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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2012

Mars Ascent Vehicle Development Status

The Mars robotic sample return mission has been a potential flagship mission for NASA s science mission directorate for decades. The Mars Exploration Program and the planetary science decadal survey have highlighted both the science value of the Mars Sample Return (MSR) mission, but also the need for risk reduction through technology development. One of the critical elements of the MSR mission is the Mars Ascent Vehicle (MAV), which must launch the sample cache from the surface of Mars and place it into low Mars orbit. The MAV has significant challenges to overcome due to tight constraints on the MAV s mass and volume, as well as environmental challenges associated with long duration storage on the Martian surface and during Entry Descent and Landing (EDL). In the fall of 2010, NASA selected three industrial partners for study phase contracts to develop MAV system concepts, identify technology needs, and recommend technology developments plans for follow-on work. In addition to the contractor recommendations, JPL s Team-X was used for a comparative assessment of the three vehicle concepts to understand relative strengths, weaknesses, and sensitivity to system growth. The GRC COMPASS team independently evaluated MAV system solutions using liquid bipropellant, solid rocket motors, and an advanced monopropellant option. The results of the study phase contracts and comparative assessment is provided herein.

Dankanich, John W.↗
NASA NTRS2013

Unibody Composite Pressurized Structure

An integrated, generic unibody composite pressurized structure (UCPS) combined with a positive expulsion device (PED), consisting of an elastomeric bladder for monopropellant hydrazine, has been quasi-standardized for spacecraft use. The combination functions as an all-composite, non-metallic, propellant tank with bladder. The integrated UCPS combines several previous innovations - specifically, the linerless, all-composite cryogenic tank technology; all-composite boss; resin formulation; and integrated stringer system. The innovation combines the UCPS with an integrated propellant management device (PMD), the PED or bladder, to create an entirely unique system for in-space use. The UCPS is a pressure vessel that incorporates skirts, stringers, and other structures so that it is both an in-space hydrazine tank, and also a structural support system for a spacecraft in a single, all-composite unit. This innovation builds on the progress in the development of a previous SBIR (Small Business Innovation Research) Phase I with Glenn Research Center and an SBIR III with Johnson Space Center that included the fabrication of two 42-in. (≈107-cm) diameter all-composite cryogenic (LOX and liquid methane) UCPS test tanks for a lunar lander. This Phase II provides hydra zine compatibility testing of the elastomeric bladder, a see-through PED to validate the expulsion process and model, and a complete UCPS-based PED with stringers and skirts that will be used to conduct initial qualification and expulsion tests. This extends the UCPS technology to include hydrazine-based, in-space pro - pulsion applications and can also be used for electric propulsion. This innovation creates a system that, in comparison to the traditional approach, is lower in weight, cost, volume, and production time; is stronger; and is capable of much higher pressures. It also has fewer failure modes, and is applicable to both chemical and electric propulsion systems.

Rufer, Markus↗
NASA NTRS2013

NASA Marshall Space Flight Center Tri-gas Thruster Performance Characterization

Historically, spacecraft reaction control systems have primarily utilized cold gas thrusters because of their inherent simplicity and reliability. However, cold gas thrusters typically have a low specific impulse. It has been determined that a higher specific impulse can be achieved by passing a monopropellant fluid mixture through a catalyst bed prior to expulsion through the thruster nozzle. This research analyzes the potential efficiency improvements from using tri-gas, a mixture of hydrogen, oxygen, and an inert gas, which in this case is helium. Passing tri-gas through a catalyst causes the hydrogen and oxygen to react and form water vapor, ultimately heating the exiting fluid and generating a higher specific impulse. The goal of this project was to optimize the thruster performance by characterizing the effects of varying several system components including catalyst types, catalyst lengths, and initial catalyst temperatures.

Dorado, Vanessa↗
NASA NTRS2014

Design, Integration, Certification and Testing of the Orion Crew Module Propulsion System

The Orion Multipurpose Crew Vehicle (MPCV) is NASA's next generation spacecraft for human exploration of deep space. Lockheed Martin is the prime contractor for the design, development, qualification and integration of the vehicle. A key component of the Orion Crew Module (CM) is the Propulsion Reaction Control System, a high‐flow hydrazine system used during re‐entry to orient the vehicle for landing. The system consists of a completely redundant helium (GHe) pressurization system and hydrazine fuel system with monopropellant thrusters. The propulsion system has been designed, integrated, and qualification tested in support of the Orion program's first orbital flight test, Exploration Flight Test One (EFT‐1), scheduled for 2014. A subset of the development challenges and lessons learned from this first flight test campaign will be discussed in this paper for consideration when designing future spacecraft propulsion systems. The CONOPS and human rating requirements of the CM propulsion system are unique when compared with a typical satellite propulsion reaction control system. The system requires a high maximum fuel flow rate. It must operate at both vacuum and sea level atmospheric pressure conditions. In order to meet Orion's human rating requirements, multiple parts of the system must be redundant, and capable of functioning after spacecraft system fault events.

McKay, Heather↗
NASA NTRS2014

Green Mono Propulsion Activities at MSFC

In 2012, the National Aeronautics & Space Administration (NASA) Space Technology Mission Directorate (STMD) began the process of building an integrated technology roadmap, including both technology pull and technology push strategies. Technology Area 1 (TA-01) for Launch Propulsion Systems and TA-02 In-Space Propulsion are two of the fourteen TA's that provide recommendations for the overall technology investment strategy and prioritization of NASA's space technology activities. Identified within these documents are future needs of green propellant use. Green ionic liquid monopropellants and propulsion systems are beginning to be demonstrated in space flight environments. Starting in 2010 with the flight of PRISMA, a one Newton thruster system began on-orbit demonstrations operating on ammonium dinitramide based propellant. The NASA Green Propellant Infusion Mission (GPIM) plans to demonstrate both 1 N, and 22 N hydroxyl ammonium nitrate based thrusters in a 2015 flight demonstration. In addition, engineers at MSFC have been evaluating green propellant alternatives for both thrusters and auxiliary power units. This paper summarizes the status of these development/demonstration activities and investigates the potential for evolution of green propellants from small spacecraft and satellites to larger spacecraft systems, human exploration, and launch system auxiliary propulsion applications.

Robinson, Joel W.↗
NASA NTRS2014

Green Mono Propulsion Activities at MSFC

In 2012, the National Aeronautics & Space Administration (NASA) Space Technology Mission Directorate (STMD) began the process of building an integrated technology roadmap, including both technology pull and technology push strategies. Technology Area 1 (TA-01) for Launch Propulsion Systems and TA-02 In-Space Propulsion are two of the fourteen TAs that provide recommendations for the overall technology investment strategy and prioritization of NASA's space technology activities. Identified within these documents are future needs of green propellant use. Green ionic liquid monopropellants and propulsion systems are beginning to be demonstrated in space flight environments. Starting in 2010 with the flight of Prisma, a 1-N thruster system began on-orbit demonstrations operating on ammonium dinitramide based propellant. The NASA Green Propellant Infusion Mission (GPIM) plans to demonstrate both 1-N, and 22-N hydroxyl ammonium nitrate (HAN)-based thrusters in a 2015 flight demonstration. In addition, engineers at MSFC have been evaluating green propellant alternatives for both thrusters and auxiliary power units (APUs). This paper summarizes the status of these development/demonstration activities and investigates the potential for evolution of green propellants from small spacecraft and satellites to larger spacecraft systems, human exploration, and launch system auxiliary propulsion applications.

Robinson, Joel W.↗
NASA NTRS2014

The Advancing State of AF-M315E Technology

The culmination of twenty years of applied research in hydroxyl ammonium nitrate (HAN)-based monopropellants, the NASA Space Technology mission Directorate's (STMD) Green Propellant Infusion Mission (GPIM) will achieve the first on-orbit demonstration of an operational AF-M315E green propellant propulsion system by the end of 2015. Following an contextual overview of the completed flight design of the GPIM propellant storage and feed system, results of first operation of a flight-representative heavyweight 20-N engineering model thruster (to be conducted in mid-2014) are presented with performance comparisons to prior lab model (heavyweight) test articles.

Masse, Robert↗
NASA NTRS2014

Green Applications for Space Power Project

Spacecraft propulsion and power for many decades has relied on Hydrazine monopropellant technology for auxiliary power units (APU), orbital circularization, orbit raising/lowering and attitude control. However, Hydrazine is toxic and therefore requires special ground handling procedures to ensure launch crew safety. The Swedish Company ECAPS has developed a technology based upon the propellant Ammonium Dinitramide (ADN) that offers higher performance, higher density and reduced ground handling support than Hydrazine. This blended propellant is called LMP-103S. Currently, the United States Air Force (USAF) is pursuing a technology based on Hydroxyl Ammonium Nitrate (HAN, otherwise known as AF-M315E) with industry partners Aerojet and Moog. Based on the advantages offered by these propellants, MSFC should explore powering APU's with these propellants. Due to the availability of space hardware, the principal investigator has found a collection of USAF hardware, that will act as a surrogate, which operates on a Hydrazine derivative. The F-16 fighter jet uses H-70 or 30% diluted Hydrazine for an Emergency Power Unit (EPU) which supplies power to the plane. The PI has acquired two EPU's from planes slated for destruction at the Davis Monthan AFB. This CIF will include a partnership with 2 other NASA Centers who are individually seeking seed funds from their respective organizations: Kennedy Space Center (KSC) and Dryden Flight Research Center (DFRC). KSC is preparing for future flights from their launch pads that will utilize green propellants and desire a low-cost testbed in which to test and calibrate new leak detection sensors. DFRC has access to F-16's which can be used by MSFC & KSC to perform a ground test that demonstrates emergency power supplied to the jet. Neither of the green propellant alternatives have been considered nor evaluated for an APU application. Work has already been accomplished to characterize and obtain the properties of these 2 propellants. However, the spacecraft are using existing leak detection sensors that are typically used for Hydrazine. Using these green propellants for the APU application requires decrementing their TRL down to 3. This task would aim to establish a TRL of 4 at conclusion by showing a proof of concept with a KSC-instrumented EPU asset at the MSFC Component Development Area (CDA). The task to accomplish this is called Green Application for Space Power or GRASP.

Robinson, Joel↗
NASA NTRS2014

Surge Pressure Mitigation in the Global Precipitation Measurement Mission Core Propulsion System

The Global Precipitation Measurement (GPM) mission is an international partnership between NASA and JAXA whose Core spacecraft performs cutting-edge measurements of rainfall and snowfall worldwide and unifies data gathered by a network of precipitation measurement satellites. The Core spacecraft's propulsion system is a blowdown monopropellant system with an initial hydrazine load of 545 kg in a single composite overwrapped propellant tank. At launch, the propulsion system contained propellant in the tank and manifold tubes upstream of the latch valves, with low-pressure helium gas in the manifold tubes downstream of the latch valves. The system had a relatively high beginning-of- life pressure and long downstream manifold lines; these factors created conditions that were conducive to high surge pressures. This paper discusses the GPM project's approach to surge mitigation in the propulsion system design. The paper describes the surge testing program and results, with discussions of specific difficulties encountered. Based on the results of surge testing and pressure drop analyses, a unique configuration of cavitating venturis was chosen to mitigate surge while minimizing pressure losses during thruster maneuvers. This paper concludes with a discussion of overall lessons learned with surge pressure testing for NASA Goddard spacecraft programs.

Pressure↗
NASA NTRS2013

Fault Protection Design and Testing for the Cassini Spacecraft in a "Mixed" Thruster Configuration

NASA's Cassini Spacecraft, launched on October 15th, 1997 and arrived at Saturn on June 30th, 2004, is the largest and most ambitious interplanetary spacecraft in history. In order to meet the challenging attitude control and navigation requirements of the orbit profile at Saturn, Cassini is equipped with a monopropellant thruster based Reaction Control System (RCS), a bipropellant Main Engine Assembly (MEA) and a Reaction Wheel Assembly (RWA). In 2008, after 11 years of reliable service, several RCS thrusters began to show signs of end of life degradation, which led the operations team to successfully perform the swap from the A-branch to the B-branch RCS system. If similar degradation begins to occur on any of the B-branch thrusters, Cassini might have to assume a "mixed" thruster configuration, where a subset of both A and B branch thrusters will be designated as prime. The Cassini Fault Protection FSW was recently updated to handle this scenario. The design, implementation, and testing of this update is described in this paper.

propellant↗
NASA NTRS2010

Cassini Spacecraft In-Flight Swap to Backup Attitude Control Thrusters

NASA's Cassini Spacecraft, launched on October 15th, 1997 and arrived at Saturn on June 30th, 2004, is the largest and most ambitious interplanetary spacecraft in history. In order to meet the challenging attitude control and navigation requirements of the orbit profile at Saturn, Cassini is equipped with a monopropellant thruster based Reaction Control System (RCS), a bipropellant Main Engine Assembly (MEA) and a Reaction Wheel Assembly (RWA). In 2008, after 11 years of reliable service, several RCS thrusters began to show signs of end of life degradation, which led the operations team to successfully perform the swap to the backup RCS system, the details and challenges of which are described in this paper. With some modifications, it is hoped that similar techniques and design strategies could be used to benefit other spacecraft.

Bates, David M.↗
NASA NTRS2015

An Overview of SBIR Phase 2 In-Space Propulsion and Cryogenic Fluids Management

Technological innovation is the overall focus of NASA's Small Business Innovation Research (SBIR) program. The program invests in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for agency projects. This report highlights innovative SBIR Phase II projects from 2007-2012 specifically addressing Areas in In-Space Propulsion and Cryogenic Fluids Management which is one of six core competencies at NASA Glenn Research Center. There are nineteen technologies featured with emphasis on a wide spectrum of applications such as high-performance Hall thruster support system, thruster discharge power converter, high-performance combustion chamber, ion thruster design tool, green liquid monopropellant thruster, and much more. Each article in this booklet describes an innovation, technical objective, and highlights NASA commercial and industrial applications. This report serves as an opportunity for NASA personnel including engineers, researchers, and program managers to learn of NASA SBIR's capabilities that might be crosscutting into this technology area. As the result, it would cause collaborations and partnerships between the small companies and NASA Programs and Projects resulting in benefit to both SBIR companies and NASA.

hall thruster power converter combustion chamber p↗
NASA NTRS2015

Hot-Fire Testing of a 1N AF-M315E Thruster

This hot-fire test continues NASA investigation of green propellant technologies for future missions. To show the potential for green propellants to replace some hydrazine systems in future spacecraft, NASA Marshall Space Flight Center (MSFC) is continuing to embark on hot-fire test campaigns with various green propellant blends. NASA completed a hot-fire test of a 1N AF-M315E monopropellant thruster at the Marshall Space Flight Center in the small altitude test stand located in building 4205. The thruster is a ground test article used for basic performance determination and catalyst studies. The purpose of the hot-fire testing was for performance determination of a 1N size thruster and form a baseline from which to study catalyst performance and life with follow-on testing to be conducted at a later date. The thruster performed as expected. The result of the hot-fire testing are presented in this paper and presentation.

Burnside, Christopher G.↗
NASA NTRS2015

Ensuring Cassini's End-of-Mission Propellant Margins

The Cassini spacecraft is in its final years. On September 15, 2017, Cassini will plunge deep into Saturn's atmosphere never to reemerge; thus concluding its second extended mission and 13 years in orbit around the ringed planet. As of October 2014, the spacecraft is four years in to its seven-year, second extended mission, the Cassini Solstice Mission (CSM). With three years left and only 2.5% of its loaded bipropellant and 37% of its loaded monopropellant remaining, the Cassini project actively manages the predicted end-of-mission propellant margins to maintain a high confidence in the spacecraft's ability to complete the CSM as designed.

Sturm, Erick J., II↗
NASA NTRS2016

Initial Satellite Formation Flight Results from the Magnetospheric Multiscale Mission

This paper will describe the results that have been obtained to date concerning MMS formation flying. The MMS spacecraft spin at a rate of 3.1 RPM, with spin axis roughly aligned with Ecliptic North. Several booms are used to deploy instruments: two 5 m magnetometer booms in the spin plane, two rigid booms of length 12.5 m along the positive and negative spin axes, and four flexible wire booms of length 60 m in the spin plane. Minimizing flexible motion of the wire booms requires that reorientation of the spacecraft spin axis be kept to a minimum: this is limited to attitude maneuvers to counteract the effects of gravity-gradient and apparent solar motion. Orbital maneuvers must therefore be carried out in essentially the nominal science attitude. These burns make use of a set of monopropellant hydrazine thrusters: two (of thrust 4.5 N) along the spin axis in each direction, and eight (of thrust 18 N) in the spin plane; the latter are pulsed at the spin rate to produce a net delta-v. An on-board accelerometer-based controller is used to accurately generate a commanded delta-v. Navigation makes use of a weak-signal GPS-based system: this allows signals to be received even when MMS is flying above the GPS orbits, producing a highly accurate determination of the four MMS orbits. This data is downlinked to the MMS Mission Operations Center (MOC) and used by the MOC Flight Dynamics Operations Area (FDOA) for maneuver design. These commands are then uplinked to the spacecraft and executed autonomously using the controller, with the ground monitoring the burns in real time.

satellite↗
NASA NTRS2016

An Overview of In-Space Propulsion and Cryogenics Fluids Management Efforts for 2014 SBIR Phases I and II

NASA's Small Business Innovation Research (SBIR) program focuses on technological innovation by investing in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for Agency programs. This report highlights 11 of the innovative SBIR 2014 Phase I and II projects from 2010 to 2012 that focus on one of NASA Glenn Research Center's six core competencies-In-Space Propulsion and Cryogenic Fluids Management. The technologies cover a wide spectrum of applications such as divergent field annular ion engines, miniature nontoxic nitrous oxide-propane propulsion, noncatalytic ignition systems for high-performance advanced monopropellant thrusters, nontoxic storable liquid propulsion, and superconducting electric boost pumps for nuclear thermal propulsion. Each article describes an innovation and technical objective and highlights NASA commercial and industrial applications. This report provides an opportunity for NASA engineers, researchers, and program managers to learn how NASA SBIR technologies could help their programs and projects, and lead to collaborations and partnerships between the small SBIR companies and NASA that would benefit both.

divergent field annular ion engine↗
NASA NTRS2016

Green Propellant Test Capabilities of the Altitude Combustion Stand at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC) is committed to providing simulated altitude rocket test capabilities to NASA programs, other government agencies, private industry partners, and academic partners. A primary facility to support those needs is the Altitude Combustion Stand (ACS). ACS provides the capability to test combustion components at a simulated altitude up to 100,000 ft. (approx.0.2 psia/10 Torr) through a nitrogen-driven ejector system. The facility is equipped with an axial thrust stand, gaseous and cryogenic liquid propellant feed systems, data acquisition system with up to 1000 Hz recording, and automated facility control system. Propellant capabilities include gaseous and liquid hydrogen, gaseous and liquid oxygen, and liquid methane. A water-cooled diffuser, exhaust spray cooling chamber, and multi-stage ejector systems can enable run times up to 180 seconds to 16 minutes. The system can accommodate engines up to 2000-lbf thrust, liquid propellant supply pressures up to 1800 psia, and test at the component level. Engines can also be fired at sea level if needed. The NASA GRC is in the process of modifying ACS capabilities to enable the testing of green propellant (GP) thrusters and components. Green propellants are actively being explored throughout government and industry as a non-toxic replacement to hydrazine monopropellants for applications such as reaction control systems or small spacecraft main propulsion systems. These propellants offer increased performance and cost savings over hydrazine. The modification of ACS is intended to enable testing of a wide range of green propellant engines for research and qualification-like testing applications. Once complete, ACS will have the capability to test green propellant engines up to 880 N in thrust, thermally condition the green propellants, provide test durations up to 60 minutes depending on thrust class, provide high speed control and data acquisition, as well as provide advanced imaging and diagnostics such as infrared (IR) imaging.

Testing↗
NASA NTRS2017

Development and Testing of a Novel Green Propellant Piston Tank

Analytical Mechanics Associates (AMA), in cooperation with NASA Marshall Space Flight Center's (MSFC's) Spacecraft Propulsion Systems Branch, developed and tested a novel propellant tank design that employs an internal piston pressurized with an inert gas to expel propellant to thrusters. During the course of this activity, AMA designed, oversaw fabrication, and delivered to MSFC for testing, a piston propellant tank sized for 3U or larger CubeSats. MSFC conducted liquid expulsion testing using ethylene glycol as a referee fluid to map the tank's performance at different pressures and piston positions. Following the expulsion test campaign, the tank is planned to be integrated into a propulsion system test bed for hot fire tests with a 100mN monopropellant thruster to evaluate the tank's influence on thruster performance when operated in a flight like manner. Described in this paper is a comprehensive summary of how the tanks were designed, built, and tested. The fundamental knowledge gained through the fabrication and testing of these tanks gives evidence that the piston tank design may be scalable to meet the requirements and constraints of other small satellites.

Diaz, C. E.↗