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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.

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.

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.

Hot-Fire Testing of 5N and 22N HPGP Thrusters

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 hot-fire testing of 5N and 22N HPGP thrusters at the Marshall Space Flight Center’s Component Development Area altitude test stand in April 2015. Both thrusters are ground test articles and not flight ready units, but are representative of potential flight hardware with a known path towards flight application. The purpose of the 5N testing was to perform facility check-outs and generate a small set of data for comparison to ECAPS and Orbital ATK data sets. The 5N thruster performed as expected with thrust and propellant flow-rate data generated that are similar to previous testing at Orbital ATK. Immediately following the 5N testing, and using the same facility, the 22N testing was conducted on the same test stand with the purpose of demonstrating the 22N performance. The results of 22N testing indicate it performed as expected.The results of the hot-fire testing are presented in this paper and presentation.

Burnside, Christopher G.

Green Propulsion Auxiliary Power Unit Demonstration 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 is one of fourteen TA's that provide recommendations for the overall technology investment strategy and prioritization of NASA's space technology activities. Identified within TA-01 was the need for a green propulsion auxiliary power unit (APU) for hydraulic power by 2015. Engineers led by the author at the Marshall Space Flight Center (MSFC) have been evaluating green propellant alternatives and have begun the development of an APU testbed to demonstrate the feasibility of use. NASA has residual APU assets remaining from the retired Space Shuttle Program. Likewise, the F-16 Falcon fighter jet also uses an Emergency Power Unit (EPU) that has similar characteristics to the NASA hardware. Both EPU's and APU components have been acquired for testing at MSFC. In concert with this effort, ATK has been developing green propellant technology based on the Swedish Space Corp ECAPS LMP-103S propellant. Propellant blending and test facilities have been established at ATK's Elkton MD facility with the intent to provide suitable propellant blends for application to green APU systems as well as thrusters. This paper will summarize the status of the testing efforts with ATK for use of the green propellant LMP-103S based on ammonium dinitramide and use of the Air Force Research Laboratory (AFRL) propellant AF-M315E based on hydroxyl ammonium nitrate with these test assets.

Robinson, Joel W.

Green Propulsion Auxiliary Power Unit Demonstration at MSFC

MSFC has embarked on use of green propellant replacement of hydrazine for a variety of applications. This paper focused on activities for auxiliary power unit but MSFC is actively investigating use of green propellants for thruster applications. MSFC is interested in partnership with the international community to address the infusion of green propellant into greater use.

Robinson, Joel W.

Operational Concept Evaluation of Solid Oxide Fuel Cells for Space Vehicle Applications

With the end of the Space Shuttle Program, NASA is evaluating many different technologies to support future missions. Green propellants, like liquid methane and liquid oxygen, have potential advantages for some applications. A Lander propelled with LOX/methane engines is one such application. When the total vehicle design and infrastructure are considered, the advantages of the integration of propulsion, heat rejection, life support and power generation become attractive for further evaluation. Scavenged residual propellants from the propulsion tanks could be used to generate needed electric power, heat and water with a Solid Oxide Fuel Cell(SOFC). In-Situ Resource Utilization(ISRU) technologies may also generate quantities of green propellants to refill these tanks and/or supply these fuel cells. Technology demonstration projects such as the Morpheus Lander are currently underway to evaluate the practicality of such designs and operational concepts. Tethered tests are currently in progress on this vertical test bed to evaluate the propulsion and avionics systems. Evaluation of the SOFC seeks to determine the feasibility of using these green propellants to supply power and identify the limits to the integration of this technology into a space vehicle prototype.

Poast, Kenneth I.

GPIM AF-M315E Propulsion System

The NASA Space Technology mission Directorate's (STMD) Green Propellant Infusion Mission (GPIM) Technology Demonstration Mission (TDM) will demonstrate an operational AF-M315E green propellant propulsion system. Aerojet-Rocketdyne is responsible for the development of the propulsion system payload. This paper statuses the propulsion system module development, including thruster design and system design; Initial test results for the 1N engineering model thruster are presented. The culmination of this program will be high-performance, green AF-M315E propulsion system technology at TRL 7+, with components demonstrated to TRL 9, ready for direct infusion to a wide range of applications for the space user community.

Spores, Ronald A.

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

ELV Payload Safety Program Workshop Green Propulsion Update

MSFC is engaged on the system solution: thrusters and power units; GRC is working plume diagnostics/modeling and independent thruster testing on GPIM.; GSFC is working slosh characteristics on GPIM tank.; JPL and ARC continually interested to infuse green propellant as potential replacement to hydrazine.; Mike Gazarik, AA of STMD, has requested MSFC lead the development of an Agency-level green propellant roadmap involving multiple Centers., Tentatively planned for August 2015 in Huntsville.

Robinson, Joel

Technology Demonstration Missions

Technology Demonstration Missions (TDM) is in its third year of execution, being initiated in 2010 and baselined in January of 2012. There are 11 projects that NASA Marshall Space Flight Center (MSFC) has contributed to or led: (1) Evolvable Cryogenics (eCryo): Cyrogenic Propellant Storage and Transfer Engineering Development Unit (EDU), a proof of manufacturability effort, used to enhance knowledge and technology related to handling cryogenic propellants, specifically liquid hydrogen. (2) Composites for Exploration Upper Stage (CEUS): Design, build, test, and address flight certification of a large composite shell suitable for the second stage of the Space Launch System (SLS). (3) Deep Space Atomic Clock (DSAC): Spaceflight to demo small, low-mass atomic clock that can provide unprecedented stability for deep space navigation. (4) Green Propellant Infusion Mission (GPIM): Demo of high-performance, green propellant propulsion system suitable for Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter (ESPA)-class spacecraft. (5) Human Exploration Telerobotics (HET): Demonstrating how telerobotics, remote control of a variety of robotic systems, can take routine, highly repetitive, dangerous or long-duration tasks out of human hands. (6) Laser Communication Relay Demo (LCRD): Demo to advance optical communications technology toward infusion into deep space and near Earth operational systems, while growing the capabilities of industry sources. (7) Low Density Supersonic Decelerator (LDSD): Demo new supersonic inflatable decelerator and parachute technologies to enable Mars landings of larger payloads with greater precision at a wider range of altitudes. (8) Mars Science Laboratory (MSL) Entry Descent & Landing Instrumentation (MEDLI): Demo of embedded sensors embedded in the MSL heat shield, designed to record the heat and atmospheric pressure experienced during the spacecraft's high-speed, hot entry in the Martian atmosphere. (9) Solar Electric Propulsion (SEP): 50-kW class spacecraft that uses flexible blanket solar arrays for power generation and an electric propulsion system that delivers payload from low-Earth orbit to higher orbits. (10) Solar Sail Demonstration (SSD): Demo to validate sail deployment techniques for solar sails that are propelled by the pressure of sunlight. (11) Terrestrial HIAD Orbit Reentry (THOR): Demo of a 3.7-m Hypersonic Inflatable Aerodynamic Decelerator (HIAD) entry vehicle to test second generation aerothermal performance and modeling.

McDougal, John

Green Propulsion Auxiliary Power Unit Demonstration 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)1 for Launch Propulsion Systems is one of fourteen TAs that provide recommendations for the overall technology investment strategy and prioritization of NASA's space technology activities. Identified within TA-01 was the need for a green propulsion auxiliary power unit (APU) for hydraulic power by 2015. Engineers led by the author at the Marshall Space Flight Center (MSFC) have been evaluating green propellant alternatives and have begun the development of an APU test bed to demonstrate the feasibility of use. NASA has residual APU assets remaining from the retired Space Shuttle Program. Likewise, the F-16 Falcon fighter jet also uses an Emergency Power Unit (EPU) that has similar characteristics to the NASA hardware. Both EPU and APU components have been acquired for testing at MSFC. This paper will summarize the status of the testing efforts of green propellant from the Air Force Research Laboratory (AFRL) propellant AFM315E based on hydroxyl ammonium nitrate (HAN) with these test assets.

Robinson, Joel W.

Development of ASCENT Propellant Thrusters and Propulsion Systems

Since the 1960s, hydrazine technology has dominated the market of propulsion technology by providing reliable performance on a wide variety of spacecraft. Efforts to replace hydrazine with a higher-performance and safer alternative have engaged numerous emerging technologies in the industry to mature. ASCENT propellant, also known as AF-M315E, is an example of one such green propellant. Initially developed to provide a safer handling environment than hydrazine, ASCENT offers higher overall performance than a hydrazine equivalent by creating more heat during ignition. The next generation of propulsion technology, based on ASCENT propellant, produces a higher impulse and energy density, expanding the realm of applicable missions from LEO to GEO and beyond. Building on a strong background in small satellite technology and expertise in thermal and oxidation resistant materials, Plasma Processes began several thruster programs for variety of small satellite applications using ASCENT-based technology. Plasma Processes’ background expertise in thermal and oxidation resistant materials provides the necessary foundation to create ASCENT-based technology hardware.

Green Propellant

Advanced Compatibility Characterization Of AF-M315E With Spacecraft Propulsion System Materials Project

All spacecraft require propulsion systems for thrust and maneuvering. Propulsion systems can be chemical, nuclear, electrical, cold gas or combinations thereof. Chemical propulsion has proven to be the most reliable technology since the deployment of launch vehicles. Performance, storability, and handling are three important aspects of liquid chemical propulsion. Bipropellant systems require a fuel and an oxidizer for propulsion, but monopropellants only require a fuel and a catalyst for propulsion and are therefore simpler and lighter. Hydrazine is the state of the art propellant for monopropellant systems, but has drawbacks because it is highly hazardous to human health, which requires extensive care in handling, complex ground ops due to safety and environmental considerations, and lengthy turnaround times for reusable spacecraft. All users of hydrazine monopropellant must contend with these issues and their associated costs. The development of a new monopropellant, intended to replace hydrazine, has been in progress for years. This project will apply advanced techniques to characterize the engineering properties of materials used in AF-M315E propulsion systems after propellant exposure. AF-M315E monopropellant has been selected HQ's Green Propellant Infusion Mission (GPIM) to replace toxic hydrazine for improved performance and reduce safety and health issues that will shorten reusable spacecraft turn-around time. In addition, this project will fundamentally strengthen JSC's core competency to evaluate, use and infuse liquid propellant systems.

McClure, Mark B.

Plume Characterization of a Laboratory Model 22 N GPIM Thruster via High-Frequency Raman Spectroscopy

The Green Propellant Infusion Mission (GPIM) will demonstrate the capability of a green propulsion system, specifically, one using the monopropellant, AF-M315E. One of the risks identified for GPIM is potential contamination of sensitive areas of the spacecraft from the effluents in the plumes of AF-M315E thrusters. Plume characterization of a laboratory-model 22 N thruster via optical diagnostics was conducted at NASA GRC in a space-simulated environment. A high-frequency pulsed laser was coupled with an electron-multiplied ICCD camera to perform Raman spectroscopy in the near-field, low-pressure plume. The Raman data yielded plume constituents and temperatures over a range of thruster chamber pressures and as a function of thruster (catalyst) operating time. Schlieren images of the near-field plume enabled calculation of plume velocities and revealed general plume structure of the otherwise invisible plume. The measured velocities are compared to those predicted by a two-dimensional, kinetic model. Trends in data and numerical results are presented from catalyst mid-life to end-of-life. The results of this investigation were coupled with the Raman and Schlieren data to provide an anchor for plume impingement analysis presented in a companion paper. The results of both analyses will be used to improve understanding of the nature of AF-M315E plumes and their impacts to GPIM and other future missions.

Raman Spectroscopy

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High

100-lbf LO2/CH4 RCS Thruster Testing and Validation

100 pound thrust liquid Oxygen-Methane thruster sized for RCS (Reaction Control System) applications. Innovative Design Characteristics include: a) Simple compact design with minimal part count; b) Gaseous or Liquid propellant operation; c) Affordable and Reusable; d) Greater flexibility than existing systems; e) Part of NASA'S study of "Green Propellants." Hot-fire testing validated performance and functionality of thruster. Thruster's dependence on mixture ratio has been evaluated. Data has been used to calculate performance parameters such as thrust and Isp. Data has been compared with previous test results to verify reliability and repeatability. Thruster was found to have an Isp of 131 s and 82 lbf thrust at a mixture ratio of 1.62.

Barnes, Frank

Material Compatibility Testing of Green Hydrazine

Green Hydrazine Propellant Blend (GHPB) is a new green propellant developed by Aerojet Rocketdyne and selected for continued testing at NASA’s Goddard Space Flight Center (GSFC). It primarily differs from previous "green” propellants by maintaining traditional hydrazine as the base constituent, along with additives that are intended to increase handling safety by lowering the concentration of hydrazine in the vapor. GSFC has performed material compatibility testing. The scope of this campaign included materials that are common in spacecraft or ground support equipment (GSE), and also included typical safety materials (e.g. permeation rates through gloves). The conclusion in a broad sense is that GHPB is less reactive than hydrazine, including the absorption of metals into the propellant, as examined by Inductively-Coupled Plasma (ICP) analysis of metals uptake.

Eric H Cardiff