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Sample Return Propulsion Technology Development Under NASA's ISPT Project

Abstract In 2009, the In-Space Propulsion Technology (ISPT) program was tasked to start development of propulsion technologies that would enable future sample return missions. Sample return missions can be quite varied, from collecting and bringing back samples of comets or asteroids, to soil, rocks, or atmosphere from planets or moons. As a result, ISPT s propulsion technology development needs are also broad, and include: 1) Sample Return Propulsion (SRP), 2) Planetary Ascent Vehicles (PAV), 3) Multi-mission technologies for Earth Entry Vehicles (MMEEV), and 4) Systems/mission analysis and tools that focuses on sample return propulsion. The SRP area includes electric propulsion for sample return and low cost Discovery-class missions, and propulsion systems for Earth Return Vehicles (ERV) including transfer stages to the destination. Initially the SRP effort will transition ongoing work on a High-Voltage Hall Accelerator (HIVHAC) thruster into developing a full HIVHAC system. SRP will also leverage recent lightweight propellant-tanks advancements and develop flight-qualified propellant tanks with direct applicability to the Mars Sample Return (MSR) mission and with general applicability to all future planetary spacecraft. ISPT s previous aerocapture efforts will merge with earlier Earth Entry Vehicles developments to form the starting point for the MMEEV effort. The first task under the Planetary Ascent Vehicles (PAV) effort is the development of a Mars Ascent Vehicle (MAV). The new MAV effort will leverage past MAV analysis and technology developments from the Mars Technology Program (MTP) and previous MSR studies. This paper will describe the state of ISPT project s propulsion technology development for future sample return missions.12

Anderson, David J.↗

Mars Relays Satellite Orbit Design Considerations for Global Support of Robotic Surface Missions

This paper discusses orbit design considerations for Mars relay satellite (MRS)support of globally distributed robotic surface missions. The orbit results reported in this paper are derived from studies of MRS support for two types of Mars robotic surface missions: 1) the mars Environmental Survey (MESUR) mission, which in its current definition would deploy a global network of up to 16 small landers, and 2)a Small Mars Sample Return (SMSR) mission, which included four globally distributed landers, each with a return stage and one or two rovers, and up to four additional sets of lander/rover elements in an extended mission phase.

Robitics Mars↗

Propulsion Technology Development for Sample Return Missions Under NASA's ISPT Program

The In-Space Propulsion Technology (ISPT) Program was tasked in 2009 to start development of propulsion technologies that would enable future sample return missions. Sample return missions could be quite varied, from collecting and bringing back samples of comets or asteroids, to soil, rocks, or atmosphere from planets or moons. The paper will describe the ISPT Program s propulsion technology development activities relevant to future sample return missions. The sample return propulsion technology development areas for ISPT are: 1) Sample Return Propulsion (SRP), 2) Planetary Ascent Vehicles (PAV), 3) Entry Vehicle Technologies (EVT), and 4) Systems/mission analysis and tools that focuses on sample return propulsion. The Sample Return Propulsion area is subdivided into: a) Electric propulsion for sample return and low cost Discovery-class missions, b) Propulsion systems for Earth Return Vehicles (ERV) including transfer stages to the destination, and c) Low TRL advanced propulsion technologies. The SRP effort will continue work on HIVHAC thruster development in FY2011 and then transitions into developing a HIVHAC system under future Electric Propulsion for sample return (ERV and transfer stages) and low-cost missions. Previous work on the lightweight propellant-tanks will continue under advanced propulsion technologies for sample return with direct applicability to a Mars Sample Return (MSR) mission and with general applicability to all future planetary spacecraft. A major effort under the EVT area is multi-mission technologies for Earth Entry Vehicles (MMEEV), which will leverage and build upon previous work related to Earth Entry Vehicles (EEV). The major effort under the PAV area is the Mars Ascent Vehicle (MAV). The MAV is a new development area to ISPT, and builds upon and leverages the past MAV analysis and technology developments from the Mars Technology Program (MTP) and previous MSR studies.

Anderson, David J.↗

Mars Sample Return - studies for a fresh look

Included in the paper are both the themes resulting from the industry studies and the general scope of the focused concepts used to assess the current planning for the Mars Sample Return (MSR) mission and precursor missions. Included in this conference are papers by the four industrial teams, as well as a fifth study by JPL's Team-X to provide further corroboration of study results. The results suggest that a scientifically justifiable mission is possible, and that technology and precursor mission demonstration plans currently in the Mars Program are justified (with some modifications).

Mars Sample Return MSR↗

Mars Orbiter Sample Return Power Design

The NASA/JPL 2003/2005 Mars Sample Return (MSR) Missions will each have a sample return canister that will be filled with samples cored from the surface of MARS. These spherical canisters will be 14.8 cm in diameter and must be powered only by solar cells on the surface and must communicate using RF transmission with the recovery vehicle that will be coming in 2006 or 2009 to retrieve the canister. This paper considers the aspect and conclusion that went into the design of the power system that achieves the maximum power with the minimum risk. The power output for the spherical orbiting canister was modeled and plotted in various views of the orbit by the SOAP program developed by JPL. The requirements and geometry for a solar array on a sphere are unique and place special constraints on the design. These requirements include 1) accommodating a lid for sample loading into the canister, surface area was restricted from use on the Northern pole of the spherical canister. 2) minimal cell surface coverage (maximum cell efficiency), less than 40%, for recovery vehicle to locate the canister by optical techniques. 3) a RF transmission during 50% of MARS orbit time on any spin axis, which requires optimum circuit placement of the solar cell onto the spherical canister. The best configuration would have been a 4.5 volt round cell, but in the real world we compromised with six triangular silicon cells connected in series to form a hexagon. These hexagon circuits would be mounted onto a flat facet cut into the spherical canister. The surface flats are required in order to maximize power, the surface of the cells connected in series must be at the same angle relative to the sun. The flat facets intersect each other to allow twelve circuits evenly spaced just North and twelve circuits South of the equator of the spherical canister. Connecting these circuits in parallel allows sufficient power to operate the transmitter at minimum solar exposure, Northern pole of the canister facing the sun. Additional power, as much as 20%, is also generated by the circuits facing MARS due to albedo of MARS.

Mardesich, N.↗

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗

Cryogenic Curation: Isolated Technology and Mission Operational Requirements for Sample Return

Future lunar, Mars, asteroid, and comet sample return missions may collect samples that have been preserved at sub-freezing or even cryogenic temperatures. For such samples, the study of volatiles and temperature-sensitive minerals will have high priority. Valuable geochemical and mineralogical information will be lost if such samples are allowed to reach ambient temperatures on Earth. The ability to store, document, subdivide, and transport extraterrestrial geologic samples while maintaining sub-freezing or cryogenic temperatures, possibly as low as 40 K, is required for the complete scientific study of samples from cold environments.

Calaway, Michael J.↗

Microspacecraft technology for planetary science missions

A summary is presented of the technology that may enable a microspacecraft, whose mass is on the order of 10 kg, to perform smaller, faster, and more frequent planetary science missions. Some of JPL's activities in microspacecraft are discussed including the benefits of microspacecraft technology to a Mars Rover sample return mission and the conceptual design of a microspacecraft to examine near earth asteroids. Major technology items allowing the decrease in system mass include lightweight carbon-carbon and other composite structural materials and microsensors and instruments.

Jones, Ross M.↗

High-Pressure Lightweight Thrusters

Returning samples of Martian soil and rock to Earth is of great interest to scientists. There were numerous studies to evaluate Mars Sample Return (MSR) mission architectures, technology needs, development plans, and requirements. The largest propulsion risk element of the MSR mission is the Mars Ascent Vehicle (MAV). Along with the baseline solid-propellant vehicle, liquid propellants have been considered. Similar requirements apply to other lander ascent engines and reaction control systems. The performance of current state-ofthe- art liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure. Pump-fed propulsion is suggested for a single-stage bipropellant MAV. Achieving a 90-percent stage propellant fraction is thought to be possible on a 100-kg scale, including sufficient thrust for lifting off Mars. To increase the performance of storable bipropellant rocket engines, a high-pressure, lightweight combustion chamber was designed. Iridium liner electrodeposition was investigated on complex-shaped thrust chamber mandrels. Dense, uniform iridium liners were produced on chamber and cylindrical mandrels. Carbon/carbon composite (C/C) structures were braided over iridium-lined mandrels and densified by chemical vapor infiltration. Niobium deposition was evaluated for forming a metallic attachment flange on the carbon/ carbon structure. The new thrust chamber was designed to exceed state-of-the-art performance, and was manufactured with an 83-percent weight savings. High-performance C/Cs possess a unique set of properties that make them desirable materials for high-temperature structures used in rocket propulsion components, hypersonic vehicles, and aircraft brakes. In particular, more attention is focused on 3D braided C/Cs due to their mesh-work structure. Research on the properties of C/Cs has shown that the strength of composites is strongly affected by the fiber-matrix interfacial bonding, and that weakening interface realizes pseudo-plastic behavior with significant increase in the tensile strength. The investigation of high-temperature strength of C/Cs under high-rate heating (critical for thrust chambers) shows that tensile and compression strength increases from 70 MPa at room temperature to 110 MPa at 1,773 K, and up to 125 MPa at 2,473 K. Despite these unique properties, the use of C/Cs is limited by its high oxidation rate at elevated temperatures. Lining carbon/carbon chambers with a thin layer of iridium or iridium and rhenium is an innovative way to use proven refractory metals and provide the oxidation barrier necessary to enable the use of carbon/ carbon composites. Due to the lower density of C/Cs as compared to SiC/SiC composites, an iridium liner can be added to the C/C structure and still be below the overall thruster weight. Weight calculations show that C/C, C/C with 50 microns of Ir, and C/C with 100 microns of Ir are of less weight than alternative materials for the same construction.

Holmes, Richard↗

Planetary Protection Technology for Mars Sample Return

The NASA Mars Exploration Program has recently adopted a plan that includes a first Mars sample return (MSR) mission proposed for launch in 2013. Such a mission would deal with two new categories of planetary protection requirements: (1) assuring a very low probability of inadvertent release of the sample in order to provide extra protection against the extremely unlikely possibility of biological hazards in the returned material and (2) keeping the samples free of round-trip Earth organisms to facilitate confirmation of safety after return to Earth. This paper describes the planetary-protection-related technical challenges awaiting any MSR mission and describes work in progress on technology needed to meet these challenges. New technology is needed for several functions. Containment assurance requires breaking the chain of contact with Mars: the exterior of the sample container must not be contaminated with Mars material either during the loading process or during launch from the Mars surface.

planetary protection↗

Nickel-coated Aluminum Particles: A Promising Fuel for Mars Missions

Combustion of metals in carbon dioxide is a promising source of energy for propulsion on Mars. This approach is based on the ability of some metals (e.g. Mg, Al) to burn in CO2 atmosphere and suggests use of the Martian carbon dioxide as an oxidizer in jet or rocket engines. Analysis shows that CO2/metal propulsion will reduce significantly the mass of propellant transported from Earth for long-range mobility on Mars and sample return missions. Recent calculations for the near-term missions indicate that a 200-kg ballistic hopper with CO2/metal rocket engines and a CO2 acquisition unit can perform 10-15 flights on Mars with the total range of 10-15 km, i.e. fulfill the exploration program typically assigned for a rover. Magnesium is currently recognized as a candidate fuel for such engines owing to easy ignition and fast burning in CO2. Aluminum may be more advantageous if a method for reducing its ignition temperature is found. Coating it by nickel is one such method. It is known that a thin nickel layer of nickel on the surface of aluminum particles can prevent their agglomeration and simultaneously facilitate their ignition, thus increasing the efficiency of aluminized propellants.

Shafirovich, Evgeny↗

Nickel-Coated Aluminum Particles: A Promising Fuel for Mars Missions

Combustion of metals in carbon dioxide is a promising source of energy for propulsion on Mars. This approach is based on the ability of some metals (e.g. Mg, Al) to burn in CO2 atmosphere and suggests use of the Martian carbon dioxide as an oxidizer in jet or rocket engines. Analysis shows that CO2/metal propulsion will reduce significantly the mass of propellant transported from Earth for long-range mobility on Mars and sample return missions. Recent calculations for the near-term missions indicate that a 200-kg ballistic hopper with CO2/metal rocket engines and a CO2 acquisition unit can perform 10-15 flights on Mars with the total range of 10-15 km, i.e. fulfill the exploration program typically assigned for a rover. Magnesium is currently recognized as a candidate fuel for such engines owing to easy ignition and fast burning in CO2. Aluminum may be more advantageous if a method for reducing its ignition temperature is found. Coating it by nickel is one such method. It is known that a thin nickel layer of nickel on the surface of aluminum particles can prevent their agglomeration and simultaneously facilitate their ignition, thus increasing the efficiency of aluminized propellants. Combustion of single Ni-coated Al particles in different gas environments (O2, CO2, air) was studied using electrodynamic levitation and laser ignition. It was shown that the combustion mechanisms depend on the ambient atmosphere. Combustion in CO2 is characterized by the smaller size and lower brightness of flame than in O2, and by phenomena such as micro-flashes and fragment ejection. The size and brightness of flame gradually decrease as the particle burns.

Shafirovich, Evgeny↗

Mars rover local navigation and hazard avoidance

A Mars rover sample return mission has been proposed for the late 1990's. Due to the long speed-of-light delays between earth and Mars, some autonomy on the rover is highly desirable. JPL has been conducting research in two possible modes of rover operation, Computer-Aided Remote Driving and Semiautonomous Navigation. A recently-completed research program used a half-scale testbed vehicle to explore several of the concepts in semiautonomous navigation. A new, full-scale vehicle with all computational and power resources on-board will be used in the coming year to demonstrate relatively fast semiautonomous navigation. The computational and power requirements for Mars rover local navigation and hazard avoidance are discussed.

Wilcox, B. H.↗

Mechanical Testing of Soils from the South Range of the Utah Test and Training Range: Derivation of Soil Properties to Support the Earth Entry System Landing for Mars Sample Return

This report summarizes results from laboratory tests conducted by Applied Research Associates, Inc. (ARA) on soil samples collected from multiple sites within the South Range of the U.S. Air Force Utah Test and Training Range (UTTR). The goal of the laboratory tests was to establish soil constitutive properties and develop computational soil models enabling NASA to simulate impact landings of the Earth Entry System (EES) for the Mars Sample Return (MSR) mission. Test methods and results are presented describing the strength, compressibility, and stiffness of soils in the UTTR South Range including methods to incorporate the measured properties into Ansys LS-DYNAÒ constitutive material models for EES landing simulations.

Soil↗

Autonomous rendezvous and docking in Mars orbit

This paper describes principally the ascent phase of the Mars Surface Sample Return mission, where the terminal rendezvous phase is emphasized to describe a newly developed automatic rendezvous and docking system. The autonomous rendezvous and docking in Mars orbit is used to reduce the payload necessary to achieve the mission so that today's-sized spacecraft can be used. Proportional navigation guidance utilizing a simple control algorithm was developed and tested to accomplish the rendezvous. This simplified guidance scheme uses only one parabolic axial control curve generated on-board based on its dispersed state and requires no closing velocity change.

Vandenberg, F.↗

In situ propellant production - A new potential for round-trip spacecraft

In situ propellant production (ISPP) greatly reduces the Earth escape requirements for some roundtrip missions, particularly Mars Sample Return. ISPP systems are described which produce oxygen or oxygen and methane from available atmospheric and surface materials. With ISPP, a 1 kg sample can be returned direct from Mars using a single Shuttle launch. Mars entry can be either direct or from orbit. Comet and asteroid sample return is also accomplished within a single Shuttle launch. Launch requirements for round-trip missions to Ganymede and Callisto are reduced by 15 to 40%.

Stancati, M. L.↗

Sample Return Container Opening Process Concept for Potential Mars Sample Return

Proposed Mars Sample Return (MSR) missions would require a pristine and secure opening method to ensure sample Contamination Control and backward Planetary Protection. In order to reach the samples, a series of five containers would need to be opened inside of a Mars Returned Sample Handling (MRSH) facility. The process would include opening the Containment Assurance Module (CAM) aboard the Earth Entry Vehicle (EEV), the Secondary Containment Vessel (SCV), Primary Containment Vessel (PCV), and the Orbiting Sample (OS) container, and finally removing and opening the Returned Sample Tube Assemblies (RSTA). Some of these containers can be opened by reversing the mechanical assembly process while others would require destructive means. Several containers are still in a conceptual design phase while others are en route to Mars aboard the M2020 rover. In order to inform the design of the containers that are still in the conceptual stages, a study was performed at each level of the containment assembly. The studies were used to determine the least destructive and most robust methods to disassemble and open the containers while minimizing risk to the samples or the personnel. In addition to the envisioned disassembly and breaching method, contingency plans were made for completing the disassembly if damage to the vehicle and containment system occurred.

Liu, Yang↗

Mars Sample Return and The Capture, Containment, and Return System New Design and Path To 2027 Launch

The Mars Sample Return (MSR) campaign is one of the most ambitious and complex exoplanet scientific exploration missions currently underway. With the participation of NASA, ESA, and a large number of industry partners, MSR aims to bring back Martian rock and atmosphere samples with the goal of answering key questions about Mars’ geological, climatological, and (potentially) biological evolution. To accomplish this ambitious goal, the campaign relies on three distinct flight elements and a ground element. The Earth Return Orbiter (ERO) mission that would host the Capture, Containment, and Return System (CCRS) is the last element of the trio. The mission would capture the orbiting sample in low Mars orbit (launched into orbit by another mission), contain it and return it to Earth, landing it at the Utah Test and Training Range (UTTR). The CCRS continues its development. Since its early architecture, several changes were adopted by the project in order to improve overall payload efficiency and reduce mass. CCRS is currently on track to achieve the next milestone, Critical Design Review, expected in late 2024. This paper will discuss the CCRS design, how the current architecture contributes to an improved mission baseline, and the next critical steps of the mission towards its launch.

Mars mission↗