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Long life feasibility study for SIRTF

The Phase A baseline for the Shuttle Infrared Telescope Facility (SIRTF) consists of an 85-cm diameter Cassegrain telescope, cooled to temperatures in the range from 10 to 20 K to provide background limited imaging for up to six instruments contained within a multiple instrument chamber (MIC). Colder temperature zones are also provided. A cryogenics system for a 15-day mission lifetime was first considered. In another study, the feasibility was assessed to extend the lifetime of the baseline SIRTF concept to at least six months, taking into account a mission involving the use of a space platform or a free-flyer configuration. According to the considered requirements, the optics temperature is to be kept below 10 K for at least 30 days. The temperatures are not to exceed 20 K at the end of the six months mission. It is shown that by using solid hydrogen, long-life operation is feasible with present technology.

Naes, L. G.↗

The 1990 NASA Aerospace Battery Workshop

This document contains the proceedings of the 21st annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on December 4-6, 1990. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers as well as participation in like kind from the European Space Agency member nations. The subjects covered included nickel-cadmium, nickel-hydrogen, silver-zinc, lithium based chemistries, and advanced technologies as they relate to high reliability operations in aerospace applications.

Kennedy, Lewis M.↗

Density and mixture fraction measurements in a GO2/GH2 uni-element rocket chamber

In recent years, there has been a renewed interest in gas/gas injectors for rocket combustion. Specifically, the proposed new concept of full-flow oxygen rich preburner systems calls for the injection of both oxygen and hydrogen into the main chamber as gaseous propellants. The technology base for gas/gas injection must mature before actual booster class systems can be designed and fabricated. Since the data base for gas/gas injection is limited to studies focusing on the global parameters of small reaction engines, there is a critical need for experiment programs that emphasize studying the mixing and combustion characteristics of GO2 and GH2 propellants from a uni-element injector point of view. The experimental study of the combusting GO2/GH2 propellant combination in a uni-element rocket chamber also provides a simplified environment, in terms of both geometry and chemistry, that can be used to verify and validate computational fluid dynamic (CFD) models.

Moser, M. D.↗

High energy density micro-fiber based nickel electrode for aerospace batteries

The nickel electrode is the specific energy limiting component in battery systems such as nickel-hydrogen, nickel-metal hydride and nickel-zinc. Lightweight, high energy density nickel electrodes have been developed which deliver in excess of 180 mAh/g at the one-hour discharge rate. These electrodes are based on a highly porous, nickel micro-fiber (less than 10 micron diameter) substrate, electrochemically impregnated with nickel-hydroxide active material. Electrodes are being tested both as a flooded half-cell and in full nickel-hydrogen and nickel-metal hydride cells. The electrode technology developed is applicable to commercial nickel-based batteries for applications such as electric vehicles, cellular telephones and laptop computers and for low-cost, high energy density military and aerospace applications.

Francisco, Jennifer↗

The 1998 NASA Aerospace Battery Workshop

This document contains the proceedings of the 31st annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on October 27-29, 1998. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-hydrogen, silver-hydrogen, nickel-metal hydride, and lithium-based technologies, as well as results from destructive physical analyses on various cell chemistries.

Brewer, Jeffrey C.↗

Fatigue Life of Haynes 188 Superalloy in Direct Connect Combustor Durability Rig

The Direct Connect Combustor Durability Rig (DCR) will provide NASA a flexible and efficient test bed to demonstrate the durability of actively cooled scramjet engine structure, static and dynamic sealing technologies, and thermal management techniques. The DCR shall be hydrogen fueled and cooled, and test hydrogen coolded structural panels at Mach 5 and 7. Actively cooled Haynes 188 superalloy DCR structural panels exposed to the combustion environment shall have electrodischarge machined (EDM) internal cooling holes with flowing liquid hydrogen. Hydrogen combustion could therefore produce severe thermal conditions that could challenge low cycle fatigue durability of this material. The objective of this study was to assess low cycle fatigue capability of Haynes 188 for DCR application. Tests were performed at 25 and 650 C, in hydrogen and helium environments, using specimens with low stress ground (LSG) and electro-discharge machined (EDM) surface finish. Initial fatigue tests in helium and hydrogen indicate the low cycle fatigue life capability of Haynes 188 in hydrogen appears quite satisfactory for the DCR application. Fatigue capability did not decrease with increasing test temperature. Fatigue capability also did not decrease with EDM surface finish. Failure evaluations indicate retention of ductility in all conditions. Additional tests are planned to reconfirm these positive trends.

Gabb, TIm↗

Mars Atmospheric Capture and Gas Separation

The Mars atmospheric capture and gas separation project is selecting, developing, and demonstrating techniques to capture and purify Martian atmospheric gases for their utilization for the production of hydrocarbons, oxygen, and water in ISRU systems. Trace gases will be required to be separated from Martian atmospheric gases to provide pure C02 to processing elements. In addition, other Martian gases, such as nitrogen and argon, occur in concentrations high enough to be useful as buffer gas and should be captured as welL To achieve these goals, highly efficient gas separation processes will be required. These gas separation techniques are also required across various areas within the ISRU project to support various consumable production processes. The development of innovative gas separation techniques will evaluate the current state-of-the-art for the gas separation required, with the objective to demonstrate and develop light-weight, low-power methods for gas separation. Gas separation requirements include, but are not limited to the selective separation of: (1) methane and water from un-reacted carbon oxides (C02- CO) and hydrogen typical of a Sabatier-type process, (2) carbon oxides and water from unreacted hydrogen from a Reverse Water-Gas Shift process, (3) carbon oxides from oxygen from a trash/waste processing reaction, and (4) helium from hydrogen or oxygen from a propellant scavenging process. Potential technologies for the separations include freezers, selective membranes, selective solvents, polymeric sorbents, zeolites, and new technologies. This paper and presentation will summarize the results of an extensive literature review and laboratory evaluations of candidate technologies for the capture and separation of C02 and other relevant gases.

Muscatello, Anthony↗

Capacitive Sensors for Measuring Masses of Cryogenic Fluids

An effort is under way to develop capacitive sensors for measuring the masses of cryogenic fluids in tanks. These sensors are intended to function in both microgravitational and normal gravitational settings, and should not be confused with level sensors, including capacitive ones. A sensor of this type is conceptually simple in the sense that (1) it includes only one capacitor and (2) if properly designed, its single capacitance reading should be readily convertible to a close approximation of the mass of the cryogenic fluid in the tank. Consider a pair of electrically insulated electrodes used as a simple capacitive sensor. In general, the capacitance is proportional to the permittivity of the dielectric medium (in this case, a cryogenic fluid) between the electrodes. The success of design and operation of a sensor of the present type depends on the accuracy of the assumption that to a close approximation, the permittivity of the cryogenic fluid varies linearly with the density of the fluid. Data on liquid nitrogen, liquid oxygen, and liquid hydrogen, reported by the National Institute of Standards and Technology, indicate that the permittivities and densities of these fluids are, indeed, linearly related to within a few tenths of a percent over the pressure and temperature regions of interest. Hence, ignoring geometric effects for the moment, the capacitance between two electrodes immersed in the fluid should vary linearly with the density, and, hence, with the mass of the fluid. Of course, it is necessary to take account of the tank geometry. Because most cryogenic tanks do not have uniform cross sections, the readings of level sensors, including capacitive ones, are not linearly correlated with the masses of fluids in the tanks. In a sensor of the present type, the capacitor electrodes are shaped so that at a given height, the capacitance per unit height is approximately proportional to the cross-sectional area of the tank in the horizontal plane at that height (see figure).

Nurge, Mark↗

Heavy Lift Launch Capability with a New Hydrocarbon Engine (NHE)

The Advanced Concepts Office (ACO) at NASA Marshall Space Flight Center has analyzed over 2000 Ares V and other heavy lift concepts in the last 3 years. These concepts were analyzed for Lunar Exploration Missions, heavy lift capability to Low Earth Orbit (LEO) as well as exploratory missions to other near earth objects in our solar system. With the pending retirement of the Shuttle fleet, our nation will be without a civil heavy lift launch capability, so the future development of a new heavy lift capability is imperative for the exploration and large science missions our Agency has been tasked to deliver. The majority of the heavy lift concepts analyzed by ACO during the last 3 years have been based on liquid oxygen / liquid hydrogen (LOX/LH2) core stage and solids booster stage propulsion technologies (Ares V / Shuttle Derived and their variants). These concepts were driven by the decisions made from the results of the Exploration Systems Architecture Study (ESAS), which in turn, led to the Ares V launch vehicle that has been baselined in the Constellation Program. Now that the decision has been made at the Agency level to cancel Constellation, other propulsion options such as liquid hydrocarbon fuels are back in the exploration trade space. NASA is still planning exploration missions with the eventual destination of Mars and a new heavy lift launch vehicle is still required and will serve as the centerpiece of our nation s next exploration architecture s infrastructure. With an extensive launch vehicle database already developed on LOX/LH2 based heavy lift launch vehicles, ACO initiated a study to look at using a new high thrust (> 1.0 Mlb vacuum thrust) hydrocarbon engine as the primary main stage propulsion in such a launch vehicle.

Threet, Grady E., Jr.↗

Simple, Robust Cryogenic Propellant Depot for Near Term Applications

The ability to refuel cryogenic propulsion stages on-orbit provides an innovative paradigm shift for space transportation supporting National Aeronautics and Space Administration s (NASA) Exploration program as well as deep space robotic, national security and commercial missions. Refueling enables large beyond low Earth orbit (LEO) missions without requiring super heavy lift vehicles that must continuously grow to support increasing mission demands as America s exploration transitions from early Lagrange point missions to near Earth objects (NEO), the lunar surface and eventually Mars. Earth-to-orbit launch can be optimized to provide competitive, cost-effective solutions that allow sustained exploration. This paper describes an experimental platform developed to demonstrate the major technologies required for fuel depot technology. This test bed is capable of transferring residual liquid hydrogen (LH2) or liquid oxygen (LO2) from a Centaur upper stage, and storage in a secondary tank for up to one year on-orbit. A dedicated, flight heritage spacecraft bus is attached to an Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter (ESPA) ring supporting experiments and data collection. This platform can be deployed as early as Q1 2013. The propellant depot design described in this paper can be deployed affordably this decade supporting missions to Earth-Moon Lagrange points and lunar fly by. The same depot concept can be scaled up to support more demanding missions and launch capabilities. The enabling depot design features, technologies and concept of operations are described.

McLean, Christopher↗

Advanced oxygen-hydrocarbon Earth-to-orbit propulsion

Liquid oxygen/hydrocarbon (LO2/HC) rocket engine cycles for a surface to orbit transportation system were evaluated. A consistent engine system data base is established for defining advantages and disadvantages, system performance and operating limits, engine parametric data, and technology requirements for candidate engine systems. Preliminary comparisons of the engine cycles utilizing delivered specific impulse values are presented. Methane and propane staged combustion cycles are the highest LO2/HC performers. The hydrogen cooled LO2/methane dual throat engine was found to be the highest performing. Technology needs identified in the study include: high temperature turbines; oxidizer-rich preburners; LO2, methane, and propane cooling; methane and propane fuel-rich preburners; the HC fuel turbopump; and application of advanced composite materials to the engine system. Parametric sensitivity analysis data are displayed which show the effect of variations in engine thrust, mixture ratio, chamber pressure, area ratio, cycle life, and turbine inlet temperature on specific impulse and engine weight.

Obrien, C. J.↗

Atomic hydrogen as a launch vehicle propellant

An analysis of several atomic hydrogen launch vehicles was conducted. A discussion of the facilities and the technologies that would be needed for these vehicles is also presented. The Gross Liftoff Weights (GLOW) for two systems were estimated; their specific impulses (I sub sp) were 750 and 1500 lb(sub f)/s/lb(sub m). The atomic hydrogen launch vehicles were also compared to the currently planned Advanced Launch System design concepts. Very significant GLOW reductions of 52 to 58 percent are possible over the Advanced Launch System designs. Applying atomic hydrogen propellants to upper stages was also considered. Very high I(sub sp) (greater than 750 lb(sub f)/s/lb(sub m)) is needed to enable a mass savings over advanced oxygen/hydrogen propulsion. Associated with the potential benefits of high I(sub sp) atomic hydrogen are several challenging problems. Very high magnetic fields are required to maintain the atomic hydrogen in a solid hydrogen matrix. The magnetic field strength was estimated to be 30 kilogauss (3 Tesla). Also the storage temperature of the propellant is 4 K. This very low temperature will require a large refrigeration facility for the launch vehicle. The design considerations for a very high recombination rate for the propellant are also discussed. A recombination rate of 210 cm/s is predicted for atomic hydrogen. This high recombination rate can produce very high acceleration for the launch vehicle. Unique insulation or segmentation to inhibit the propellant may be needed to reduce its recombination rate.

Palaszewski, Bryan A.↗

Atomic hydrogen as a launch vehicle propellant

An analysis of several atomic hydrogen launch vehicles was conducted. A discussion of the facilities and the technologies that would be needed for these vehicles is also presented. The Gross Liftoff Weights (GLOW) for two systems were estimated; their specific impulses (I sub sp) were 750 and 1500 lb (sub f)/s/lb(sub m). The atomic hydrogen launch vehicles were also compared to the currently planned Advanced Launch System design concepts. Very significant GLOW reductions of 52 to 58 percent are possible over the Advanced Launch System designs. Applying atomic hydrogen propellants to upper stages was also considered. Very high I(sub sp) (greater than 750 1b(sub f)/s/lb(sub m) is needed to enable a mass savings over advanced oxygen/hydrogen propulsion. Associated with the potential benefits of high I(sub sp) atomic hydrogen are several challenging problems. Very high magnetic fields are required to maintain the atomic hydrogen in a solid kilogauss (3 Tesla). Also the storage temperature of the propellant is 4 K. This very low temperature will require a large refrigeration facility for the launch vehicle. The design considerations for a very high recombination rate for the propellant are also discussed. A recombination rate of 210 cm/s is predicted for atomic hydrogen. This high recombination rate can produce very high acceleration for the launch vehicle. Unique insulation or segmentation to inhibit the propellant may be needed to reduce its recombination rate.

Palaszewski, Bryan A.↗

High Power Flex-Propellant Arcjet Performance

A MW-class electrothermal arcjet based on a water-cooled, wall-stabilized, constricted arc discharge configuration was subjected to extensive performance testing using hydrogen and simulated ammonia propellants with the deliberate aim of advancing technology readiness level for potential space propulsion applications. The breadboard design incorporates alternating conductor/insulator wafers to form a discharge barrel enclosure with a 2.5-cm internal bore diameter and an overall length of approximately 1 meter. Swirling propellant flow is introduced into the barrel, and a DC arc discharge mode is established between a backplate tungsten cathode button and a downstream ringanode/ spin-coil assembly. The arc-heated propellant then enters a short mixing plenum and is accelerated through a converging-diverging graphite nozzle. This innovative design configuration differs substantially from conventional arcjet thrusters, in which the throat functions as constrictor and the expansion nozzle serves as the anode, and permits the attainment of an equilibrium sonic throat (EST) condition. During the test program, applied electrical input power was varied between 0.5-1 MW with hydrogen and simulated ammonia flow rates in the range of 4-12 g/s and 15-35 g/s, respectively. The ranges of investigated specific input energy therefore fell between 50-250 MJ/kg for hydrogen and 10-60 MJ/kg for ammonia. In both cases, observed arc efficiencies were between 40-60 percent as determined via a simple heat balance method based on electrical input power and coolant water calorimeter measurements. These experimental results were found to be in excellent agreement with theoretical chemical equilibrium predictions, thereby validating the EST assumption and enabling the utilization of standard TDK nozzle expansion analyses to reliably infer baseline thruster performance characteristics. Inferred specific impulse performance accounting for recombination kinetics during the expansion process implied nearly frozen flow in the nozzle and yielded performance ranges of 800-1100 sec for hydrogen and 400-600 sec for ammonia. Inferred thrust-to-power ratios were in the range of 30-10 lbf/MWe for hydrogen and 60-20 lbf/MWe for ammonia. Successful completion of this test series represents a fundamental milestone in the progression of high power arcjet technology, and it is hoped that the results may serve as a reliable touchstone for the future development of MW-class regeneratively-cooled flex-propellant plasma rockets.

Litchford, Ron J.↗

Methane Post-Processing and Hydrogen Separation for Spacecraft Oxygen Loop Closure

State-of-the-art life support oxygen recovery technology on the International Space Station is based on the Sabatier reaction where only about half of the oxygen required for the crew is recovered from metabolic carbon dioxide (CO2). The Sabatier reaction produces water as the primary product and methane as a byproduct. Oxygen recovery is constrained by both the limited availability of reactant hydrogen from water electrolysis and Sabatier methane (CH4) being vented as a waste product resulting in a continuous loss of reactant hydrogen. Post-processing methane with the Plasma Pyrolysis Assembly (PPA) to recover this hydrogen has the potential to substantially increase oxygen recovery and thus dramatically reduce the logistical challenges associated with oxygen resupply. The PPA decomposes methane into predominantly hydrogen and acetylene. A purification system is necessary to purify hydrogen before it is recycled back to the Sabatier reactor. Testing and evaluation of acetylene removal systems and PPA system architectures are presented and discussed.

Greenwood, Zachary W.↗

Space shuttle auxiliary propulsion system design study. Phase D report: Oxygen-hydrogen special RCS studies

Two alternate oxygen-hydrogen auxiliary propulsion system concepts for use with the space shuttle vehicle were evaluated. The two concepts considered were: (1) gaseous oxygen-hydrogen systems with electric or hydraulic motor driven pumps to provide system pressure and (2) liquid oxygen-hydrogen systems which delivered propellants to the engines in a liquid state without the need for pumps. The various means of implementing each of the concepts are compared on the basis of weight, technology requirements, and operational considerations. It was determined that the liquid oxygen-hydrogen system concepts have the potential to produce substantial weight reductions in the space shuttle orbiter total impulse range.

Baumann, T. L.↗

Human Exploration and Settlement of the Moon Using LUNOX-Augmented NTR Propulsion

An innovative trimodal nuclear thermal rocket (NTR) concept is described which combines conventional liquid hydrogen (LH2)-cooled NTR, Brayton cycle power generation and supersonic combustion ramjet (scramjet) technologies. Known as the liquid oxygen (LOX) augmented NTR (LANTR), this concept utilizes the large divergent section of the NTR nozzle as an 'afterburner' into which LOX is injected and supersonically combusted with nuclear preheated hydrogen emerging from the LANTR's choked sonic throat--'scramjet propulsion in reverse.' By varying the oxygen-to-hydrogen mixture ratio (MR), the LANTR can operate over a wide range of thrust and specific impulse (Isp) values while the reactor core power level remains relatively constant. As the MR varies from zero to seven, the thrust-to-weight ratio for a 15 thousand pound force (klbf) NTR increases by approximately 440%--from 3 to 13--while the Isp decreases by only approximately 45%--from 940 to 515 seconds. This thrust augmentation feature of the LANTR means that 'big engine' performance can be obtained using smaller more affordable, easier to test NTR engines. 'Reoxidizing' the bipropellant LANTR system in low lunar orbit (LLO) with high density 'lunar-derived' LOX (LUNOX) enables a reusable, reduced size and mass lunar transfer vehicle (LTV) which can be deployed and resupplied using two 66 t-class Shuttle-derived launch vehicles. The reusable LANTR can also transport 200 to 300% more payload on each piloted round trip mission than an expendable 'all LH2' NTR system. As initial outposts grow to eventual lunar settlements and LUNOX production capacity increases, the LANTR concept can also enable a rapid 'commuter' shuttle capable of 36 to 24 hour 'one way' trips to the Moon and back with reasonable size vehicles and initial mass in low Earth orbit (IMLEO) requirements.

Borowski, Stanley K.↗

Subsonic Ultra Green Aircraft Research Phase II: N+4 Advanced Concept Development

This final report documents the work of the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team on Task 1 of the Phase II effort. The team consisted of Boeing Research and Technology, Boeing Commercial Airplanes, General Electric, and Georgia Tech. Using a quantitative workshop process, the following technologies, appropriate to aircraft operational in the N+4 2040 timeframe, were identified: Liquefied Natural Gas (LNG), Hydrogen, fuel cell hybrids, battery electric hybrids, Low Energy Nuclear (LENR), boundary layer ingestion propulsion (BLI), unducted fans and advanced propellers, and combinations. Technology development plans were developed.

Bradley, Marty K.↗