure of the underlying monel material. There was no evidence of melting or oxidation due to the oxygen exposure. The articulating, self-centering hydrostatic bearing exhibited no bearing load or stability problems. The only anomaly was higher than predicted flow losses which were attributed to a faulty ring seal. The TPA will be refurbished prior to the 400 F oxygen test series but its condition is acceptable, as is, for continued operating. This was a highly successful test program.
The design, fabrication, and initial testing of a rocket engine turbopump (TPA) for the delivery of high pressure liquid oxygen using hot oxygen for the turbine drive fluid are described. This TPA is basic to the dual expander engine which uses both oxygen and hydrogen as working fluids. Separate tasks addressed the key issue of materials for this TPA. All materials selections emphasized compatibility with hot oxygen. The OX TPA design uses a two-stage centrifugal pump driven by a single-stage axial turbine on a common shaft. The design includes ports for three shaft displacement/speed sensors, various temperature measurements, and accelerometers.
The following subject areas are covered: majority of propulsion technology development work is directly related to the ESA's Ariane 5 program and heavily involves SEP (Societe Europeenne de Propulsion) in all areas; Hermes; advanced work on magnetic bearings for turbomachinery; electric propulsion using Cs and Xe propellants done by SEP in France, MBB ERNO in West Germany, and by Culham Lab in UK; successfully tested fired H/O composite nozzle exit cone on 3rd stage of Ariane; turbine blades made of composites to allow increase in gas temperature and improvement in efficiency; combined cycle (turboramjet-rocket) engine analysis work done by Hyperspace; and ESA advanced program studies.
Recent advances in computational fluid mechanics are discussed in reviews and reports. Sections are devoted to (1) the modeling of local phenomena and edge effects in solids, (2) stochastic modeling and simulation of fracture toughness, and (3) partitioning strategy and new finite elements. Particular attention is given to global and local finite-element/spectral-boundary-element techniques for failure analysis, simulations of microfracture in metal-matrix composites, fatigue analysis of cracked anisotropic plates under stochastic loading, mathematical modeling for the analysis of nonlinear aircraft dynamics, physical and mathematical modeling of wave propagation in the Ariane 5 VEB structure, partitioning based on symmetry transformations, an FEM approach to adaptive reliability assurance, and time-domain FEMs for the large rotational dynamics of multibody systems.
This report covers the work done in preparation for a liquid oxygen rocket engine turbopump test utilizing high pressure hot oxygen gas for the turbine drive. The turbopump (TPA) is designed to operate with 400 F oxygen turbine drive gas. The goal of this test program was to demonstrate the successful operation of the TPA under simulated engine conditions including the hot oxygen turbine drive. This testing follows a highly successful series of tests pumping liquid oxygen with gaseous nitrogen as the turbine drive gas. That testing included starting of the TPA with no assist to the hydrostatic bearing. The bearing start entailed a rubbing start until the pump generated enough pressure to support the bearing. The articulating, self-centering hydrostatic bearing exhibited no bearing load or stability problems. The TPA was refurbished for the hot gas drive tests and facility work was begun, but unfortunately funding cuts prohibited the actual testing.
Fulfillment of the exploration vision will require new cross-mission directorate and multi-technical discipline synergies in order to achieve the necessary long-term sustainability. In part, lessons from the Apollo-era, as well as more recent research efforts, suggest that the aeronautics and specifically the vertical lift research community can and will make significant contributions to the exploration effort. A number of notional concepts and associated technologies for such contributions are outlined.
No abstract available
Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.
This paper describes in brief the architecture, applications, and operating theory of BEAM.
Technology available for gears used in advanced Orbital Transfer Vehicle rocket engines and the design of a cryogenic adapted tester used for evaluating advanced gears are presented. The only high-speed, unlubricated gears currently in cryogenic service are used in the RL10 rocket engine turbomachinery. Advanced rocket engine gear systems experience operational load conditions and rotational speed that are beyond current experience levels. The work under this task consisted of a technology assessment and requirements definition followed by design of a self-contained portable cryogenic adapted gear test rig system.
The Hypersonics Investment Area (HIA) within NASA's Advanced Space Transportation Program (ASTP) has the responsibility to develop hypersonic airbreathing vehicles for access to space. The Airframe Research and Technology (AR and T) Project, as one of six projects in the HIA, will push the state-of-the-art in airframe and vehicle systems for low-cost, reliable, and safe space transportation. The individual technologies within the project are focused on advanced, breakthrough technologies in airframe and vehicle systems and cross-cutting activities that are the basis for improvements in these disciplines. Both low and medium technology readiness level (TRL) activities are being pursued. The key technical areas that will be addressed by the project include analysis and design tools, integrated vehicle health management (IVHM), composite (polymer, metal, and ceramic matrix) materials development, thermal/structural wall concepts, thermal protection systems, seals, leading edges, aerothermodynamics, and airframe/propulsion flowpath technology. Each of the technical areas or sub-projects within the Airframe R and T Project is described in this paper.
Significant efforts have been devoted to establishing the technology foundation to enable the progression to large scale composite structures fabrication. We are not capable today of fabricating many of the composite structures envisioned for the second generation reusable launch vehicle (RLV). Conventional 'aerospace' manufacturing and processing methodologies (fiber placement, autoclave, tooling) will require substantial investment and lead time to scale-up. Out-of-autoclave process techniques will require aggressive efforts to mature the selected technologies and to scale up. Focused composite processing technology development and demonstration programs utilizing the building block approach are required to enable envisioned second generation RLV large composite structures applications. Government/industry partnerships have demonstrated success in this area and represent best combination of skills and capabilities to achieve this goal.