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Solid Rocket Motor Technology

These Conference Proceedings contain the 36 papers presented at the AGARD Propulsion and Energetics Panel 53rd Symposium on "Solid Rocket Motor Technology", which was held in Oslo, Norway, 2-5 April 1979. The questions and answers after the various presentations are included as well as the Round Table Discussion. The Symposium was organized into seven sessions: Survey Papers (2); Ignition, Extinction and Internal Ballistics (8); Burn Rate Modelling and Combustion of Metal (5); New Propellants (5); Combustion Instability (7); Heat Transfer and Materials (3); and Testing and Instrumentation (6).The Symposium provided a forum for discussion and exchange between research scientists ,propellant formulators and motor technologists. Though main emphasis was placed on transient processes like ignition and extinction and on combustion instability with the various related aspects there were a number of papers dealing with propellants, their characteristics and their development. Whether the symposium achieved its initial aim, i.e. furnishing a comprehensive survey of the technology available for solid propellant rocket motors and its further development capabilities, will be assessed in a Technical Evaluation Report, to be published as AGARD Advisory Report AR 151.

Advisory Group for Aerospace Research and Developm↗

Exploring Transfers Between Earth-Moon Halo Orbits via Multi-Objective Reinforcement Learning

Multi-Reward Proximal Policy Optimization, a multi-objective deep reinforcement learning algorithm, is used to examine the design space of low-thrust trajectories for a SmallSat transferring between two libration point orbits in the Earth-Moon system. Using Multi-Reward Proximal Policy Optimization, multiple policies are simultaneously and efficiently trained on three distinct trajectory design scenarios. Each policy is trained to create a unique control scheme based on the trajectory design scenario and assigned reward function: a unique combination of weights scaling competing objectives that guide the spacecraft to the target mission orbit, incentivize faster flight times, and penalize propellant mass usage. Then, the policies are evaluated on the same set of perturbed initial conditions in each scenario to generate the propellant mass usages, flight times, and state discontinuities from a reference trajectory for each control scheme. This solution space of low-thrust trajectories for a SmallSat is used to examine the multi-objective trade space for the trajectory design scenario. By autonomously constructing the solution space, insights into the required propellant mass, flight time, and transfer geometry are rapidly achieved.

Christopher J Sullivan↗

Exploring Transfers Between Earth-Moon Halo Orbits via Multi-Objective Reinforcement Learning

Multi-Reward Proximal Policy Optimization, a multi-objective deep reinforcement learning algorithm, is used to examine the design space of low-thrust trajectories for a SmallSat transferring between two libration point orbits in the Earth- Moon system. Using Multi-Reward Proximal Policy Optimiza- tion, multiple policies are simultaneously and efficiently trained on three distinct trajectory design scenarios. Each policy is trained to create a unique control scheme based on the trajectory design scenario and assigned reward function: a unique combination of weights scaling competing objectives that guide the spacecraft to the target mission orbit, incentivize faster flight times, and penalize propellant mass usage. Then, the policies are evaluated on the same set of perturbed initial conditions in each scenario to generate the propellant mass usages, flight times, and state discontinuities from a reference trajectory for each control scheme. This solution space of low-thrust trajectories for a SmallSat is used to examine the multi-objective trade space for the trajectory design scenario. By autonomously constructing the solution space, insights into the required propellant mass, flight time, and transfer geometry are rapidly achieved.

Mashiku, Alinda K.↗

Testing of TVS Augmented Injectors for Tank-to-Tank Transfer of Cryogens

NASA is developing reusable cryogenic systems to enable manned missions to the Moon and Mars. These cryogenic systems will require replenishing cryogens on-orbit via a tanker or propellant depot with minimal loss to boil-off. Three additively manufactured injectors augmented with a Thermodynamic Venting System have been developed for use in tank-to-tank cryogenic fluid transfer. A Vented Chill/No-Vent Fill approach to tank-to-tank transfer has been the industry standard and is explored in this work with emphasis on injector spray patterns and compared to the Charge-Hold-Vent chill method.

Cryogenic Transfer↗

Testing of TVS Augmented Injectors for Tank-to-Tank Transfer of Cryogens

NASA is developing reusable cryogenic systems to enable manned missions to the Moon and Mars. These cryogenic systems will require replenishing cryogens on-orbit via a tanker or propellant depot with minimal loss to boil-off. Three additively manufactured injectors augmented with a Thermodynamic Venting System have been developed for use in tank-to-tank cryogenic fluid transfer. A Vented Chill/No-Vent Fill approach to tank-to-tank transfer has been the industry standard and is explored in this work with emphasis on injector spray patterns and compared to the Charge-Hold-Vent chill method.

Cryogenic Transfer↗

Low thrust chemical orbit to orbit propulsion system propellant management study

Low thrust chemical propulsion systems were sized for transfer of large space systems from LEO to GEO. The influence of propellant combination, tankage and insulation requirements, and propellant management techniques on the LTPS mass and volume were studied. Liquid oxygen combined with hydrogen, methane or kerosene were the propellant combinations. Thrust levels of 445, 2230, and 4450 N were combined with 1, 4 and 8 perigee burn strategies. This matrix of systems was evaluated using multilayer insulation and spray-on-foam insulation systems. Various combinations of toroidal, cylindrical with ellipsoidal domes, and ellipsoidal tank shapes were investigated. Results indicate that low thrust (445 N) and single perigee burn approaches are considerably less efficient than the higher thrust level and multiple burn strategies. A modified propellant settling approach minimized propellant residuals and decreased system complexity, in addition, the toroid/ellipsoidal tank combination was predicted to be shortest.

Dergance, R. H.↗

Nuclear Thermal Propulsion (NTP): A Proven, Growth Technology for Fast Transit Human Missions to Mars

The "fast conjunction" long surface stay mission option was selected for NASA's recent Mars Design Reference Architecture (DRA) 5.0 study because it provided adequate time at Mars (approx. 540 days) for the crew to explore the planet's geological diversity while also reducing the "1-way" transit times to and from Mars to approx. 6 months. Short transit times are desirable in order to reduce the debilitating physiological effects on the human body that can result from prolonged exposure to the zero-gravity (0-gE) and radiation environments of space. Recent measurements from the RAD detector attached to the Curiosity rover indicate that astronauts would receive a radiation dose of approx. 0.66 Sv (approx. 66 rem)-the limiting value established by NASA-during their 1-year journey in deep space. Proven nuclear thermal rocket (NTR) technology, with its high thrust and high specific impulse (Isp approx. 900 s), can cut 1-way transit times by as much as 50 percent by increasing the propellant capacity of the Mars transfer vehicle (MTV). No large technology scale-ups in engine size are required for these short transit missions either since the smallest engine tested during the Rover program-the 25 klbf "Pewee" engine is sufficient when used in a clustered arrangement of three to four engines. The "Copernicus" crewed MTV developed for DRA 5.0 is a 0-gE design consisting of three basic components: (1) the NTP stage (NTPS); (2) the crewed payload element; and (3) an integrated "saddle truss" and LH2 propellant drop tank assembly that connects the two elements. With a propellant capacity of approx. 190 t, Copernicus can support 1-way transit times ranging from approx. 150 to 220 days over the 15-year synodic cycle. The paper examines the impact on vehicle design of decreasing transit times for the 2033 mission opportunity. With a fourth "upgraded" SLS/HLV launch, an "in-line" LH2 tank element can be added to Copernicus allowing 1-way transit times of 130 days. To achieve 100 to 120 day transit times, Copernicus' saddle truss/drop tank assembly is replaced by a "star truss" assembly with paired modular drop tanks to further increase the vehicle's propellant capacity. The HLV launch count increases (from approx. 5 to 7) and a fourth engine is needed to reduce total mission burn time and gravity losses. Using a "split mission" approach, the NTPS, in-line tank and the saddle truss/LH2 drop tank elements can be configured as a pre-deployed Earth Return Vehicle/propellant tanker supporting 90-day crewed mission transits. The split mission approach also eliminates the need for on-orbit assembly. Mission scenario descriptions, key features and operational characteristics for five different vehicle configurations are presented.

Borowski, Stanley K.↗

Thermal Model of a Zero Boil Off System for the Nuclear Thermal Propulsion System

NASA is currently developing an updated concept for a nuclear thermal propulsion (NTP) system. To enable this concept, efficient thermal insulation and cryocooler heat exchanger systems are required to eliminate boil-off of propellant. This paper presents the results of a thermal model used to assess the feasibility of using active cooling with a tube-on-tank heat exchanger configuration for the inline tank of the NTP system. Results show that: cryocooler working fluid temperature and mass flow rate can be adjusted to achieve zero boil off (ZBO) with broad area cooling, over-sizing the cryocooler lift directly translates into a reduction in tank pressure, and broad area cooling may still maintain ZBO despite the reduced heat transfer between tank wall and propellant that is expected in reduced gravity.

zero boil off↗

Gamma guidance of trajectories for coplanar, aeroassisted orbital transfer

The optimization and guidance of trajectories for coplaner, aeroassisted orbital transfer (AOT) from high Earth orbit (HEO) to low Earth orbit (LEO) are examined. In particular, HEO can be a geosynchronous Earth orbit (GEO). It is assumed that the initial and final orbits are circular, that the gravitational field is central and is governed by the inverse square law, and that at most three impulses are employed: one at HEO exit, one at atmospheric exit, and one at LEO entry. It is also assumed that, during the atmospheric pass, the trajectory is controlled via the lift coefficient. The presence of upper and lower bounds on the lift coefficient is considered. First, optimal trajectories are computed by minimizing the total velocity impulse (hence, the propellant consumption) required for AOT transfer. The sequential gradient-restoration algorithm (SGRA) is used for optimal control problems. The optimal trajectory is shown to include two branches: a relatively short descending flight branch (branch 1) and a long ascending flight branch (branch 2). Next, attention is focused on guidance trajectories capable of approximating the optimal trajectories in real time, while retaining the essential characteristics of simplicity, ease of implementation, and reliability. For the atmospheric pass, a feedback control scheme is employed and the lift coefficient is adjusted according to a two-stage gamma guidance law. Further improvements are possible via a modified gamma guidance which is more stable with respect to dispersion effects arising from navigation errors, variations of the atmospheric density, and uncertainties in the aerodynamic coefficients than gamma guidance trajectory. A byproduct of the studies on dispersion effects is the following design concept. For coplaner aeroassisted orbital transfer, the lift-range-to-weight ratio appears to play a more important role than the lift-to-drag ratio. This is because the lift-range-to-weight ratio controls mainly the minimum altitude (hence, the peak heating rate) of the guidance trajectory; on the other hand, the lift-to-drag ratio controls mainly the duration of the atmospheric pass of the guidance trajectory.

Miele, A.↗

An Overview of the NASA Ames Millimeter-Wave Thermal Launch System

The Millimeter-Wave Thermal Launch System (MTLS) is a beamed-energy propulsion concept being designed at NASA Ames Research Center. This effort is in response to the NASA Office of the Chief Technologist s announcement of the Ride the Light program. Our objective is to produce a design that goes beyond the feasibility analysis level of previous studies and provides a solid foundation for low cost access to space. The MTLS is designed to place a 500 lb payload into Low Earth Orbit (LEO) two times a day. This frequent launch, small payload niche is well suited for the particular advantages and constraints of beamed-energy propulsion, and has the potential to drastically increase access to space by reducing the cost per kilogram of placing payloads into LEO. This paper summarizes the findings of the MTLS study. The chemical rocket engine is in principle a simple device. It acts by releasing the chemical energy stored in propellants such as hydrogen and oxygen through combustion, then converting that thermal energy into kinetic energy by expansion through a nozzle. As such, it is fundamentally limited by the energy released in combustion reactions and the molecular weight of the products of those reactions. The highest performing conventional propellant combination, liquid oxygen and liquid hydrogen, can produce vacuum specific impulses of around 450 seconds. The design space of current launch vehicles (which tend to be large, multi-stage, and expendable) are defined by these limitations. An entirely new approach may be necessary in order to enable future launch vehicles of radically improved capabilities. Beamed-energy propulsion (BEP) is an alternative approach that bypasses the energy limitations of chemical propulsion. Instead of relying on a chemical reaction as the energy source, it is supplied externally via a beam of electromagnetic energy produced on the ground. In the concept examined in the MTLS, this energy is absorbed by a heat exchanger which then transfers the energy to the propellant. This decouples the energy source from the working fluid, vastly expanding the design space. For example, a launch vehicle could use only water as propellant, making it very safe and easy to handle. However, the most commonly proposed way to take advantage of this decoupling is to use pure hydrogen as the working fluid, which enables specific impulses of around 800 seconds1 if the heat exchanger material can operate at 2200 K. With such a significantly increased Isp, it may be possible to build single-stage to orbit vehicles, with enough mass margins left over to permit lower cost fabrication techniques.

Murakami, David↗

Nodal Modeling of Liquid Propellant Feed and Pressurization System

Nodal or network flow modeling plays an important role in the design and operation of the feed and pressurization system of a liquid rocket engine. Model development and execution time is relatively short for nodal codes in comparison to the Navier-Stokes based CFD codes. Nodal models also allow the inclusion of several components into one model to predict the behavior of a larger system. Unlike CFD models, the nodal models do not need very fine discretization of the flow field because they use empirical correlations to model fluid friction and heat transfer. This paper presents several applications of nodal modeling of liquid propellant feed and pressurization systems using the Generalized Fluid System Simulation Program (GFSSP), a nodal code developed at NASA/ Marshall Space Flight Center. GFSSP discretizes the flow field into nodes which are connected by branches. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The momentum equations are solved at the branches to calculate flow rates. Applications include a) tank pressurization by inert gas as well as autogenous pressurization by gaseous propellant, b) submerged pressurization by helium, c) self-pressurization due to boil-off of cryogenic propellant, d) chilldown of a transfer line of a cryogenic propellant feed system, and e) chilldown and filling of a cryogenic tank. Each of the above-mentioned models was verified and validated by comparing with test data.

Nodal Model↗

Nodal Modeling of Liquid Propellant Feed and Pressurization System

Nodal or network flow modeling plays an important role in the design and operation of the feed and pressurization system of a liquid rocket engine. Model development and execution time is relatively short for nodal codes in comparison to the Navier-Stokes based CFD codes. Nodal models also allow the inclusion of several components into one model to predict the behavior of a larger system. Unlike CFD models, the nodal models do not need very fine discretization of the flow field because they use empirical correlations to model fluid friction and heat transfer. This paper presents several applications of nodal modeling of liquid propellant feed and pressurization systems using the Generalized Fluid System Simulation Program (GFSSP), a nodal code developed at NASA/ Marshall Space Flight Center. GFSSP discretizes the flow field into nodes which are connected by branches. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The momentum equations are solved at the branches to calculate flow rates. Applications include a) tank pressurization by inert gas as well as autogenous pressurization by gaseous propellant, b) submerged pressurization by helium, c) self-pressurization due to boil-off of cryogenic propellant, d) chilldown of a transfer line of a cryogenic propellant feed system, and e) chilldown and filling of a cryogenic tank. Each of the above-mentioned models was verified and validated by comparing with test data.

Nodal Model↗

Small arms suppression project (LLNL final report)

US Special Operations Command (USSOCOM) was seeking a technological leap in small firearms weapon suppressor technology, because anticipated enemy capabilities are requiring the operators to have smaller detection cross sections to ensure the safe execution of missions. Suppressors have been developed almost exclusively through trial-and-error methods since the time of the original design by Hiram Maxim over one hundred years ago. Consequently USSOCOM deemed it prudent to perform a physicsbased study of weapon suppression to understand performance limits and possibly identify breakthrough technologies. Lawrence Livermore National Laboratory’s (LLNL’s) high performance production level computational tool called ALE3D (Arbitrary Lagrangian-Eulerian 3D and 2D) has unique physics models and numerical algorithms for modeling suppressor dynamics. The flexible and extendable code framework supports fully integrated hydrodynamics, heat transfer, solid and fluid dynamics, and chemistry that can be applied to simulating propellant-driven motion of a bullet down a gun barrel, the transfer of heat from the burning propellant to the barrel and suppressor, the chemistry of muzzle flash, and the shock/acoustic/optical signatures in the near-field. LLNL’s originally anticipated role was to augment ALE3D for this task, by developing the software and analysis methodologies specific to the simulation of blast and muzzle flash phenomena. It was believed that insights provided by our ALE3D simulations in tandem with a coordinated experimental component by our other team members from Oak Ridge National Laboratory (ORNL) and the U. S. Army Armament, Research, Development and Engineering Center (ARDEC), would have excellent prospects of yielding useful suppressor design improvements that could be transitioned to industry and utilized by US Special Operations Command. The three year effort has come to fruition with the development of revolutionary suppressor designs that far outperform any previous or current design by anyone outside this multi-lab team.

42 ENGINEERING↗

Nuclear Rocket Technology Conference

The Lewis Research Center has a strong interest in nuclear rocket propulsion and provides active support of the graphite reactor program in such nonnuclear areas as cryogenics, two-phase flow, propellant heating, fluid systems, heat transfer, nozzle cooling, nozzle design, pumps, turbines, and startup and control problems. A parallel effort has also been expended to evaluate the engineering feasibility of a nuclear rocket reactor using tungsten-matrix fuel elements and water as the moderator. Both of these efforts have resulted in significant contributions to nuclear rocket technology. Many successful static firings of nuclear rockets have been made with graphite-core reactors. Sufficient information has also been accumulated to permit a reasonable Judgment as to the feasibility of the tungsten water-moderated reactor concept. We therefore consider that this technoIogy conference on the nuclear rocket work that has been sponsored by the Lewis Research Center is timely. The conference has been prepared by NASA personnel, but the information presented includes substantial contributions from both NASA and AEC contractors. The conference excludes from consideration the many possible mission requirements for nuclear rockets. Also excluded is the direct comparison of nuclear rocket types with each other or with other modes of propulsion. The graphite reactor support work presented on the first day of the conference was partly inspired through a close cooperative effort between the Cleveland extension of the Space Nuclear Propulsion Office (headed by Robert W. Schroeder) and the Lewis Research Center. Much of this effort was supervised by Mr. John C. Sanders, chairman for the first day of the conference, and by Mr. Hugh M. Henneberry. The tungsten water-moderated reactor concept was initiated at Lewis by Mr. Frank E. Rom and his coworkers. The supervision of the recent engineering studies has been shared by Mr. Samuel J. Kaufman, chairman for the second day of the conference, and Mr. Roy V. Humble. Dr. John C. Eward served as general chairman for the conference.

Source record↗

Disposal of radioactive iodine in space

The possibility of space disposal of iodine waste from nuclear power reactors is investigated. The space transportation system utilized relies upon the space shuttle, a liquid hydrogen/liquid oxygen orbit transfer vehicle, and a solid propellant final stage. The iodine is assumed to be in the form of either an iodide or an iodate, and calculations assume that the final destination is either solar orbit or solar system escape. It is concluded that space disposal of iodine is feasible.

Burns, R. E.↗

LeRC reduced gravity fluid management technology program

A survey of the reduced gravity fluid management technology program is presented. Information on reduced gravity fluid behavior, techniques for thermal control of cryogenic tankage, and design for fluid management systems are discussed. The development of Spacelab experiments, propellant management systems for orbit transfer vehicles, and computer techniques for simulating reduced gravity fluid dynamic processes is reported.

Aydelott, J. C.↗