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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1996

Reusable Launch Vehicle Technology Program

Industry/NASA Reusable Launch Vehicle (RLV) Technology Program efforts are underway to design, test, and develop technologies and concepts for viable commercial launch systems that also satisfy national needs at acceptable recurring costs. Significant progress has been made in understanding the technical challenges of fully reusable launch systems and the accompanying management and operational approaches for achieving a low-cost program. This paper reviews the current status of the Reusable Launch Vehicle Technology Program including the DC-XA, X-33 and X-34 flight systems and associated technology programs. It addresses the specific technologies being tested that address the technical and operability challenges of reusable launch systems including reusable cryogenic propellant tanks, composite structures, thermal protection systems, improved propulsion, and subsystem operability enhancements. The recently concluded DC-XA test program demonstrated some of these technologies in ground and flight tests. Contracts were awarded recently for both the X-33 and X-34 flight demonstrator systems. The Orbital Sciences Corporation X-34 flight test vehicle will demonstrate an air-launched reusable vehicle capable of flight to speeds of Mach 8. The Lockheed-Martin X-33 flight test vehicle will expand the test envelope for critical technologies to flight speeds of Mach 15. A propulsion program to test the X-33 linear aerospike rocket engine using a NASA SR-71 high speed aircraft as a test bed is also discussed. The paper also describes the management and operational approaches that address the challenge of new cost-effective, reusable launch vehicle systems.

Freeman, Delma C., Jr.↗

NASA NTRSDate not supplied

Development and Validation of Two-Phase CFD Models for Key Elements of Propellant Tank CFM Operations in 1G and Microgravity – An Overview

This paper presents an overview of the state-of-the-art two-phase CFD models that have been developed for various propellant tank storage and transfer operations in 1g, partial gravity and microgravity. The models are developed in the framework of the industry standard ANSYS/Fluent CFD code, the capabilities of which have been significantly enhanced and customized through incorporation of unique submodels via User Defined Functions (UDF)s to satisfy the requirements of its intended variable gravity Cryogenic Fluid Management (CFM) applications. These models/submodels have been validated against experimental data that cross spatial scales, fluid types, and gravity levels in order to properly anchor the models’ physical and numerical fidelity. The CFM application/processes that have been modeled include tank self-pressurization, tank autogenous pressurization, tank pressure control using both subcooled jet mixing and droplet spray injection mechanisms, tank chilldown/filling, tank drainage, tank slosh for both volatile and non-volatile fluids. The strength and shortcomings of the two-phase models for each application is highlighted and discussed briefly.

Propellant Storage & Pressure Control↗

NASA NTRS1989

NASA Space Engineering Research Center for Utilization of Local Planetary Resources

Progress toward the goal of exploiting extraterrestrial resources for space missions is documented. Some areas of research included are as follows: Propellant and propulsion optimization; Automation of propellant processing with quantitative simulation; Ore reduction through chlorination and free radical production; Characterization of lunar ilmenite and its simulants; Carbothermal reduction of ilmenite with special reference to microgravity chemical reactor design; Gaseous carbonyl extraction and purification of ferrous metals; Overall energy management; and Information management for space processing.

Ramohalli, Kumar↗

NASA NTRS2009

Rendezvous Integration Complexities of NASA Human Flight Vehicles

Propellant-optimal trajectories, relative sensors and navigation, and docking/capture mechanisms are rendezvous disciplines that receive much attention in the technical literature. However, other areas must be considered. These include absolute navigation, maneuver targeting, attitude control, power generation, software development and verification, redundancy management, thermal control, avionics integration, robotics, communications, lighting, human factors, crew timeline, procedure development, orbital debris risk mitigation, structures, plume impingement, logistics, and in some cases extravehicular activity. While current and future spaceflight programs will introduce new technologies and operations concepts, the complexity of integrating multiple systems on multiple spacecraft will remain. The systems integration task may become more difficult as increasingly complex software is used to meet current and future automation, autonomy, and robotic operation requirements.

Brazzel, Jack P.↗

NASA NTRSDate not supplied

Experimental and CFD Investigation of the Titled Jet Behavior in the Zero Boil-Off Tank (ZBOT) Experiment

Screens are used in cryogenic storage tanks to diffuse the incoming gas or liquid injection/flow into the tank. Meshed screens were also used in the jet mixing pressure control tests of the Zero Boil-Off Tank (ZBOT) Experiment which was recently performed aboard the International Space Station (ISS). The ZBOT pressure control studies used a liquid jet that was intended to be aligned with the longitudinal axis of the tank. A cartridge consisting of a honeycomb flow straightener and two screen diffusers, one upstream of the honeycomb, and one downstream, were designed to obtain the desired velocity profile in a manner that would be consistent in all the tests and could also be used as an input to the CFD simulations. Unfortunately, during the flight operations, the Digital Particle Image Velocimetry (DPIV) measurements indicated that the jet actually exited the nozzle at an angle to the main axis. This unexpected tilt affected the motion and deformation of the ullage during the pressure control tests, influencing the initial pressure drops. Upon disassembling the experiment hardware, it was discovered that the screen diffuser upstream of the honeycomb was clogged with debris. Since this behavior is important, not only to the follow-on ZBOT-NC experiment, but also to the operation of cryogenics storage tanks in general, a series of ground-based experiments and parametric CFD model simulations were performed to understand and characterize the tilted flow in terms of the clogged area of the upstream screen and the jet velocity. The experimental and CFD results surprisingly and non-intuitively showed that although the modification of the flow originated from the clogging of the upstream screen, the presence of the downstream unclogged screen was also necessary to produce the tilted jet. Two different CFD models were used for the numerical simulations, and only the one using a porous media formulation to capture the screen pressure drop was able to produce the correct tilting behavior. Parametric runs with the porous media CFD model were used to characterize the jet tilt in terms of the blockage area and jet velocity for both the future ZBOT-NC Experiment and other propellant tank applications. Supported by NASA Biological & Physical Sciences (BPS) Division, Physical Sciences Research Program, NASA HQ, USA.

Cryogenic Fluid Management↗

NASA NTRS2003

ASK Talks with Alex McCool

As a charter member at Marshall, McCool was instrumental in the design of the propulsion systems for the Saturn launch vehicles that propelled Apollo to the Moon and directed project engineering for Skylab, the first space science laboratory. Alex McCool's 48-year career includes exceptional contributions to the vehicles that launched America into orbit and carried human beings to the moon. Presently, he is the manager of the Space Shuttle Projects Office at Marshall. Among his many honors he recently received the National Space Club's 2002 Astronautics Engineer Award. The award recognizes those who have made outstanding contributions in engineering management to the national space program.

Source record↗

NASA NTRSDate not supplied

Development of a Test Article to Demonstrate the Long Duration Storage of Liquid Hydrogen via a Two-Stage Active Cooling Approach

A NASA team is developing a test article for the purpose of demonstrating the long duration storage of liquid hydrogen utilizing passive Cryogenic Fluid Management and cryocoolers via a two-stage active cooling approach. Funded by NASA’s Technology Demonstration Mission Program and managed by the Cryogenic Fluid Management Portfolio Project, the team is leveraging demonstrations conducted under pervious NASA activities to develop a fully integrated test article that will demonstrate the zero boil-off storage of liquid hydrogen. This paper discusses the previous activities being leveraged from NASA’s Cryogenic Propellant Storage and Transfer project, the test article design and build, hardware and instrumentation selections, control methodology, and the planned primary and secondary test objectives. The test article assembly and demonstration are both to be conducted in the East Test Area at NASA Marshall Space Flight Center and are currently scheduled for Fiscal Year 2024.

Active Cooling↗

NASA NTRS2000

The 2001 Mars In-Situ-Propellant-Production Precursor (MIP) Flight Demonstration

The successful performance of the five individual demonstrations of MARS IN-SITU-PROPELLANT-PRODUCTION PRECURSOR (MIP) will provide both knowledge of and confidence in the reliability of this technology. At the completion of this flight demonstration, the MIP Team will be able to: a) recommend preferred hardware configurations for the intake and adsorption of carbon dioxide from the Martian atmosphere; b) understand the performance characteristics of zirconia cells to generate propellant-grade oxygen; c) understand long-term performance characteristics of advanced solar cells/arrays operated in the actual Mars environment; d) evaluate the functionality of methods to mitigate the deposition of airborne dust onto solar arrays; and e) recommend preferred hardware designs for innovative thermal management including the radiation of heat to the outside environment.

Kaplan, David I.↗

NASA NTRS2019

Sun search desgin for the Psyche spacecraft

Psyche is a scientific mission to explore the large asteroid (16) Psyche that orbits the Sun at ~3 AU. Managed by JPL, it is the first instance of Maxar’s product line of geosynchronous communication satellites being repurposed for deep space. This paper presents the design of a unique sun sensor configuration for Safe Mode of the spacecraft. It enables quick, robust, and propellant-efficient safing while leveraging sensors, avionics, and algorithms that have extensive, flight-proven heritages

Turner, Eric↗

NASA NTRS2015

Zero Boil-Off System Testing

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration plans due to their high specific impulse for rocket motors of upper stages. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for long duration missions. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler temperature to control tank pressure. The technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center in a vacuum chamber and cryoshroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.

Reverse turbo-Brayton cycle↗

NASA NTRS1977

Liquid Rocket Lines, Bellows, Flexible Hoses, and Filters

Fluid-flow components in a liquid propellant rocket engine and the rocket vehicle which it propels are interconnected by lines, bellows, and flexible hoses. Elements involved in the successful design of these components are identified and current technologies pertaining to these elements are reviewed, assessed, and summarized to provide a technology base for a checklist of rules to be followed by project managers in guiding a design or assessing its adequacy. Recommended procedures for satisfying each of the design criteria are included.

Source record↗

NASA NTRS1992

Excitation of slosh waves associated with low frequency impulsive reverse gravity acceleration of geyser initiation

The objective of the cryogenic fluid management of the spacecraft propulsion system is to develop the technology necessary for acquisition or positioning of liquid and vapor within a tank in reduced gravity to enable liquid outflow or vapor venting. The requirement to settle or to position liquid fuel over the outlet end of the spacecraft propellant tank prior to main engine restart poses a microgravity fluid behavior problem. The purpose of the present study is to investigate the stability of the most efficient technique for propellant resettling through the minimization of propellant usage and weight penalties. In this study slosh wave excitation induced by the resettling flow field activated by 0.1 Hz low frequency, impulsive reverse gravity acceleration, during reorientation with the initiation of geyser for liquid fill levels of 30, 50, 65, 70 and 80 percent, have been studied. Characteristics of slosh waves with various frequencies excited are discussed. Slosh wave excitation shift the fluid mass distribution in the container which impose time dependent variations in spacecraft moment of inertia. This information is important for the spacecraft control during the course of liquid reorientation.

Hung, R. J.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the displays and controls subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results corresponding to the Orbiter Displays and Controls (D and C) subsystem hardware. The function of the D and C hardware is to provide the crew with the monitor, command, and control capabilities required for management of all normal and contingency mission and flight operations. The D and C hardware for which failure modes analysis was performed consists of the following: Acceleration Indicator (G-METER); Head Up Display (HUD); Display Driver Unit (DDU); Alpha/Mach Indicator (AMI); Horizontal Situation Indicator (HSI); Attitude Director Indicator (ADI); Propellant Quantity Indicator (PQI); Surface Position Indicator (SPI); Altitude/Vertical Velocity Indicator (AVVI); Caution and Warning Assembly (CWA); Annunciator Control Assembly (ACA); Event Timer (ET); Mission Timer (MT); Interior Lighting; and Exterior Lighting. Each hardware item was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode.

Trahan, W. H.↗

NASA NTRS2000

Microreactor System Design for a NASA In Situ Propellant Production Plant on Mars

The NASA In Situ Resource Utilization (ISRU) program is planning near-term missions to Mars that will include chemical processes for converting the carbon dioxide (CO2) and possibly water from the Martian environment to propellants, oxygen, and other useful chemicals. The use of indigenous resources reduces the size and weight of the payloads from Earth significantly, representing enormous cost savings that make human exploration of Mars affordable. Extraterrestrial chemical processing plants will need to be compact, lightweight, highly efficient under reduced gravity, and extraordinarily reliable for long periods. Microchemical and thermal systems represent capability for dramatic reduction in size and weight, while offering high reliability through massive parallelization. In situ propellant production (ISPP), one aspect of the ISRU program, involves collecting and pressurizing atmospheric CO2, conversion reactions, chemical separations, heat exchangers, and cryogenic storage. A preliminary system design of an ISPP plant based on microtechnology has demonstrated significant size, weight, and energy efficiency gains over the current NASA baseline. Energy management is a strong driver for Mars-based processes, not only because energy is a scarce resource, but because heat rejection is problematic; the low pressure environment makes convective heat transfer ineffective. Energy efficiency gains are largely achieved in the microchemical plant through extensive heat recuperation and energy cascading, which has a small size and weight penalty because the added micro heat exchangers are small. This leads to additional size and weight gains by reducing the required area of waste heat radiators. The microtechnology-based ISPP plant is described in detail, including aspects of pinch analysis for optimizing the heat exchanger network. Three options for thermochemical compression Of CO2 from the Martian atmosphere, adsorption, absorption, and cryogenic freezing, are presented, as well as three options for water decomposition, low temperature electrolysis, high temperature electrolysis, and thermochemical decomposition. Other elements of the plant include Sabatier and reverse water gas shift reactors, water recovery, chemical separations, and cryogenic storage. Data are presented supporting preliminary sizing of components, and results of the system design are compared to the existing NASA baseline that is based on conventional technologies.

TeGrotenhuis, W. E.↗

NASA NTRS1972

Preliminary design of an auxiliary power unit for the space shuttle. Volume 1: Summary

Numerous candidate APU concepts are considered, each meeting the space shuttle APU problem statement. Evaluation of these concepts indicates that the optimum concept is a hydrogen-oxygen APU incorporating a recuperator to utilize the exhaust energy and using the cycle hydrogen flow as a means of cooling the component heat loads. A preliminary design of the selected APU concept is presented, placing primary emphasis on the cycle thermal management and the controls. Results for both steady state and transient APU performance are also included, based on digital computer programs developed during the study. The selected APU provides up to 400 hp out of the gearbox, has a fixed weight of about 277 lb, and requires about 2 lb/shp-hr of propellants.

Hamilton, M. L.↗

NASA NTRS2007

Simulating Flights of Future Launch Vehicles and Spacecraft

Marshall Aerospace Vehicle Representation in C (MAVERIC) is a computer program for generic, low-to-high-fidelity simulation of the flight(s) of one or more launch vehicle(s) or spacecraft. MAVERIC is designed to accommodate multi-staged vehicles, powered serially or in parallel, with multiple engines, tanks, and cargo elements. Engines can be of jet or conventional rocket types, using either liquid or solid propellants. MAVERIC includes generic subsystem software models for propulsion systems, mass properties, reaction control systems, aerodynamic properties, guidance systems, and navigation systems. Simulations can be started at points other than liftoff. Also included are guidance-system software models that accommodate the ascent, orbit, coasting, deorbiting, entry, terminal-area-energy-management, approach, and landing phases of flight. Options to use different wind profiles and atmospheres are included. A Monte Carlo capability is provided for modeling dispersions associated with atmospheric effects (including winds), propulsion, navigation, aerodynamics, and mass properties. Failures of engines and other subsystems can be modeled. The program is written in the C programming language, which makes it possible for the program to have high degrees of modularity, reusability, and maintainability, thereby also facilitating modification for modeling new vehicles.

McCarter, James W.↗

NASA NTRS2019

Liquid Nitrogen Testing of ISRU Liquefaction Methods in Unsteady Applications

To enable NASA’s planned long duration missions, the agency is putting emphasis on reusable cryogenic systems. Such systems will require replenishing of cryogens on-orbit via a cryogenic tanker or refueling depot, and potentially on the lunar or Martian surfaces with the utilization of in-situ resources. Surface replenishing requires the in-situ production of gaseous oxygen (and hydrogen if on the lunar surface), followed by liquefaction and storage. Funded by NASA’s Advanced Exploration Systems, and managed under the Advanced Cis-Lunar Space Capability Project, the Cryogenic Fluid In-Situ Liquefaction for Landers (CryoFILL) multi center team was formed to develop a liquefaction and storage system that is efficient, reliable and scalable. This presentation will demonstrate the liquefaction and storage of “In-Situ like” propellant via a Tube-On-Tank Heat Exchanger integrated with Active Cooling (cryocooler) (verify proof of concept and obtain relevant data for model validation) and gather lessons learned from “brassboard” testing which will be applied to future liquefaction system prototype testing, then eventually to an end-to-end demonstration.

Stephens, J. R.↗

NASA NTRSDate not supplied

A Green Propulsion Dual Mode (GPDM) In-Space Technology Demonstration on a 6U CubeSat

Over the past decade there has been an increase in the launch and operations of small spacecraft. Small spacecraft (defined as having a total vehicle mass of < 180 kg) provide an opportunity for low-cost, high impact technology demonstrations on a small scale. They also create opportunities for government, industry, and academic to engage, transfer knowledge, and extend partnerships with non-traditional partners. NASA’s Marshall Space Flight Center (MSFC) is leading a collaborative effort to demonstrate a dual-mode (chemical and electrospray) propulsion system using a common propellant system as a payload on a 6U CubeSat. The novel feature in the propulsion system is the interfacing of propulsion technologies requiring dramatically different operating conditions and support hardware. GPDM will use a low toxicity or “green” propellant known as Advanced Spacecraft Energetic Non-Toxic (ASCENT) to demonstrate using a chemical thruster for translation burns and electrospray propulsion for both attitude control and translational burns on the spacecraft. Specific mission activities could include demonstration of collision avoidance during frequent altitude adjustment maneuvers to validate thruster performance and managing extended duration thruster burns of at least 24 hours with limited vehicle contact times. This paper will summarize the ground testing, spacecraft development, mission objectives, and mission planning activities to achieve some of GPDM’s technical objectives.

Nehemiah Joel Williams↗