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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 NTRS1986

Manned Mars mission cost estimate

The potential costs of several options of a manned Mars mission are examined. A cost estimating methodology based primarily on existing Marshall Space Flight Center (MSFC) parametric cost models is summarized. These models include the MSFC Space Station Cost Model and the MSFC Launch Vehicle Cost Model as well as other modes and techniques. The ground rules and assumptions of the cost estimating methodology are discussed and cost estimates presented for six potential mission options which were studied. The estimated manned Mars mission costs are compared to the cost of the somewhat analogous Apollo Program cost after normalizing the Apollo cost to the environment and ground rules of the manned Mars missions. It is concluded that a manned Mars mission, as currently defined, could be accomplished for under $30 billion in 1985 dollars excluding launch vehicle development and mission operations.

Hamaker, Joseph↗

NASA NTRS2015

Space Technology Mission Directorate: Game Changing Development

NASA and the aerospace community have deep roots in manufacturing technology and innovation. Through it's Game Changing Development Program and the Advanced Manufacturing Technology Project NASA develops and matures innovative, low-cost manufacturing processes and products. Launch vehicle propulsion systems are a particular area of interest since they typically comprise a large percentage of the total vehicle cost and development schedule. NASA is currently working to develop and utilize emerging technologies such as additive manufacturing (i.e. 3D printing) and computational materials and processing tools that could dramatically improve affordability, capability, and reduce schedule for rocket propulsion hardware.

Gaddis, Stephen W.↗

NASA NTRS2020

Parametric Cost Estimates of Four 20 Ton Payload Mars EDL Vehicle Concepts

Cost is one of the biggest obstacles to sending humans to Mars. Many studies have examined various vehicles and/or technologies which could be used to send humans to Mars. However, nearly all of these studies have either ignored cost or have used the mass of the vehicles as a surrogate for cost. This work presents parametric cost estimates of four Mars Entry, Descent, and Landing vehicle concepts capable of landing 20 tons of payload on the surface of Mars. The concepts are the Co-Optimization Blunt-body Re-entry Analysis-Mid lift to drag ratio Rigid Vehicle (Cobra–MRV), Adaptive Deployable Entry and Placement Technology (ADEPT), Hypersonic Inflatable Aerodynamic Decelerator (HIAD), and Capsule concepts. Two variants of the HIAD concept are studied, one with a single HIAD heatshield and one with two HIADs. The study presents the development and production cost of each vehicle and the total cost to build five flight units and fifteen flight units. Five flight units is representative of a single mission, or a "Flags and Footprints" style campaign, whereas fifteen flight units is representative of multiple missions going to multiple sites on Mars. All costs presented in this work are normalized to the average of the first unit production cost of the lander concepts. There is a large amount of uncertainty both in the design of the vehicles and the cost of the vehicles and it is impossible to claim with certainty which vehicle will cost the least. However, it is likely that the total cost to produce five flight units will be in the following ranking from least costly to most costly, Single HIAD, Capsule, Dual HIAD, Cobra, ADEPT. The ranking for fifteen units is similar but with the positions of the Dual HIAD and Cobra reversed. This study only considers the cost of the entry vehicle and does not take into account the effect of the entry vehicle’s mass on the cost of the in-space propulsion stage or launch vehicle.

Paul D Friz↗

NASA NTRS1998

Macroeconomic Benefits of Low-Cost Reusable Launch Vehicles

The National Aeronautics and Space Administration (NASA) initiated its Reusable Launch Vehicle (RLV) Technology Program to provide information on the technical and commercial feasibility of single-stage to orbit (SSTO), fully-reusable launchers. Because RLVs would not depend on expendable hardware to achieve orbit, they could take better advantage of economies of scale than expendable launch vehicles (ELVs) that discard costly hardware on ascent. The X-33 experimental vehicle, a sub-orbital, 60%-scale prototype of Lockheed Martin's VentureStar SSTO RLV concept, is being built by Skunk Works for a 1999 first flight. If RLVs achieve prices to low-earth orbit of less than $1000 US per pound, they could hold promise for eliciting an elastic response from the launch services market. As opposed to the capture of existing market, this elastic market would represent new space-based industry businesses. These new opportunities would be created from the next tier of business concepts, such as space manufacturing and satellite servicing, that cannot earn a profit at today's launch prices but could when enabled by lower launch costs. New business creation contributes benefits to the US Government (USG) and the US economy through increases in tax revenues and employment. Assumptions about the costs and revenues of these new ventures, based on existing space-based and aeronautics sector businesses, can be used to estimate the macroeconomic benefits provided by new businesses. This paper examines these benefits and the flight prices and rates that may be required to enable these new space industries.

Shaw, Eric J.↗

NASA NTRS1998

Low Cost Large Core Vehicle Structures Assessment

Boeing Information, Space, and Defense Systems executed a Low Cost Large Core Vehicle Structures Assessment (LCLCVSA) under contract to NASA Marshall Space Flight Center (MSFC) between November 1997 and March 1998. NASA is interested in a low-cost launch vehicle, code named Magnum, to place heavy payloads into low earth orbit for missions such as a manned mission to Mars, a Next Generation Space Telescope, a lunar-based telescope, the Air Force's proposed space based laser, and large commercial satellites. In this study, structural concepts with the potential to reduce fabrication costs were evaluated in application to the Magnum Launch Vehicle (MLV) and the Liquid Fly Back Booster (LFBB) shuttle upgrade program. Seventeen concepts were qualitatively evaluated to select four concepts for more in-depth study. The four structural concepts selected were: an aluminum-lithium monocoque structure, an aluminum-lithium machined isogrid structure, a unitized composite sandwich structure, and a unitized composite grid structure. These were compared against a baseline concept based on the Space Shuttle External Tank (ET) construction. It was found that unitized composite structures offer significant cost and weight benefits to MLV structures. The limited study of application to LFBB structures indicated lower, but still significant benefits. Technology and facilities development roadmaps to prepare the approaches studied for application to MLV and LFBB were constructed. It was found that the cost and schedule to develop these approaches were in line with both MLV and LFBB development schedules. Current Government and Boeing programs which address elements of the development of the technologies identified are underway. It is recommended that NASA devote resources in a timely fashion to address the specific elements related to MLV and LFBB structures.

Hahn, Steven E.↗

NASA NTRS1990

On-orbit assembly/servicing task definition study

The OEXP vehicles being envisioned to carry out the Presidential space goals of a lunar outpost and human exploration of Mars will require on-orbit assembly, refurbishment, checkout, and launch. The On-orbit Assembly/Servicing Task Definition Study applies the space vehicle processing experience and procedures archives resident at NASA's Kennedy Space Center (KSC) to determine the task flows, and resources/facilities necessary to process the OEXP vehicles at Space Station Freedom (SSF). This data base is examined to find the closest analogies to OEXP vehicle components and assembly/refurbishment tasks. Transition tables are generated to provide traceability from KSC hardware processing experience to analogous on-orbit processing of the OEXP vehicles. Iterations in which the task flows are broken down into realistic extravehicular activity (EVA) primitive subtasks and times, and to apply automation and robotic technology to reduce crew risks and minimize EVA time, will enhance the value and accuracy of the predicted flows. These processing scenarios and the resulting resource/facility requirements are used to determine impacts of SSF, resulting in change requests to SSF requirements for provision of 'hooks and scars' to evolve the assembly complete Space Station into a transportation node. Study results to date include assembly analysis of the Martin Marietta Phobos Gateway Vehicle, refurbishment analysis of the Martin Marietta Lunar Evolution Piloted and Cargo Vehicles, and assembly analysis of the Boeing Mars Evolution Vehicle. The results of this study will be accumulated into the vehicle processing operations data base for subsequent modeling, life cycle cost, vehicle growth, and SSF impact analysis.

Vargo, Rick↗

NASA NTRS1991

A white paper: Operational efficiency. New approaches to future propulsion systems

Advanced launch systems for the next generation of space transportation systems (1995 to 2010) must deliver large payloads (125,000 to 500,000 lbs) to low earth orbit (LEO) at one tenth of today's cost, or 300 to 400 $/lb of payload. This cost represents an order of magnitude reduction from the Titan unmanned vehicle cost of delivering payload to orbit. To achieve this sizable reduction, the operations cost as well as the engine cost must both be lower than current engine system. The Advanced Launch System (ALS) is studying advanced engine designs, such as the Space Transportation Main Engine (STME), which has achieved notable reduction in cost. The results are presented of a current study wherein another level of cost reduction can be achieved by designing the propulsion module utilizing these advanced engines for enhanced operations efficiency and reduced operations cost.

Rhodes, Russel↗

NASA NTRS1975

A semibuoyant vehicle for general transportation missions

The concept of a small, semibuoyant, lifting-body airship with either a disposable or nondisposable buoyant fluid is discussed. Estimations of fuel consumption, payload capability, power requirements and productivity are made and compared to other flight systems. Comparisons are made on the basis of equal cost vehicles. The assumption is made that, to a first-order approximation, the costs of developing, procuring, and operating a commercial air transport vehicle are proportional to vehicle empty weight. It must be noted that no historical cost data exist for the lifting-body airship and therefore these comparisons must be considered preliminary.

Havill, C. D.↗

NASA NTRS1985

DACC program cost and work breakdown structure-dictionary. General purpose aft cargo carrier study, volume 2

Results of detailed cost estimates and economic analysis performed on the updated 201 configuration of the dedicated Aft Cargo Carrier (DACC) are given. The objective of this economic analysis is to provide the National Aeronautics and Space Administration (NASA) with information on the economics of using the DACC on the Space Transportation System (STS). The detailed cost estimates for the DACC are presented by a work breakdown structure (WBS) to ensure that all elements of cost are considered in the economic analysis and related subsystem trades. Costs reported by WBS provide NASA with a basis for comparing competing designs and provide detailed cost information that can be used to forecast phase C/D planning for new projects or programs derived from preliminary conceptual design studies. The scope covers all STS and STS/DACC launch vehicle cost impacts for delivering an orbital transfer vehicle to a 120 NM low Earth orbit (LEO).

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NASA NTRS2008

A Fast, Affordable, Science and Technology SATellite (FASTSAT) and the Small Satellite Market Development Environment

The National Aeronautics and Space Administr ation at Marshall Space Flight Center and the National Space Science and Technology Center in Huntsville Alabama USA, are jointly developing a new class of science and technology mission small satellites. The Fast, Affordable, Science and Technology SATell ite (FASTSAT) was designed and developed using a new collaborative and best practices approach. The FASTSAT development, along with the new class of low cost vehicles currently being developed, would allow performance of ~ 30 kg payload mass missions for a cost of less than 10 million US dollars.

Boudreaux, Mark↗

NASA NTRS1981

The Scout Launch Vehicle program

The Scout Launch Vehicle Program to utilize solid propellant rockets by the DOD and to provide a reliable, low cost vehicle for scientific and applications aircraft is discussed. The program's history is reviewed and a vehicle description is given. The Vandenberg Air Force Base and the San Marco launch sites are described, and capabilities such as payload weight, orbital inclinations, payload volume and mission integration time spans are discussed. Current and future plans for improvement, including larger heat shields and individual rocket motors are also reviewed.

Foster, L. R., Jr.↗

NASA NTRS2014

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Protz, Christopher↗

NASA NTRS2013

Estimation Model of Spacecraft Parameters and Cost Based on a Statistical Analysis of COMPASS Designs

The Collaborative Modeling for Parametric Assessment of Space Systems (COMPASS) team at Glenn Research Center has performed integrated system analysis of conceptual spacecraft mission designs since 2006 using a multidisciplinary concurrent engineering process. The set of completed designs was archived in a database, to allow for the study of relationships between design parameters. Although COMPASS uses a parametric spacecraft costing model, this research investigated the possibility of using a top-down approach to rapidly estimate the overall vehicle costs. This paper presents the relationships between significant design variables, including breakdowns of dry mass, wet mass, and cost. It also develops a model for a broad estimate of these parameters through basic mission characteristics, including the target location distance, the payload mass, the duration, the delta-v requirement, and the type of mission, propulsion, and electrical power. Finally, this paper examines the accuracy of this model in regards to past COMPASS designs, with an assessment of outlying spacecraft, and compares the results to historical data of completed NASA missions.

cost modeling↗

NASA NTRS1974

Space shuttle/food system study. Volume 2, Appendix A: Active heating system-screening analysis. Appendix B: Reconstituted food heating techniques analysis

Technical data are presented which were used to evaluate active heating methods to be incorporated into the space shuttle food system design, and also to evaluate the relative merits and penalties associated with various approaches to the heating of rehydrated food during space flight. Equipment heating candidates were subject to a preliminary screening performed by a selection rationale process which considered the following parameters; (1) gravitational effect; (2) safety; (3) operability; (4) system compatibility; (5) serviceability; (6) crew acceptability; (7) crew time; (8) development risk; and (9) operating cost. A hot air oven, electrically heated food tray, and microwave oven were selected for further consideration and analysis. Passive, semi-active, and active food preparation approaches were also studied in an effort to determine the optimum method for heating rehydrated food. Potential complexity, cost, vehicle impact penalties, and palatability were considered in the analysis. A summary of the study results is provided along with cost estimates for each of the potential sytems

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NASA NTRS1990

Mission management, planning, and cost: PULSE Attitude And Control Systems (AACS)

The Pluto unmanned long-range scientific explorer (PULSE) is a probe that will do a flyby of Pluto. It is a low weight, relatively low costing vehicle which utilizes mostly off-the-shelf hardware, but not materials or techniques that will be available after 1999. A design, fabrication, and cost analysis is presented. PULSE will be launched within the first decade of the twenty-first century. The topics include: (1) scientific instrumentation; (2) mission management, planning, and costing; (3) power and propulsion systems; (4) structural subsystem; (5) command, control, and communication; and (6) attitude and articulation control.

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NASA NTRS2002

Liquid Oxygen Propellant Densification Unit Ground Tested With a Large-Scale Flight-Weight Tank for the X-33 Reusable Launch Vehicle

Propellant densification has been identified as a critical technology in the development of single-stage-to-orbit reusable launch vehicles. Technology to create supercooled high-density liquid oxygen (LO2) and liquid hydrogen (LH2) is a key means to lowering launch vehicle costs. The densification of cryogenic propellants through subcooling allows 8 to 10 percent more propellant mass to be stored in a given unit volume, thereby improving the launch vehicle's overall performance. This allows for higher propellant mass fractions than would be possible with conventional normal boiling point cryogenic propellants, considering the normal boiling point of LO2 and LH2.

Tomsik, Thomas M.↗

NASA NTRS1985

GPACC program cost work breakdown structure-dictionary. General purpose aft cargo carrier study, volume 3

The results of detailed cost estimates and economic analysis performed on the updated Model 101 configuration of the general purpose Aft Cargo Carrier (ACC) are given. The objective of this economic analysis is to provide the National Aeronautics and Space Administration (NASA) with information on the economics of using the ACC on the Space Transportation System (STS). The detailed cost estimates for the ACC are presented by a work breakdown structure (WBS) to ensure that all elements of cost are considered in the economic analysis and related subsystem trades. Costs reported by WBS provide NASA with a basis for comparing competing designs and provide detailed cost information that can be used to forecast phase C/D planning for new projects or programs derived from preliminary conceptual design studies. The scope covers all STS and STS/ACC launch vehicle cost impacts for delivering payloads to a 160 NM low Earth orbit (LEO).

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NASA NTRS2017

Capsulation Satellite or CapSat: A Low-Cost, Reliable, Rapid-Response Spacecraft Platform

The National Aeronautics and Space Administration (NASA) Goddard's Rideshare Office estimates that between 2013 and 2022, NASA launches of primary satellites will have left unused more than 20,371 kilograms of excess capacity. This equates to hundreds of millions of dollars in launch-vehicle costs going unutilized. To fill this void with a standard CubeSat or SmallSat spacecraft platform, which when required to be more reliable, still will cost in the neighborhood of $1M a kilogram, making it prohibitively expensive. A newly proposed solution, which NASA is pursuing, is called the Capsulation Satellite or CapSat. CapSat is a modularized, pressurized, thermally controlled spacecraft designed to host ruggedized commercially available instrumentation in a terrestrial like environment on orbit. Using a technique that is under review for a patent, CapSat actively manages internal air temperatures in a manner similar to a household thermostat. This gives CapSat high-thermal stability, which, in turn, provides component longevity. CapSat was specifically designed to take advantage of the United States Air Force (USAF) Rideshare Program and the Evolved Expendable Launch Vehicle Secondary Payload Adaptor, or ESPA ring. The ESPA ring comes in two sizes: standard and Grande. CapSat primarily will take advantage of the ESPA Grande to provide a 300-kilogram payload capability per attachment point, with up to four attachment points per ring. This approach combines a high-mass capability with a proven Rideshare mechanical interface and secondary payload management infrastructure. Opportunities for ESPA based co-manifests are continuing to expand. The CapSat program is currently funded to design and build a limited prototype and perform thermal-vacuum testing. CapSat is currently in the concept/study phase for both single missions and constellation of earth- and space-observing missions. One of these studies includes land imaging using state-of-the-art advanced infrared detector technology. This paper will report on the current status of the CapSat hardware design, testing, and results as well as any openly available advanced concept study results. The CapSat solution is intended to be a game-changing paradigm shift. CapSat will repurpose currently available, already-proven technology to reduce spaceflight hardware costs to less than $50,000 per kilogram.

Burt, Joe↗