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NASA NTRS2020

Case Study of Using Flocad to Model a Ground Test Station Ln2 Heat Exchanger

This paper presents a case study of using FLOCAD to model the heat transfer and boiling flow behavior of a Liquid Nitrogen (LN2) ground station equipment heat exchanger. The unique aspect of this work is that is one of very few studies documenting the use of FLOCAD in the spacecraft thermal control community. The results of the simulations described herein were used to guide and plan the execution of thermal vacuum testing spacecraft hardware using a ground test heat exchanger such as the one modeled herein. The paper will review the theory of two-phase boiling flow and correlations used by SINDA/FLUINT as well as the terminology and nomenclature used within Thermal Desktop / FLOCAD regarding two-phase boiling flow heat transfer modeling and simulation. Results for using the ground station heat exchanger as a heat sink in a thermal vacuum test set up are shown in order to demonstrate the set-up and execution of a typical FLOCAD model. Results indicate that properly modeling of the two-phase behavior is critical in order to ascertain the time constant associated with the heat exchanger, as well as understanding the temperature distribution across the test equipment and prediction of required LN2 flowrates to be used during testing. The paper is meant to augment the FLOCAD user’s manual and serve as a tutorial for thermal engineers and analysts wishing to learn and apply FLOCAD to industrial problems.

Anderson, Kevin R.↗

NASA NTRS2015

SOAREX-8 Suborbital Experiments 2015 - A New Paradigm for Small Spacecraft Communication

In 2015 NASA plans to launch a payload to 280 Km altitude on a sounding rocket from the Wallops Flight Facility. This payload will contain several novel technologies that work together to demonstrate methodologies for space sample return missions and for nanosatellite communications in general. The payload will deploy and test an Exo-Brake, which slows the payload aerodynamically, providing eventual de-orbit and recovery of future ISS samples through a Small Payload Quick Return project. In addition, this flight addresses future Mars mission entry technology, space-to-space communications using the Iridium Short Messaging Service (SMS), GPS tracking, and wireless sensors using the ZigBee protocol. SOAREX-8 is being assembled and tested at Ames Research Center (ARC) and the NASA Engineering and Safety Center (NESC) is funding sensor and communications work. Open source Arduino technology and software are used for system control. The ZigBee modules used are XBee units that connect analog sensors for temperature, air pressure and acceleration measurement wirelessly to the payload telemetry system. Our team is developing methods for power distribution and module mounting, along with software for sensor integration, data assembly and downlink. We have demonstrated relaying telemetry to the ground using the Iridium satellite constellation on a previous flight, but the upcoming flight will be the first time we integrate useful flight test data from a ZigBee wireless sensor network. Wireless sensor data will measure the aerodynamic efficacy of the Exo-Brake permitting further on orbit flight tests of improved designs. The Exo-Brake is 5 sq m in area and will be stored in a container and deployed during ascent once the payload is jettisoned from the launch vehicle. We intend to further refine the hardware and continue testing on balloon launches, future sounding rocket flights and on nanosatellite missions. The use of standards-based and open source hardware/software has allowed for this project to be completed with a very modest budget and a challenging schedule. There is a wealth of hardware and software available for both the Arduino platform and the XBee, all low-cost or open-source. Along with the Exo-Brake hardware and deployment discussion, this paper will describe in detail the system architecture emphasizing the successful use of open source hardware and software to minimize effort and cost. Testing procedures, radio frequency interference (RFI) mitigation, success criteria and expected results will also be discussed. The use of Iridium short messaging capability for space-to-space links, standards-based wireless sensor networks, and other innovative communications technology are also presented.

aerobrake↗

NASA NTRS1999

Work on Planetary Atmospheres and Planetary Atmosphere Probes

A summary final report of work accomplished is presented. Work was performed in the following areas: (1) Galileo Probe science analysis, (2) Galileo probe Atmosphere Structure Instrument, (3) Mars Pathfinder Atmosphere Structure/Meteorology instrument, (4) Mars Pathfinder data analysis, (5) Science Definition for future Mars missions, (6) Viking Lander data analysis, (7) winds in Mars atmosphere Venus atmospheric dynamics, (8) Pioneer Venus Probe data analysis, (9) Pioneer Venus anomaly analysis, (10) Discovery Venus Probe Titan probe instrument design, and (11) laboratory studies of Titan probe impact phenomena. The work has resulted in more than 10 articles published in archive journals, 2 encyclopedia articles, and many working papers. This final report is organized around the four planets on which there was activity, Jupiter, Mars, Venus, and Titan, with a closing section on Miscellaneous Activities. A major objective was to complete the fabrication, test, and evaluation of the atmosphere structure experiment on the Galileo probe, and to receive, analyze and interpret data received from the spacecraft. The instrument was launched on April 14, 1989. Calibration data were taken for all experiment sensors. The data were analyzed, fitted with algorithms, and summarized in a calibration report for use in analyzing and interpreting data returned from Jupiter's atmosphere. The sensors included were the primary science pressure, temperature and acceleration sensors, and the supporting engineering temperature sensors. Computer programs were written to decode the Experiment Data Record and convert the digital numbers to physical quantities, i.e., temperatures, pressures, and accelerations. The project office agreed to obtain telemetry of checkout data from the probe. Work to extend programs written for use on the Pioneer Venus project included: (1) massive heat shield ablation leading to important mass loss during entry; and (2) rapid planet rotation, which introduced terms of motion not needed on Venus. When the Galileo Probe encountered Jupiter, analysis and interpretation of data commenced. The early contributions of the experiment were to define (1) the basic structure of the deep atmosphere, (2) the stability of the atmosphere, (3) the upper atmospheric profiles of density, pressure, and temperature. The next major task in the Galileo Probe project was to refine, verify and extend the analysis of the data. It was the verified, and corrected data, which indicated a dry abiabatic atmosphere within measurement accuracy. Temperature in the thermosphere was measured at 900 K. Participation in the Mars atmospheric research included: (1) work as a team member of the Mars Atmosphere Working Group, (2) contribution to the Mars Exobiology Instrument workshop, (3) asssistance in planning the Mars global network and (4) assitance in planning the Soviet-French Mars mission in 1994. This included a return to the Viking Lander parachute data to refine and improve the definition of winds between 1.5 and 4 kilometer altitude at the two entry sites. The variability of the structure of Mars atmosphere was addressed, which is known to vary with season, latitude, hemisphere and dust loading of the atmosphere. This led to work on the Pathfinder project. The probe had a deployable meteorology mast that had three temperature sensors, and a wind sensor at the tip of the mast. Work on the Titan atmospheric probe was also accomplished. This included developing an experiment proposal to the European Space Agency (ESA), which was not selected. However, as an advisor in the design and preparation of the selected experiment the researcher interacted with scientist on the Huygens Probe Atmosphere Structure Experiment. The researcher also participated in the planning for the Venus Chemical Probe. The science objectives of the probe were to resolve unanswered questions concerning the minor species chemistry of Venus' atmosphere that control cloud formation, greenhouse effectiveness, and the thermal structure. The researcher also reviewed problems with the Pioneer Venus Probe, that caused anomalies which occurred on the Probes at and below 12.5 km level of the Venus' atmosphere. He convened and participated in a workshop that concluded the most likely hardware cause was insulation failure in the electrical harness outside the Probes' pressure vessels. It was discovered that the shrink tubing material failed at 600K. This failure could explain the anomalies experienced by the probes. The descent data of the Pioneer probes, and the Soviet Vega Lander was analyzed to evaluate the presence of small scale gravity waves in and below the Venus cloud layer.

Lester, Peter↗

NASA NTRS2011

Fission Surface Power Systems (FSPS) Project Final Report for the Exploration Technology Development Program (ETDP): Fission Surface Power, Transition Face to Face

The Fission Surface Power Systems Project became part of the ETDP on October 1, 2008. Its goal was to demonstrate fission power system technology readiness in an operationally relevant environment, while providing data on fission system characteristics pertinent to the use of a fission power system on planetary surfaces. During fiscal years 08 to 10, the FSPS project activities were dominated by hardware demonstrations of component technologies, to verify their readiness for inclusion in the fission surface power system. These Pathfinders demonstrated multi-kWe Stirling power conversion operating with heat delivered via liquid metal NaK, composite Ti/H2O heat pipe radiator panel operations at 400 K input water temperature, no-moving-part electromagnetic liquid metal pump operation with NaK at flight-like temperatures, and subscale performance of an electric resistance reactor simulator capable of reproducing characteristics of a nuclear reactor for the purpose of system-level testing, and a longer list of component technologies included in the attached report. Based on the successful conclusion of Pathfinder testing, work began in 2010 on design and development of the Technology Demonstration Unit (TDU), a full-scale 1/4 power system-level non-nuclear assembly of a reactor simulator, power conversion, heat rejection, instrumentation and controls, and power management and distribution. The TDU will be developed and fabricated during fiscal years 11 and 12, culminating in initial testing with water cooling replacing the heat rejection system in 2012, and complete testing of the full TDU by the end of 2014. Due to its importance for Mars exploration, potential applicability to missions preceding Mars missions, and readiness for an early system-level demonstration, the Enabling Technology Development and Demonstration program is currently planning to continue the project as the Fission Power Systems project, including emphasis on the TDU completion and testing.

Palac, Donald T.↗

NASA NTRS2000

BUNDLE: A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Carrasquillo, Edgar J.↗

NASA NTRS2001

BUNDLE - A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

Carrasquillo, Edgar J.↗

NASA NTRS1973

Shuttle active thermal control system development testing. Volume 7: Improved radiator coating adhesive tests

Silver/Teflon thermal control coatings have been tested on a modular radiator system projected for use on the space shuttle. Seven candidate adhesives have been evaluated in a thermal vacuum test on radiator panels similar to the anticipated flight hardware configuration. Several classes of adhesives based on polyester, silicone, and urethane resin systems were tested. These included contact adhesives, heat cured adhesives, heat and pressure cured adhesives, pressure sensitive adhesives, and two part paint on or spray on adhesives. The coatings attached with four of the adhesives, two silicones and two urethanes, had no changes develop during the thermal vacuum test. The two silicone adhesives, both of which were applied to the silver/Teflon as transfer laminates to form a tape, offered the most promise based on application process and thermal performance. Each of the successful silicone adhesives required a heat and pressure cure to adhere during the cryogenic temperature excursion of the thermal-vacuum test.

Reed, M. W.↗

NASA NTRS2023

Development of an Efficient Alternative to Recovery O2 From Metabolic CO2 Via Electrolysis Operated at Ambient Temperature and Driven By A Highly Selective Catalysis

The current State of Art (SOA) on oxygen recovery onboard the Environmental Control and Life Support System (ECLSS) at the International Space Station (ISS) is complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O 2 ) from metabolic carbon dioxide (CO 2 ). For future long duration beyond low earth orbit missions (LEO), O 2 recovery systems will need to be highly reliable, efficient, and recover a minimum of 75% O 2 from metabolic CO 2 . An alternative technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) has the potential to significantly increase O 2 recovery currently limited to 50% (Sabatier) and reduce the complexity of ECLSS O 2 recovery. MSFC and University of Texas in Arlington (UTA) have jointly designed and fabricated a microfluid electrochemical reactor (MFECR) that operates at ambient conditions and utilizes a proprietary catalysis highly selective on reducing CO 2 to ethylene (C 2 H 4 ) at the cathode while O 2 is generated at the anode. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current CO 2 Reduction Assembly (CRA) (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly (OGA). It is designed to interface directly with the CO 2 Removal Assembly (CDRA) and the Water Processing Assembly (WPA) to supply CO 2 reactant and water replenish respectively. This is expected to substantially improve sustainability of the ISS ECLSS and reduce requirement on power and weight. Here, we discuss the current development and evaluation efforts on different alternatives on not only the configuration and setup of the MFECR at an Engineering Design Unit (EDU) scale but also the selection of component materials.

Jesus A Dominguez↗

NASA NTRS2015

Propulsion System Testing for the Iodine Satellite (iSAT) Demonstration Mission

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cm cu and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high delta v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. 3, 4 Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature (less than 100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp -6) torr at −75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. An iodine-based system is not without its challenges. The primary challenge is that the entire feed system must be maintained at an elevated temperature to prevent the iodine from depositing (transitioning from the gas phase directly back into the solid phase), which will block the propellant feed lines. Furthermore, deposition will occur unless the temperature in the lines is not greater than the temperature of the propellant reservoir. The flow rate can be controlled by adjusting the heating applied to the reservoir, but as with any thermal control there is a relatively slow response to changes in the heating rate. In the present paper, we describe the propulsion and propellant feed system for the iodine satellite (iSAT) flight demonstration mission. The system is based around the Busek BHT-200 Hall thruster, which has been modified for chemical compatibility with iodine vapor. While the gross propellant flow rate is maintained by the heated propellant reservoir, the flow to the anode and cathode are adjusted using two heated Vacco proportional flow control valves (PFCV), which provide very fast response on the flow rate adjustment. The flight mission design layout will be presented, showing how the system will be packaged into the overall 12-U spacecraft and the techniques being employed to protect the remaining spacecraft hardware from the propulsion system (e.g., plasma impingement, iodine deposition, thermal loads). In addition to the flight system design, results of testing the thruster and cathode with both operating on iodine propellant are presented. The tests are conducted on a thrust stand (see Fig. 1) in a large vacuum chamber containing a beam dump chilled to below -100 C to 'cryopump' the propellant. The thruster performance during these tests is presented, with these data used to evaluate the feed system and guide further refinements. Results of relatively long duration testing are presented to demonstrate the capability to operate for the length of the iSAT mission and to perform a number of re-starts as will be required by the mission concept of operations.

Polzin, Kurt A.↗

NASA NTRSDate not supplied

Developmental Efforts of an Electrochemical Oxygen Recovery System for Advanced Life Support

The current State of Art (SOA) Environmental Control and Life Support System (ECLSS) oxygen recovery system onboard the International Space Station (ISS) is a complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O2) from metabolic carbon dioxide (CO2). For future long-duration missions, O2recovery systems will need to be highly reliable, efficient, and recover maximum metabolic CO2. Investigations into various technologies to help meet these requirements for exploration are ongoing; however, most of these proposed technologies ultimately result in a more complex system. A Macrofluidic Electrochemical Reactor (MFECR) is one proposed technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) that has the potential to significantly reduce the complexity of ECLSSO2recovery system. The MFECR operates at standard conditions, giving it an advantage over other technologies being investigated, which require high temperatures resulting in heavy reactors and high power consumption. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current Carbon Dioxide Reduction Assembly (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly(OGA). It is designed to interface directly with the Carbon Dioxide Removal Assembly (CDRA) and the Water Processor Assembly (WPA). This allows for a less complex system and higher reliability than the current SOA as well as reduced power, weight and H2Oconsumption of ECLSS. Here, we will discuss the current development efforts of the MFECR and how this technology may aide in the advancement of future long-duration life support systems.

Brittany R Brown↗

NASA NTRS2003

Guide for Hydrogen Hazards Analysis on Components and Systems

The physical and combustion properties of hydrogen give rise to hazards that must be considered when designing and operating a hydrogen system. One of the major concerns in the use of hydrogen is that of fire or detonation because of hydrogen's wide flammability range, low ignition energy, and flame speed. Other concerns include the contact and interaction of hydrogen with materials, such as the hydrogen embrittlement of materials and the formation of hydrogen hydrides. The low temperature of liquid and slush hydrogen bring other concerns related to material compatibility and pressure control; this is especially important when dissimilar, adjoining materials are involved. The potential hazards arising from these properties and design features necessitate a proper hydrogen hazards analysis before introducing a material, component, or system into hydrogen service. The objective of this guide is to describe the NASA Johnson Space Center White Sands Test Facility hydrogen hazards analysis method that should be performed before hydrogen is used in components and/or systems. The method is consistent with standard practices for analyzing hazards. It is recommended that this analysis be made before implementing a hydrogen component qualification procedure. A hydrogen hazards analysis is a useful tool for hydrogen-system designers, system and safety engineers, and facility managers. A hydrogen hazards analysis can identify problem areas before hydrogen is introduced into a system-preventing damage to hardware, delay or loss of mission or objective, and possible injury or loss of life.

Beeson, Harold↗

NASA NTRS2010

Labyrinth Seal Flutter Analysis and Test Validation in Support of Robust Rocket Engine Design

High energy-density turbomachines, like the SSME turbopumps, utilize labyrinth seals, also referred to as knife-edge seals, to control leakage flow. The pressure drop for such seals is order of magnitude higher than comparable jet engine seals. This is aggravated by the requirement of tight clearances resulting in possible unfavorable fluid-structure interaction of the seal system (seal flutter). To demonstrate these characteristics, a benchmark case of a High Pressure Oxygen Turbopump (HPOTP) outlet Labyrinth seal was studied in detail. First, an analytical assessment of the seal stability was conducted using a Pratt & Whitney legacy seal flutter code. Sensitivity parameters including pressure drop, rotor-to-stator running clearances and cavity volumes were examined and modeling strategies established. Second, a concurrent experimental investigation was undertaken to validate the stability of the seal at the equivalent operating conditions of the pump. Actual pump hardware was used to construct the test rig, also referred to as the (Flutter Rig). The flutter rig did not include rotational effects or temperature. However, the use of Hydrogen gas at high inlet pressure provided good representation of the critical parameters affecting flutter especially the speed of sound. The flutter code predictions showed consistent trends in good agreement with the experimental data. The rig test program produced a stability threshold empirical parameter that separated operation with and without flutter. This empirical parameter was used to establish the seal build clearances to avoid flutter while providing the required cooling flow metering. The calibrated flutter code along with the empirical flutter parameter was used to redesign the baseline seal resulting in a flutter-free robust configuration. Provisions for incorporation of mechanical damping devices were introduced in the redesigned seal to ensure added robustness

El-Aini, Yehia↗

NASA NTRS1988

High-strength silicon carbides by hot isostatic pressing

Silicon carbide has strong potential for heat engine hardware and other high-temperature applications because of its low density, good strength, high oxidation resistance, and good high-temperature creep resistance. Hot isostatic pressing (HIP) was used for producing alpha and beta silicon carbide (SiC) bodies with near-theoretical density, ultrafine grain size, and high strength at processing temperatures of 1900 to 2000 C. The HIPed materials exhibited ultrafine grain size. Furthermore, no phase transformation from beta to alpha was observed in HIPed beta-SiC. Both materials exhibited very high average flexural strength. It was also shown that alpha-SiC bodies without any sintering aids, when HIPed to high final density, can exhibit very high strength. Fracture toughness K (sub C) values were determined to be 3.6 to 4.0 MPa m (sup 1/2) for HIPed alpha-SiC and 3.7 to 4.1 MPa m (sup 1/2) for HIPed beta-SiC. In the HIPed specimens strength-controlling flaws were typically surface related. In spite of improvements in material properties such as strength and fracture toughness by elimination of the larger strength-limiting flaws and by grain size refinement, HIPing has no effect on the Weibull modulus.

Dutta, Sunil↗

NASA NTRS1989

High-strength silicon carbides by hot isostatic pressing

Dutta, Sunil↗

NASA NTRS2000

Braided Carbon Fiber Rope Flow Characteristics

I am submitting the following technical subject for consideration as a thesis topic for the master degree: The reusable solid rocket motor (RSRM) nozzle internal joints are being evaluated for the incorporation of a carbon fiber rope (CFR) as a thermal barrier. The CFR is approximately 0.260 in. diameter and is composed of approximately 12,000 carbon fibers, woven in ten sheaths or layers. The CFR is manufactured by a sub-tier vendor and subsequently several of its manufacturing details are proprietary to that vendor. The CFR design intent is to prevent hot motor combustion products and slag from intruding into the joint scaling area while still approaching a vented joint design to avoid the detriments of gas jet impingement. As a member of the Heat Transfer section at Thiokol Propulsion, two main goals exist as part of this NASA funded design effort: (1) development of flow model through the CFR and (2) development of a heat transfer model through the CFR. While both models are needed and most probably interrelated, the gas flow model is being targeted as the subject matter. Essentially, the topic would be "Modeling of Gas Flow through a Braided Carbon Fiber Rope". An AIAA journal or conference paper is being considered through Thiokol/NASA as well. A sub-scale CFR flow test fixture was designed to simulate the relative levels of CFR compression. The test fixture provides the means to measure gas mass flow rate upstream of the CFR and the pressure and temperature both upstream and downstream of the CFR. The test fixture was designed to eliminate the possibility of dynamic gapping at the CFR location and provide minimal flow resistance to ambient for gases exiting the rope. The data collected in the experiment will be evaluated to define a permeability/flow resistance model. Two possibilities exist for the flow characteristics through the CFR from choked flow to strictly friction driven. A test matrix for evaluating the CFR has been compiled, which addresses both of these characteristics. The range of pressures to be tested covers a relatively low delta pressure where non-choked flow is impossible, while the high pressure shown is dictated by the RSRM joint operating pressure where choking is possible. The test matrix, was also designed for a range of rope compressions or test fixture gaps ranging from 0.025" to 0.070". These gaps are controlled by the range of RSRM full-scale hardware joint gaps that will be expected by virtue of the joint design.

Heman, J. R. C.↗

NASA NTRS2003

Development of Algorithms for Control of Humidity in Plant Growth Chambers

Algorithms were developed to control humidity in plant growth chambers used for research on bioregenerative life support at Kennedy Space Center. The algorithms used the computed water vapor pressure (based on measured air temperature and relative humidity) as the process variable, with time-proportioned outputs to operate the humidifier and de-humidifier. Algorithms were based upon proportional-integral-differential (PID) and Fuzzy Logic schemes and were implemented using I/O Control software (OPTO-22) to define and download the control logic to an autonomous programmable logic controller (PLC, ultimate ethernet brain and assorted input-output modules, OPTO-22), which performed the monitoring and control logic processing, as well the physical control of the devices that effected the targeted environment in the chamber. During limited testing, the PLC's successfully implemented the intended control schemes and attained a control resolution for humidity of less than 1%. The algorithms have potential to be used not only with autonomous PLC's but could also be implemented within network-based supervisory control programs. This report documents unique control features that were implemented within the OPTO-22 framework and makes recommendations regarding future uses of the hardware and software for biological research by NASA.

Costello, Thomas A.↗

NASA NTRSDate not supplied

Hydrogen Peroxide-Water-Ethanol Monopropellant Blend for CubeSat Propulsion

Monopropellant propulsion that provides high performance and low hazards compared to state-of-art hydrazine are being investigated under NASA, DOD and commercially sponsored green propellant research and development programs. This NASA effort looks at phosphate stabilized 50% hydrogen peroxide/water –ethanol blends to evaluate their stability and combustion behavior in submillimeter diameter microtube combustion apparatus for cubesat propulsion applications. Exploratory 7-day stability tests find no pressure rise in a sealed test tube environment at room temperature indicating at least short term stability of the mixture. Temperature rise during combustion testing in resistively heated nickel microtube apparatus shows that micro-combustion is achieved in the tube. Propellant density is approximately 1.2 g/cu.cm compared to 1.0 g/cu.cm for hydrazine. Theoretical specific impulse of the stoichiometric blend is 219 s at a chamber pressure of 20 psia and an area ratio of 30:1. Density-specific impulse of this blend is 263 s while hydrazine is only about 215-220 s in small reaction control system thrusters. This provides about 20-22% more density-specific impulse for the cube sat compared to hydrazine. The the oretical combustion temperature is 2168°F, which is thermally compatible with stainless steel materials of construction and the nickel catalyst used in the tests. Combustion test results are given for stoichiometric, as well as fuel-lean and fuel-rich propellant formulations. These tests focus on thermally and catalytically supported combustion in the microtube, which requires a microtube preheat temperature of about 900°F and sufficient residence time to achieve combustion that is stable and anchored in the tube without blowing through the tube unreacted. Thrust class is expected to be in the 10 m N range based on flow rate and estimated specific impulse. Power requirements are generally below 25 W to heat the tube. Steady state combustion testing is typically conducted for 3 minutes and shows little degradation of the hardware over multiple test cycles indicating that there is little catalyst degradation over time and little catalyst deactivation due to the phosphate stabilizer in the hydrogen peroxide.

Monopropellant↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗