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Mars Hybrid Propulsion System Trajectory Analysis: Cargo Missions - Part II

NASA's Human Spaceflight Architecture Team is developing a reusable hybrid transportation architecture in which both chemical and electric propulsion systems are used to send crew and cargo to Mars destinations such as Phobos, Deimos, the surface of Mars, and other orbits around Mars. By combining chemical and electrical propulsion into a single spaceship and applying each where it is more effective, the hybrid architecture enables a series of Mars trajectories that are more fuel-efficient than an all chemical architecture without significant increases in flight times. This paper shows the feasibility of the hybrid transportation architecture to pre-deploy cargo to Mars and Phobos in support of the Evolvable Mars Campaign crew missions. The analysis shows that the hybrid propulsion stage is able to deliver all of the current manifested payload to Phobos and Mars through the first three crew missions. The conjunction class trajectory also allows the hybrid propulsion stage to return to Earth in a timely fashion so it can be reused for additional cargo deployment. The 1,100 days total trip time allows the hybrid propulsion stage to deliver cargo to Mars every other Earth-Mars transit opportunity. For the first two Mars surface mission in the Evolvable Mars Campaign, the short trip time allows the hybrid propulsion stage to be reused for three round-trip journeys to Mars, which matches the hybrid propulsion stage's designed lifetime for three round-trip crew missions to the Martian sphere of influence.

Chai, Patrick R.↗

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗

Hybrid propulsion technology program: Phase 1. Volume 3: Thiokol Corporation Space Operations

Three candidate hybrid propulsion (HP) concepts were identified, optimized, evaluated, and refined through an iterative process that continually forced improvement to the systems with respect to safety, reliability, cost, and performance criteria. A full scale booster meeting Advanced Solid Rocket Motor (ASRM) thrust-time constraints and a booster application for 1/4 ASRM thrust were evaluated. Trade studies and analyses were performed for each of the motor elements related to SRM technology. Based on trade study results, the optimum HP concept for both full and quarter sized systems was defined. The three candidate hybrid concepts evaluated are illustrated.

Schuler, A. L.↗

Design Optimization of Gas Generator Hybrid Propulsion Boosters

A methodology used in support of a study for NASA/MSFC to optimize the design of gas generator hybrid propulsion booster for uprating the National Space Transportation System (NSTS) is presented. The objective was to compare alternative configurations for this booster approach, optimizing each candidate concept on different bases, in order to develop data for a trade table on which a final decision was based. The methodology is capable of processing a large number of independent and dependent variables, adjusting the overall subsystems characteristics to arrive at a best compromise integrated design to meet various specific optimization criteria subject to selected constraints. For each system considered, a detailed weight statement was generated along with preliminary cost and reliability estimates.

Weldon, Vincent↗

Design optimization of gas generator hybrid propulsion boosters

A methodology used in support of a contract study for NASA/MSFC to optimize the design of gas generator hybrid propulsion booster for uprating the National Space Transportation System (NSTS) is presented. The objective was to compare alternative configurations for this booster approach, optimizing each candidate concept on different bases, in order to develop data for a trade table on which a final decision was based. The methodology is capable of processing a large number of independent and dependent variables, adjusting the overall subsystems characteristics to arrive at a best compromise integrated design to meet various specified optimization criteria subject to selected constraints. For each system considered, a detailed weight statement was generated along with preliminary cost and reliability estimates.

Weldon, Vincent↗

Sensitivity Analysis of Hybrid Propulsion Transportation System for Human Mars Expeditions

The National Aeronautics and Space Administration continues to develop and refine various transportation options to successfully field a human Mars campaign. One of these transportation options is the Hybrid Transportation System which utilizes both solar electric propulsion and chemical propulsion. The Hybrid propulsion system utilizes chemical propulsion to perform high thrust maneuvers, where the delta-V is most optimal when ap- plied to save time and to leverage the Oberth effect. It then utilizes solar electric propulsion to augment the chemical burns throughout the interplanetary trajectory. This eliminates the need for the development of two separate vehicles for crew and cargo missions. Previous studies considered single point designs of the architecture, with fixed payload mass and propulsion system performance parameters. As the architecture matures, it is inevitable that the payload mass and the performance of the propulsion system will change. It is desirable to understand how these changes will impact the in-space transportation system's mass and power requirements. This study presents an in-depth sensitivity analysis of the Hybrid crew transportation system to payload mass growth and solar electric propulsion performance. This analysis is used to identify the breakpoints of the current architecture and to inform future architecture and campaign design decisions.

Chai, Patrick R.↗

Hybrid propulsion based on fluid-controlled solid gas generators

The use of fuel-rich solid (gas generator-type) propellants for hybrid propulsion affords some design and utilization efficiency advantages. Both forward and aft liquid injection control concepts are evaluated from the operational standpoints of ballistics, throttling, stability and extinguishment. Steady-state and non-steady ballistics analyses are employed for this evaluation. Stability of solid motor operation is enhanced by fluid injection with adequate injector pressure drop. Efficient throttling and reliable extinguishment are attained through a combination of solid propellant combustion tailoring, grain design, control valves and sensors. Initial results from a laboratory-scale slab combustor, combining a gas generator propellant with gaseous oxygen injection, are also presented.

Cohen, Norman S.↗

Hybrid propulsion technology program: Phase 1, volume 1

A number of booster propulsion system concepts are being considered for the next generation of manned and unmanned space launch vehicles. The one propulsion system concept that has potential for reducing costs with increased safety, reliability, and performance is hybrid propulsion (HP). A HP system may be thought of as a liquid propulsion system with solid fuel or a solid propulsion system with a liquid oxidizer. The liquid propulsion features that are most attractive are the higher specific impulse, clean exhaust, separated propellants, and oxidizer loading just prior to launch. The most attractive solid propulsion features includes low life cycle costs, no rotating machinery, compact size, and a robust case. In addition, a HP system has a robust LO2 tank; provides thrust control for ignition, to alleviate flight loads, and for thrust termination; and uses an inert grain that is not sensitive to anomalies such as cracks, voids, and separations. The object is to develop the technology to enable the application of HP to manned and unmanned space launch vehicles. This program will identify the necessary technology, acquire that technology, and demonstrate that technology. This volume is the executive summary.

Schuler, A. L.↗

Hybrid Propulsion In-Situ Resource Utilization Test Facility Results

Hybrid rockets present a promising alternative to conventional chemical propulsion systems for In-Situ Resource Utilization (ISRU) and in-space applications. While they have many benefits for these applications, there are still many small details that require research before they can be adopted into flight systems. A flexible test facility was developed at JPL to test operation of hybrid motors at small scale (5 cm outer diameter fuel grains) over a range of conditions. Specifically, this paper studies two of the major advantages: low temperature performance and throttling. Paraffin-based hybrid rockets are predicted to have good performance at low temperatures. This could significantly decrease the overall system mass by minimizing the thermal conditioning required for Mars or outer planet applications. Therefore, the coefficient of thermal expansion and glass transition of paraffin are discussed. Additionally, deep throttling has been considered for several applications. This was a natural starting point for hotfire testing using the hybrid propulsion ISRU test facility. Additionally, short length to diameter ratio (L/D) fuel grains are tested to determine if these systems can be packaged into geometrically constrained spaces.

Karp, Ashley Chandler↗

Hybrid propulsion for launch vehicle boosters: A program status update

Results obtained in studying the origin and suppression of large-amplitude pressure oscillations in a 24 in. diameter hybrid motor using a liquid oxygen/hydroxylterminated polybutadiene/polycyclopentadiene propellant system are discussed. Tests conducted with liquid oxygen flow rates varying from 10 to 40 lbm/sec were designed to gauge the effectiveness of various vaporization chamber flow fields, injector designs, and levels of heat addition in suppressing high-frequency longitudinal mode oscillations. Longitudinal acoustic modes did not arise in any tests. However, initial testing revealed the presence of high-amplitude, sinusoidal, nonacoustic oscillations persisting throughout the burn durations. Analysis showed this to be analogous to chug mode instability in liquid rocket engines brought about by a coupling of motor combustion processes and the liquid oxygen feed system. Analytical models were developed and verified by test data to predict the amplitude and frequency of feed-system-coupled combustion pressure oscillations. Subsequent testing showed that increasing the feed system impedance eliminated the bulk mode instability. This paper documents the work completed to date in performance of the Hybrid Propulsion Technology for Launch Vehicle Boosters Program (NAS8-39942) sponsored by NASA's George C. Marshall Space Flight Center.

Carpenter, R. L.↗

Hybrid Propulsion Technology Program

Future launch systems of the United States will require improvements in booster safety, reliability, and cost. In order to increase payload capabilities, performance improvements are also desirable. The hybrid rocket motor (HRM) offers the potential for improvements in all of these areas. The designs are presented for two sizes of hybrid boosters, a large 4.57 m (180 in.) diameter booster duplicating the Advanced Solid Rocket Motor (ASRM) vacuum thrust-time profile and smaller 2.44 m (96 in.), one-quater thrust level booster. The large booster would be used in tandem, while eight small boosters would be used to achieve the same total thrust. These preliminary designs were generated as part of the NASA Hybrid Propulsion Technology Program. This program is the first phase of an eventual three-phaes program culminating in the demonstration of a large subscale engine. The initial trade and sizing studies resulted in preferred motor diameters, operating pressures, nozzle geometry, and fuel grain systems for both the large and small boosters. The data were then used for specific performance predictions in terms of payload and the definition and selection of the requirements for the major components: the oxidizer feed system, nozzle, and thrust vector system. All of the parametric studies were performed using realistic fuel regression models based upon specific experimental data.

Jensen, G. E.↗

Human Mars Mission In-Space Transportation Sensitivity for Nuclear Electric / Chemical Hybrid Propulsion

NASA's Human Exploration and Operation Mission Directorate is continuing to study different concepts and options to field human Mars missions as part of NASA's Moon2Mars directive. In this study, an update to the Hybrid propulsion system was established with the introduction of nuclear electric propulsion system to replace the solar electric propulsion system in an effort to understand the potential impact of a shorter mission to Mars. For crewed missions to Mars, the transportation system sizing is highly dependent on the type of mission and the mission duration. An integrated trajectory analysis capability has been developed and updated to enable this investigation. Longer duration mission may utilize higher efficiency low thrust propulsion system more, but would require higher payload mass due to increase to crew logistics loading and habitation volume. Conversely, shorter duration mission may have lower payload mass, but will require significant increase to propulsion system performance and/or overall system mass. An overall integrated design trade space is defined in this paper to investigate the tradeoff between these scenarios to illuminate the optimality of the transportation system option from a mass perspective. The sensitivity analysis developed in this study will be crucial to understanding the Mars mission design trade space for crewed Mars missions, and will help inform design decisions and investment strategies.

Patrick R. Chai↗

Application of hybrid propulsion systems to planetary missions

The feasibility and application of hybrid rocket propulsion to outer-planet orbiter missions is assessed in this study and guidelines regarding future development are provided. A Jupiter Orbiter Mission was selected for evaluation because it is the earliest planetary mission which may require advanced chemical propulsion. Mission and spacecraft characteristics which affect the selection and design of propulsion subsystems are presented. Alternative propulsion subsystems, including space-storable bipropellant liquids, a solid/monopropellant vernier, and a hybrid, are compared on the basis of performance, reliability, and cost. Cost-effectiveness comparisons are made for a range of assumptions including variation in (1) the level of need for spacecraft performance (determined in part by launch vehicle injected mass capability), and (2) achievable reliability at corresponding costs. The results indicated that the hybrid and space-storable bipropellant mechanizations are competitive.

Don, J. P.↗

Advancement of the General Aviation Synthesis Program Using Python to Enable Optimization-Based Hybrid-Propulsion Aircraft Design

In support of the Electrified Powertrain Flight Demonstrator and Advanced Air Transport Technologies projects at NASA, a new tool has been developed at NASA’s Ames and Glenn Research Centers to enable coupled engine and airframe optimization and analysis. The new tool combines the engineering-level analysis methods and empirical models of the FORTRAN General Aviation Synthesis Program (GASP) with the Python-based OpenMDAO framework to provide a modular framework for efficient gradient-based optimization with the aim of incorporating new subsystem models for unconventional configurations. The tool has been verified against GASP analyses of several aircraft models and mission formulations. Preliminary efforts have been made to integrate pyCycle, a thermodynamic cycle analysis tool, to enable simultaneous optimization of hybrid propulsion system and vehicle parameters while taking full mission performance and constraints into account. This will improve current capabilities to assess impacts of electrified powertrain technologies on future aircraft designs.

Kenneth R. Lyons↗

Advancement of the General Aviation Synthesis Program Using Python to Enable Optimization-Based Hybrid-Propulsion Aircraft Design

In support of the Electrified Powertrain Flight Demonstrator and Advanced Air Transport Technologies projects at NASA, a new tool has been developed at NASA's Ames and Glenn Research Centers to enable coupled engine and airframe optimization and analysis. The new tool combines the engineering-level analysis methods and empirical models of the FORTRAN General Aviation Synthesis Program (GASP) with the Python-based OpenMDAO framework to provide a modular framework for efficient gradient-based optimization with the aim of incorporating new subsystem models for unconventional configurations. The tool has been verified against GASP analyses of several aircraft models and mission formulations. Preliminary efforts have been made to integrate pyCycle, a thermodynamic cycle analysis tool, to enable simultaneous optimization of hybrid propulsion system and vehicle parameters while taking full mission performance and constraints into account. This will improve current capabilities to assess impacts of electrified powertrain technologies on future aircraft designs.

Kenneth R Lyons↗

Hybrid propulsion technology program: Phase 1, volume 4

The use of a liquid oxidizer-solid fuel hybrid propellant combination in booster rocket motors appears extremely attractive due to the integration of the best features of liquid and solid propulsion systems. The hybrid rocket combines the high performance, clean exhaust, and safety of liquid propellant engines with the low cost and simplicity of solid propellant motors. Additionally, the hybrid rocket has unique advantages such as an inert fuel grain and a relative insensitivity to fuel grain and oxidizer injection anomalies. The advantages mark the hybrid rocket as a potential replacement or alternative for current and future solid propellant booster systems. The issues are addressed and recommendations are made concerning oxidizer feed systems, injectors, and ignition systems as related to hybrid rocket propulsion. Early in the program a baseline hybrid configuration was established in which liquid oxygen would be injected through ports in a solid fuel whose composition is based on hydroxyl terminated polybutadiene (HTPB). Liquid oxygen remained the recommended oxidizer and thus all of the injector concepts which were evaluated assumed only liquid would be used as the oxidizer.

Claflin, S. E.↗