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NASA NTRS2015

Final Report on the Detection of Green Monopropellants

In 2014, National Aeronautics and Space Administration (NASA) Kennedy Space Center (KSC) funded a project titled "Familiarization and Detection of Green Monopropellants" utilizing Independent Research and Technology Development (IR&TD) and Center Innovation Fund (CIF) funding. The purpose of the project was to evaluate methods of detection for ammonium dinitramide (ADN) and hydroxylammonium nitrate (HAN). An Engineering Services Contract (ESC) task order was created with the scope of evaluation of several methods of detecting ADN- and HAN-based propellants, as well as development of methods for detection. Detection methods include developed methods such as colorimetric indicating absorbent socks, and commercial-off-the- shelf (COTS) units for ammonia detection. An additional goal of the task order was for ESC to become familiar with ADN's and HAN's material properties and material compatibility. Two approaches were initially investigated as possible methods for the detection of HAN (or AFM315E) and ADN (or LMP-103S). These approaches were colorimetric analysis and instrumentation-based COTS vapor sensors utilization. Initial testing showed that the relatively non-existent vapor pressure of the AF-M315E (of which HAN is a major component) propellant would make the use of COTS sensors difficult for real-time area monitoring of HAN; a small response was detected through the use of active COTS sensors, including the RAE Systems MultiRAE Lite and Drager X-act (registered) 5000, but the levels detected were below the threshold limit value for the toxic gas ammonia. Therefore, a detection system ased upon a colorimetric indicator impregnated into an absorbent material was developed. Preliminary analysis (ESC-245-FDG-001) identified a particularly outstanding candidate as a colorimetric indicator for the detection of the presence of AF-M315E in the form of a Methyl Red (Basic) indicator. Materials impregnated with this indicator exhibit significant color change and the materials are not susceptible to interference from exposure to water or carbon dioxide. The completed detection system for HAN/AF-M315E consists of absorbent socks packed with Fisher Universal Spill Absorbent capable of absorbing and containing any propellant spills that they come into contact with along with indicating wipes. The absorbent socks are also chemically treated with a Methyl Red (Basic) indicator solution to provide the end user with a visual indication that a leak has occurred and proper protective precautions must be undertaken. An added benefit of this detection system is that the absorbent socks should neutralize/absorb any commodity that it comes into contact with (until saturation is reached). Additional adsorbent socks can be deployed until a color change is not seen, indicating that the HAN/AF-M315E contamination has been contained. The indicating wipes provide the user the opportunity to wipe surfaces to determine if there is any HAN/AF-M315E or HAN/AFM315E residue present. The wipes should allow the detection of fuel levels that may be too small to detect with the absorbent socks. The development of a detection system for the ADN/LMP-103S focused on the use of various COTS sensors used as real-time area monitoring devices and personal dosimeters. These COTS based sensor systems were of several different types, including both actively pumped and diffusion-based passive systems, as well as a "rope"-type chemical sensing cable. The results highlighted some of the major differences between the two monopropellants undergoing evaluation. Unlike HAN, ADN (which is the major constituent of LMP-103S) exhibits a much more volatile nature in comparison to AF-M315E. In fact, testing showed that a large percentage of the fuel was lost during the sampling measurement (greater than 10 percent by mass); although this testing cannot tell if the volatile component is the ADN itself or another component of the monopropellant solution. Not surprisingly, all four of the procured vapor-based COTS sensors showed positive results when exposed to solutions of the LMP-103S (ESC-245-FDG-002). The completed detection system for ADN/LMP-103S consists of a combination of two of the tested COTS sensor systems, the RAE Systems MultiRAE Lite and the BW Technologies GasAlert Extreme. These systems are meant to be used in conjunction with one another, which allows for the end-user to have both real-time area monitoring (MultiRAE Lite) as well as a personal dosimeter device (GasAlert Extreme) which can be worn as additional personal protective equipment. An stainless steel extension wand was fabricated and included in the detection system for the MultiRAE Lite to allow for more remote sensing, and connects via the active pumping inlet of the sensor. As stated, the final results of this testing resulted in the production of two "kits" which can be used for the detection of HAN/AF-M315E and ADN/LMP-103s (ESC-245-FDG-003).

Detection↗
NASA NTRS2000

Development and Testing of Cooled CMCs for High Thermal Flux Applications

Ceramic Matrix Composites (CMCS) offer the potential for significant weight savings and improved performance for a range of propulsion components utilizing refractory materials. This paper describes the fabrication and testing of functionally graded CMCs produced via a low cost process that represents an order of magnitude cost savings over conventionally fabricated CMCS. Test cylinders were fabricated, characterized and evaluated during exposure to high thermal fluxes of up to 10MW/meters squared at the Laser Hardened Materials Evaluation Laboratory (LHMEL). The bulk density of the CMC tubes was approximately 2.2 grams per cubic centimeters. The performance of cryogenically cooled CMCs was compared with uncooled CMCs against similar thermal loads, and fundamental property data collected for this relatively new breed of CMC. Finally, test thrust cells were fabricated from the functionally graded composite and tested using liquid H2 and O2 propellants at NASA Glen.

Patterson , Mark↗
NASA NTRS1992

Material selection and evaluation aimed at resolving deficiencies of a space technology material

NASA-Kennedy Space Center propellant handlers' visors are undergoing conversion from Plexiglass G to a Surlyn 8920-based material; various Surlyn compositions are here subjected to a battery of environmental and mechanical-properties tests under the relevant conditions. Specially-molded Surlyn samples have exhibited much higher impact strengths than either Plexiglass G or Lexan, and passed the ANSI weight-drop test. DSC results show that Surlyn and Plexiglass G exhibit strikingly different thermal transitions.

Ray, Asit K.↗
NASA NTRS1963

Performance Capability of Single-Cavity Vortex Gaseous Nuclear Rockets

An analysis was made to determine the maximum powerplant thrust-to-weight ratio possible with a single-cavity vortex gaseous reactor in which all the hydrogen propellant must diffuse through a fuel-rich region. An assumed radial temperature profile was used to represent conduction, convection, and radiation heat-transfer effects. The effect of hydrogen property changes due to dissociation and ionization was taken into account in a hydrodynamic computer program. It is shown that, even for extremely optimistic assumptions of reactor criticality and operating conditions, such a system is limited to reactor thrust-to-weight ratios of about 1.2 x 10(exp -3) for laminar flow. For turbulent flow, the maximum thrust-to-weight ratio is less than 10(exp -3). These low thrusts result from the fact that the hydrogen flow rate is limited by the diffusion process. The performance of a gas-core system with a specific impulse of 3000 seconds and a powerplant thrust-to-weight ratio of 10(exp -2) is shown to be equivalent to that of a 1000-second advanced solid-core system. It is therefore concluded that a single-cavity vortex gaseous reactor in which all the hydrogen must diffuse through the nuclear fuel is a low-thrust device and offers no improvement over a solid-core nuclear-rocket engine. To achieve higher thrust, additional hydrogen flow must be introduced in such a manner that it will by-pass the nuclear fuel. Obviously, such flow must be heated by thermal radiation. An illustrative model of a single-cavity vortex system employing supplementary flow of hydrogen through the core region is briefly examined. Such a system appears capable of thrust-to-weight ratios of approximately 1 to 10. For a high-impulse engine, this capability would be a considerable improvement over solid-core performance. Limits imposed by thermal radiation heat transfer to cavity walls are acknowledged but not evaluated. Alternate vortex concepts that employ many parallel vortices to achieve higher hydrogen flow rates offer the possibility of sufficiently high thrust-to-weight ratios, if they are not limited by short thermal-radiation path lengths.

Ragsdale, Robert G.↗
NASA NTRS2020

Effective and Environmentally Compliant Cleaner Solstice® Performance Fluid

On January 1, 2015, the United States Environmental Protection Agency identified exemptions on the continued use of the hydrochlorofluorocarbon (HCFC)-225ca and -225cb. As these solvents are commonly used in cleaning and verification of aerospace propulsion systems using liquid and gaseous oxygen, the NESC supported the Agency initiative to identify and characterize acceptable alternate fluids. Honeywell’s Solstice® Performance Fluid (PF), PF-high purity (HP), and PF-HP spray are an effective nonflammable cleaning solution system, with a favorable toxicity profile and low environmental impact. Solstice PF is suitable for electronics, metal, and precision cleaning. It can be used in vapor degreasing equipment and may be dispensed with a propellant to create an aerosol contact cleaner. Solstice PF has been shown to have negligible ozone depletion and a global warming potential of 1. With these characterized environmental and solvency properties, Solstice PF, PF-HP, or PF-HP spray may be an excellent choice for a variety of cleaning applications.

Effective Compliant Cleaner↗
NASA NTRS1983

Flutter analysis of advanced turbopropellers

The two-dimensional subsonic cascade unsteady aerodynamic theory of Jones and Rao (1975) has been modified to account for the variable sweep angles of the blades of advanced turbopropellers. The aerodynamics and the structural modal properties have been formally integrated to determine the generalized aerodynamic coefficients matrix for the blade modes. Modal flutter analysis has been conducted for two SR-5 five- and ten-blade propellers, and analytical results have been found to be in very good agreement with wind tunnel test data.

Elchuri, V.↗
NASA NTRS2004

Removal of Perfluorinated Grease Components from NTO Oxidizer

Perfluorinated greases are typically used as a thread lubricant in the assembly of non-welded nitrogen tetroxide (NTO) oxidizer systems. These greases, typically a perfluoroalkylether, with suspended polytetrafluoroethylene (PTFE) micro-powder, have attractive lubricating properties toward threaded components and are relatively chemically inert toward NTO oxidizers. A major drawback, however, is that perfluoroalkylether greases are soluble or dispersible in NTO oxidizers and can contaminate the propellant. The result is propellant that fails the non-volatile residue (NVR) specification analyses and that may have negative effects on test hardware performance and lifetime. Consequently, removal of the grease contaminants from NTO may be highly desirable. Methods for the removal of perfluorinated grease components from NTO oxidizers including distillation, adsorption, filtration, and adjustment of temperature are investigated and reported in this work. Solubility or dispersibility data for the perfluoroalkylether oil (Krytox(tm)143 AC) component of a perfluorinated grease (Krytox 240 AC) and for Krytox 240 AC in NTO were determined and are reported.

McClure, Mark B.↗
NASA NTRS2003

Small Signal Point-to-Point Tracking of a Propellant Mixer

This paper addresses some theoretical modelling and control issues for a mixing chamber used in rocket engine testing at NASA Stennis Space Center. The mixer is responsible for combining high pressure LH2 and GH2 to produce a hydrogen flow that meets certain thermodynamic properties before it is fed into a test article. The desired properties are maintained by precise control of the LH2 and GH2 flows. The mixer is modelled as a general multi-flow lumped volume for single constituent fluids using density and internal energy as states. The set of nonlinear differential equations is modelled in the SIMULINK environment including a table look-up feature of the fluid thermodynamic properties. a small-signal (linear) model is developed based on the nonlinear model and simulated as well. Pulse disturbances are introduced to the valve positions and the quality of the linear model is ascertained by comparing its behavior against the nonlinear model simulations. Valve control strategies that simulate an operator-in-the-loop scenario are then explored demonstrating the need for automatic feedback control. Finally, classical optimal single-output and multi-output Proportional/Integral controllers are designed based on the linear model and applied to the nonlinear model with excellent results to track simultaneous, constant setpoint changes in desired exit flow, exit temperature, and mixer pressure, as well as to reject unmeasurable but bounded additive step perturbations in the valve positions.

Barbieri, Enrique↗
NASA NTRS1973

Hollow cathode restartable 15 cm diameter ion thruster

The effects of substituting high perveance dished grids for low perveance flat ones on performance variables and plasma properties within a 15 cm modified SERT II thruster are discussed. Results suggest good performance may be achieved as an ion thruster is throttled if the screen grid transparency is decreased with propellant flow rate. Thruster startup tests, which employ a pulsed high voltage tickler electrode between the keeper and the cathode to initiate the discharge, are described. High startup reliability at cathode tip temperatures of about 500 C without excessive component wear over 2000 startup cycles is demonstrated. Testing of a single cusp magnetic field concept of discharge plasma containment is discussed. A theory which explains the observed behavior of the device is presented and proposed thruster modifications and future testing plans are discussed.

Wilbur, P. J.↗
NASA NTRS1995

Plume Particle Collection and Sizing from Static Firing of Solid Rocket Motors

Thermal radiation from the plume of any solid rocket motor, containing aluminum as one of the propellant ingredients, is mainly from the microscopic, hot aluminum oxide particles in the plume. The plume radiation to the base components of the flight vehicle is primarily determined by the plume flowfield properties, the size distribution of the plume particles, and their optical properties. The optimum design of a vehicle base thermal protection system is dependent on the ability to accurately predict this intense thermal radiation using validated theoretical models. This article describes a successful effort to collect reasonably clean plume particle samples from the static firing of the flight simulation motor (FSM-4) on March 10, 1994 at the T-24 test bed at the Thiokol space operations facility as well as three 18.3% scaled MNASA motors tested at NASA/MSFC. Prior attempts to collect plume particles from the full-scale motor firings have been unsuccessful due to the extremely hostile thermal and acoustic environment in the vicinity of the motor nozzle.

Sambamurthi, Jay K.↗
NASA NTRS2011

Why Density Dependent Propulsion?

In 2004 Khoury and Weltman produced a density dependent cosmology theory they call the Chameleon, as at its nature, it is hidden within known physics. The Chameleon theory has implications to dark matter/energy with universe acceleration properties, which implies a new force mechanism with ties to the far and local density environment. In this paper, the Chameleon Density Model is discussed in terms of propulsion toward new propellant-less engineering methods.

Robertson, Glen A.↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗
NASA NTRS2003

Modeling, Simulation and Control of a Propellant Mixer

This paper addresses some modeling and control issues for a mixing chamber used in rocket engine testing at NASA Stennis Space Center. The mixer must combine high pressure liquid hydrogen (LH2) and gaseous hydrogen (GH2) to produce and output flow that meets certain thermodynamic properties before it is fed into a test article. More precisely, this paper considers that the quantities to be tracked and/or regulated are mixer internal pressure, exit mass flow, and exit temperature. The available control inputs are given by three value positions, namely those of the GH2, LH2 and exit valves. The mixer is modelled by a system of two nonlinear ordinary differential equations having density and internal energy as states. The model must be simple enough to lend itself to subsequent feedback controller design, yet its accuracy must be tested against real data. For this reason, the model includes function calls to thermodynamic property data. Some structural properties of the resulting model that pertain to controller design, such as controllability and uniqueness of the equilibrium point are shown to hold. Validation of the model against real data is also provided. As a first control approach, a small-signal (linear) model is developed based on the nonlinear model and simulated as well. Pulse disturbances are introduced to the valve positions and the quality of the linear model is ascertained by comparing its behavior against the nonlinear model simulations. Valve control strategies that simulate an operator-in-the-loop scenario are then explored demonstrating the need for automatic feedback control. Classical optimal single-output and multi-output Proportional/Integral controllers are designed based on the linear model and applied to the nonlinear model with excellent results to track simultaneous, constant setpoint changes in desired exit flow, exit temperature, and mixer pressure, as well as to reject unmeasurable but bounded additive step perturbations in the valve positions. A feedback linearization controller is designed and used to achieve tracking and regulation of the outputs over an extended range of the variables of interest.

Richter, Hanz↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗