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NASA NTRSDate not supplied

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Peter Edward Marshall↗

NASA NTRSDate not supplied

Developments on Reusable TPS Materials Based Upon Shuttle Tile

Thermal Protection Systems↗

NASA NTRS1985

Design optimization for a space based, reusable orbit transfer vehicle

Future NASA and DOD missions will benefit from high performance, reusable orbit transfer vehicles. With the advent of a space station, advanced engine technology, and various new vehicle concepts, reusable orbit transfer vehicles that provide significant economic benefits and mission capability improvements will be realized. Engine and vehicle design criteria previously have lacked definition with regard to issues such as space basing and servicing, man-rating and reliability, performance, mission flexibility, and life cycle cost for a reusable vehicle. The design study described here has resulted in the definition of a reusable orbit transfer vehicle concept and subsequent recommendations for the design criteria of an advanced LO2/LH2 engine. These design criteria include number of engines per vehicle, nozzle design, etc. The major characteristics of the vehicle preliminary design include low lift to drag aerocapture capability, a main propulsion system failure criteria of fail operational/fail safe, and either two main engines with a high performance attitude control system for back-up or three main engines with which to meet this failure criteria. In addition, a maintenance approach has been established for the advanced vehicle concept.

Redd, L.↗

NASA NTRS1995

Damage-mitigating control of a reusable rocket engine for high performance and extended life

The goal of damage mitigating control in reusable rocket engines is to achieve high performance with increased durability of mechanical structures such that functional lives of the critical components are increased. The major benefit is an increase in structural durability with no significant loss of performance. This report investigates the feasibility of damage mitigating control of reusable rocket engines. Phenomenological models of creep and thermo-mechanical fatigue damage have been formulated in the state-variable setting such that these models can be combined with the plant model of a reusable rocket engine, such as the Space Shuttle Main Engine (SSME), for synthesizing an optimal control policy. Specifically, a creep damage model of the main thrust chamber wall is analytically derived based on the theories of sandwich beam and viscoplasticity. This model characterizes progressive bulging-out and incremental thinning of the coolant channel ligament leading to its eventual failure by tensile rupture. The objective is to generate a closed form solution of the wall thin-out phenomenon in real time where the ligament geometry is continuously updated to account for the resulting deformation. The results are in agreement with those obtained from the finite element analyses and experimental observation for both Oxygen Free High Conductivity (OFHC) copper and a copper-zerconium-silver alloy called NARloy-Z. Due to its computational efficiency, this damage model is suitable for on-line applications of life prediction and damage mitigating control, and also permits parametric studies for off-line synthesis of damage mitigating control systems. The results are presented to demonstrate the potential of life extension of reusable rocket engines via damage mitigating control. The control system has also been simulated on a testbed to observe how the damage at different critical points can be traded off without any significant loss of engine performance. The research work reported here is built upon concepts derived from the disciplines of Controls, Thermo-fluids, Structures, and Materials. The concept of damage mitigation, as presented in this report, is not restricted to control of rocket engines. It can be applied to any system where structural durability is an important issue.

Ray, Asok↗

NASA NTRS1995

The reusable launch vehicle technology program

Today's launch systems have major shortcomings that will increase in significance in the future, and thus are principal drivers for seeking major improvements in space transportation. They are too costly; insufficiently reliable, safe, and operable; and increasingly losing market share to international competition. For the United States to continue its leadership in the human exploration and wide ranging utilization of space, the first order of business must be to achieve low cost, reliable transportatin to Earth orbit. NASA's Access to Space Study, in 1993, recommended the development of a fully reusable single-stage-to-orbit (SSTO) rocket vehicle as an Agency goal. The goal of the Reusable Launch Vehicle (RLV) technology program is to mature the technologies essential for a next-generation reusable launch system capable of reliably serving National space transportation needs at substantially reduced costs. The primary objectives of the RLV technology program are to (1) mature the technologies required for the next-generation system, (2) demonstrate the capability to achieve low development and operational cost, and rapid launch turnaround times and (3) reduce business and technical risks to encourage significant private investment in the commercial development and operation of the next-generation system. Developing and demonstrating the technologies required for a Single Stage to Orbit (SSTO) rocket is a focus of the program becuase past studies indicate that it has the best potential for achieving the lowest space access cost while acting as an RLV technology driver (since it also encompasses the technology requirements of reusable rocket vehicles in general).

Cook, S.↗

NASA NTRS1999

Technology Maturity Towards Highly Reusable Space Transportation Goals

The National Aeronautics and Space Administration's (NASA) Advanced Space Transportation Program (ASTP) has advanced key propulsion and launch vehicle systems technologies towards enabling the concepts identified by the Highly Reusable Space Transportation (HRST) Study as having significant potential for reducing the cost of access to space. The Marshall Space Flight Center (MSFC) manages the ASTP for the NASA Aero-Space Technology Enterprise. The HRST Study was conducted from 1995 through 1997 to evaluated launch concepts with the potential to reduce launch cost to $100 to $200 per pound of payload to low Earth orbit in the 2016 to 2022 timeframe. The HRST represents a generation of launch vehicles beyond the Lockheed-Martin VentureStar concept with a goal of another factor of ten reduction in launch cost below the next generation Reusable Launch Vehicle. Several concepts were developed and evaluated during the initial HRST studies. At the completion of the concept development phase in 1997, four task forces were formed to integrate the results of the study. These task forces were System Concept Definition, Operations Assessment. Cost Assessment and Technology Assessment. The Operations Assessment task force published its final report in November 1998. The Operations Assessment task force evaluated both single stage to orbit (SSTO) and two-stage to orbit (TSTO) concepts. SSTO concepts included horizontal takeoff and horizontal landing, vertical takeoff and vertical landing and vertical takeoff and horizontal landing. Horizontally launched concepts including launch assist options. SSTO concepts included airbreathing and all rocket as well as combination propulsion systems. The Operations Assessment considered the significance of performance margin, flight rate capability, reliability, launch assist, design optimization and technology development. These studies serve as a guide for the ASTP to prioritize technology development towards future highly reusable launch systems. Although the ASTP supports the development of technology that is focused at a near term fully reusable launch vehicle, the core of the technology development is looking ahead to future generations of launch vehicles that will enable dramatic growth in civil and commercial space enterprise. The primary focus of the paper is to status the key enabling technologies including rocket based combined cycle (RBCC) propulsion, magnetic launch assist, long life, low weight rocket propulsion, integral hot structures. robust thermal protection systems and integrated vehicle health management. The ASTP technology roadmap is leading rapidly towards system demonstration and eventual future X vehicle flight demonstrations.

Lyles, Garry↗

NASA NTRS2003

Operational Issues in the Development of a Cost-Effective Reusable LOX/LH2 Engine

The NASA Space Launch Initiative (SLI) was initiated in early 2001 to conduct technology development and to reduce the business and technical risk associated with developing the next-generation reusable launch system. In the field of main propulsion, two LOXLH2 rocket engine systems, the Pratt & Whitney / Aerojet Joint Venture (JV) COBRA and the Rocketdyne RS-83, were funded to develop a safe, economical, and reusable propulsion system. Given that a large-thrust reusable rocket engine program had not been started in the U.S. since 1971, with the Space Shuttle Main Engine (SSME), this provided an opportunity to build on the experience developed on the SSME system, while exploiting advances in technology that had occurred in the intervening 30 years. One facet of engine development that was identified as being especially vital in order to produce an optimal system was in the areas of operability and maintainability. In order to achieve the high levels of performance required by the Space Shuttle, the SSME system is highly complex with very tight tolerances and detailed requirements. Over the lifetime of the SSME program, the engine has required a high level of manpower to support the performance of inspections, maintenance (scheduled and unscheduled) and operations (prelaunch and post-flight). As a consequence, the labor- intensive needs of the SSME provide a significant impact to the overall cost efficiency of the Space Transportation System (STS). One of the strategic goals of the SLI is to reduce cost by requiring the engine(s) to be easier (Le. less expensive) to operate and maintain. The most effective means of accomplishing this goal is to infuse the operability and maintainability features into the engine design from the start. This paper discusses some of the operational issues relevant to a reusable LOx/LH2 main engine, and the means by which their impact is mitigated in the design phase.

Ballard, Richard O.↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗

NASA NTRSDate not supplied

Computationally Guided Design of Polymer-Coated Microparticles as Reusable Materials

Long-duration space exploration missions and sustained lunar or Martian surface operations present greater demands for multifunctional and reusable materials. By scaling down the amount of material to be launched from Earth, both mission cost and risk can be reduced. In this regard, leveraging in-space manufacturing capabilities with reusable feedstock materials is an attractive option, as it will allow for articles to be generated on demand, utilized, and then recycled for additional use. NASA’s Enabling Sustained Presence Using Recyclables (ESPUR) project aims to develop reusable materials using polymer-coated microparticles that are bonded via reversible Diels-Alder reactions, where only modest heat is needed to trigger the reverse reaction and enable reuse. For proof-of-concept demonstration, research is currently focused on the fabrication of epoxy microparticles that contain a copoly(carbonate urethane) coating with maleimide and furan functionalities. Here, we discuss the integration of computational materials modeling approaches to help navigate the large design space in this development effort. We perform molecular dynamics (MD) simulations with atomistic and coarse-grained models of the copolymer, which allow us to evaluate the effects of design parameters like the molecular weight and composition on the molecular interactions and chain dynamics. We show how the properties change with the reversible bonds. We also leverage discrete element method (DEM) simulations to assess how microparticle design parameters like the size ratio and volume fraction can be tuned to increase the packing density and number of microparticle contacts to improve the mechanical properties. Our results demonstrate how computational tools can be used in close collaboration with experimental efforts to accelerate material design.

reusable materials↗

NASA NTRSDate not supplied

Modernization of Insulative Reusable Thermal Protection Systems (IRTPS)

Insulative thermal protection systems, such as Flexible Reusable Surface Insulation blankets and High Temperature Reusable Surface Insulation tiles, were developed for the Shuttle Orbiter to enable reuse of the vehicle for low-earth orbit missions. Since reusability is essential to many new industry launch and space vehicles, Shuttle-derived thermal protection materials (TPMs) are being sought for their flight proven performance. Alumina Enhanced Thermal Barrier (AETB) is the state-of-the-art tile material that was developed in the 90’s. AETB along with associated coatings, reaction cured glass (RCG) and Toughened Unipiece Fibrous Insulation (TUFI), are currently made by NASA using heritage raw materials derived from lifetime purchases. Finding viable replacements for raw materials that have changed in nature or are obsolete is important for continuation of these TPMs. In some cases, the use of modern raw materials has been shown to yield tile with reduced performance, most notably in mechanical properties. In this work, the production of AETB will be discussed to better understand the process-structure-property relationships and for allowing use of these modern alternatives. A small-scale tile casting system was developed for rapid and efficient exploration of the manufacturing variables such raw material selection and pre-processing, casting process parameters, and billet firing protocols. An optical transmission defect characterization technique was implemented to correlate process variables to structure. Comparisons between TUFI/RCG coated AETB derived from heritage and modern raw materials will be shown including AHF arc jet test results completed under a collaboration with Stratolaunch.

thermal protection materials↗

NASA NTRS1967

Reusable Aerospace Passenger Transport - Study of Incremental Development Approaches Summary Report

This report summarizes the results of studies of economical orbital transportation systems, exploring, in particular , possible options for time - phases and incremental development of such systems. The major conclusions are : 1. Incremental development is a practical way for development of an economic logistics system, minimizing development risk and annual funding, and offering planning flexibility at only a nominal penalty in total systems cost. 2. The most promising first development appears to be that of a re- usable payload carrier with a capacity of 9 to 12 passengers. 3. Systems comparisons show that, for the foreseeable variations of the mission market, a partially reusable concept could bring about most of the program savings that can be expected from reusability at moderate development risk and funding rate. 4. A further development leading to a fully reusable system has high risk and uncertain payoff. Conceivably, at that time, a more advanced concept might be introduced.

Dietrich W Fellenz↗

NASA NTRS1973

Condition monitoring helps make the Space Shuttle Main Engine reusable

The Space Shuttle Main Engine (SSME) is a reusable, high-performance liquid-propellant rocket engine being developed for the Space Shuttle Orbiter Vehicle. The SSME has been designed for long life, rapid postflight maintenance, and a fast vehicle turnaround cycle of 160 hours. To meet the unique reusability requirements, the SSME considers maintainability and condition monitoring much as airlines do today. The condition monitoring capabilities designed into this engine are discussed with major emphasis on internal inspection and techniques which ensure the reusability of the SSME.

Lacroix, W. P.↗

NASA NTRS1975

SERV - A reusable single stage to orbit space shuttle concept

Feasibility studies were made on the SERV (Single-stage Earth-orbital Reusable Vehicle), which is a single-stage, fully reusable space shuttle concept. The studies show that a reusable single-stage-to-orbit shuttle can be built using present technology. The SERV satisfies all of NASA's requirements for low earth orbital and space station resupply missions. The baseline vehicle has a modified Apollo external configuration, 90 ft in diameter and 66 ft in height, with a cargo hold 23 ft in diameter and 60 ft long. Take-off is vertical, powered by an integral aerospike rocket engine. An Apollo-type ballistic reentry profile is used, and precision vertical landing is possible with power provided by an array of turbojet engines. The key feasibility issues discussed are engine performance, aerodynamic drag, subsystem weights, method and type of thermal protection during reentry, descent aerodynamic characteristics, and landing method.

Tharratt, C. E.↗

NASA NTRS1987

Reusable rocket engine optical condition monitoring

Plume emission spectrometry and optical leak detection are described as two new applications of optical techniques to reusable rocket engine condition monitoring. Plume spectrometry has been used with laboratory flames and reusable rocket engines to characterize both the nominal combustion spectra and anomalous spectra of contaminants burning in these plumes. Holographic interferometry has been used to identify leaks and quantify leak rates from reusable rocket engine joints and welds.

Wyett, L.↗

NASA NTRS1989

An SSE approach to reusability

The SSE project has engineering analysis and design efforts under way for the development of the SSE reusability library management system. An ad hoc committee on reuse has been meeting for several months identifying design considerations and learning about Ruben Prieto-Diaz faceted classification, CAMP domain analysis, SPC activities, SEI activities, and SPS activities. A standard format was developed for the Ada prologue for reusable components (both specification and body). The SSE reusability process can be viewed as a transformation process with minimized losses and difficulties.

Badal, David L.↗

NASA NTRS1989

Application of reusable software components at the SEI

Robert Holibaugh of the Software Engineering Institute described a project which is studying the application of reusable software components. The primary goals are to gain practical experience with state-of-the-art reusable components, methods, and tools and to capture the lessons learned in the application of reuse technology. In addition the project will assess the impact of reuse on the software development process and products and will identify and validate the information that facilities software reuse during system development. The project includes two tasks - a reuse experiment and a redevelopment effort. The reuse experiment will define a life cycle and a methodology for reuse-based development, and define and implement a data collection mechanism for measuring the development. The redevelopment effort will construct a reuse test bed and will redevelop and realistically test subsystems from an embedded mission-critical real-time application. The reuse experiment will produce several products including a tested real-time application, reuse-based components and tools evaluation, a reuse-based development method, a framework for data collection, a framework for measuring productivity, and lessons learned data. Successful development with reusable components will require a rich set of components and an integrating methodology. The Tomahawk Land Attack Missile system is the application for the redevelopment effort.

Holibaugh, Robert↗

NASA NTRS1989

Reusable high-temperature heat pipes and heat pipe panels

A reusable, durable heat pipe which is capable of operating at temperatures up to about 3000 F in an oxidizing environment and at temperatures above 3000 F in an inert or vacuum environment is produced by embedding a refractory metal pipe within a carbon-carbon composite structure. A reusable, durable heat pipe panel is made from an array of refractory-metal pipes spaced from each other. The reusable, durable, heat-pipe is employed to fabricate a hypersonic vehicle leading edge and nose cap.

Camarda, Charles J.↗

NASA NTRS1991

Conceptual design of a next-generation, fully reusable manned launch system

The conceptual design of a rocket-powered, two-stage fully reusable launch vehicle has been performed as a part of the Advanced Manned Launch System (AMLS) study at the NASA Langley Research Center. The main goals of the AMLS study are to provide routine, low-cost manned access to space. Technologies and system approaches have been studied that would contribute to significant reductions in operating costs relative to current systems. System and operational characteristics of the two-stage fully reusable vehicle are presented, and the various tools and methods used in the design process are summarized. The results of a series of trade studies performed to examine the effect of varying major vehicle parameters on the reference two-stage fully reusable vehicle are also summarized.

Stanley, Douglas O.↗