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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Combustion of Metals in Carbon Dioxide and Reduced-Gravity Environments

Ongoing exploration and future mission2001110444 s to Mars have given impetus to research on the use of natural resources of the planet. Since carbon dioxide (CO2) constitutes approximately 95% of the Mars atmosphere and since it reacts directly and vigorously with several metals, this investigation focuses on metal-CO2 reactions as a possible combination for rocket-propellant production and energy generation. Magnesium (Mg) has been initially selected as the metal fuel owing to its low ignition temperature and high specific impulse and burning rate in CO2. Our studies in this field started with low gravity (g) combustion tests of Mg in O2, CO2, and CO. Reduced gravity provided a clear picture of the burning phenomena by eliminating the intrusive buoyant flows in high-temperature metal reactions and by removing the destructive effect of gravity on the shape of molten metal samples. Suspended cylindrical metal samples of 2, 3, and 4-mm in diameter and length were radiatively ignited in low-g to generate free-floating samples exhibiting a spherically symmetric flame with increasing metal-oxide accumulation in an outer shell. For the Mg-CO2 combination, burning times twice as long as in normal-g and five times longer than in Mg-O2 flames were observed, revealing a diffusion-controlled reaction. The burning time is proportional to the square of the sample diameter. In tests conducted with pure CO, combustion was not possible without constant heating of the sample due to the formation of a thick carbon-containing coating around the Mg sample generated by surface reactions. The following work presents two new studies that attempt to explain some of the low-g experimental observations. First, a simplified one-dimensional, quasi-steady numerical model is developed to obtain temperature, species concentrations, and burning rates of the spherically symmetric diffusion flame around the Mg sample burning in O2 and CO2. Second, a Planar Laser Induced Fluorescence (PLIF) technique is implemented to provide spatially resolved measurements of magnesium oxide (MgO) in the reaction zone of Mg samples burning in O2 and CO2. These experiments reveal fundamental differences between the two combustion systems.

Branch, M. C.↗
NASA NTRS2009

Modeling and Simulation of Variable Mass, Flexible Structures

The advent of the new Ares I launch vehicle has highlighted the need for advanced dynamic analysis tools for variable mass, flexible structures. This system is composed of interconnected flexible stages or components undergoing rapid mass depletion through the consumption of solid or liquid propellant. In addition to large rigid body configuration changes, the system simultaneously experiences elastic deformations. In most applications, the elastic deformations are compatible with linear strain-displacement relationships and are typically modeled using the assumed modes technique. The deformation of the system is approximated through the linear combination of the products of spatial shape functions and generalized time coordinates. Spatial shape functions are traditionally composed of normal mode shapes of the system or even constraint modes and static deformations derived from finite element models of the system. Equations of motion for systems undergoing coupled large rigid body motion and elastic deformation have previously been derived through a number of techniques [1]. However, in these derivations, the mode shapes or spatial shape functions of the system components were considered constant. But with the Ares I vehicle, the structural characteristics of the system are changing with the mass of the system. Previous approaches to solving this problem involve periodic updates to the spatial shape functions or interpolation between shape functions based on system mass or elapsed mission time. These solutions often introduce misleading or even unstable numerical transients into the system. Plus, interpolation on a shape function is not intuitive. This paper presents an approach in which the shape functions are held constant and operate on the changing mass and stiffness matrices of the vehicle components. Each vehicle stage or component finite element model is broken into dry structure and propellant models. A library of propellant models is used to describe the distribution of mass in the fuel tank or Solid Rocket Booster (SRB) case for various propellant levels. Based on the mass consumed by the liquid engine or SRB, the appropriate propellant model is coupled with the dry structure model for the stage. Then using vehicle configuration data, the integrated vehicle model is assembled and operated on by the constant system shape functions. The system mode shapes and frequencies can then be computed from the resulting generalized mass and stiffness matrices for that mass configuration. The rigid body mass properties of the vehicle are derived from the integrated vehicle model. The coupling terms between the vehicle rigid body motion and elastic deformation are also updated from the constant system shape functions and the integrated vehicle model. This approach was first used to analyze variable mass spinning beams and then prototyped into a generic dynamics simulation engine. The resulting code was tested against Crew Launch Vehicle (CLV-)class problems worked in the TREETOPS simulation package and by Wilson [2]. The Ares I System Integration Laboratory (SIL) is currently being developed at the Marshall Space Flight Center (MSFC) to test vehicle avionics hardware and software in a hardware-in-the-loop (HWIL) environment and certify that the integrated system is prepared for flight. The Ares I SIL utilizes the Ares Real-Time Environment for Modeling, Integration, and Simulation (ARTEMIS) tool to simulate the launch vehicle and stimulate avionics hardware. Due to the presence of vehicle control system filters and the thrust oscillation suppression system, which are tuned to the structural characteristics of the vehicle, ARTEMIS must incorporate accurate structural models of the Ares I launch vehicle. The ARTEMIS core dynamics simulation models the highly coupled nature of the vehicle flexible body dynamics, propellant slosh, and vehicle nozzle inertia effects combined with mass and flexible body properties that vary significant with time during the flight. All forces that act on the vehicle during flight must be simulated, including deflected engine thrust force, spatially distributed aerodynamic forces, gravity, and reaction control jet thrust forces. These forces are used to excite an integrated flexible vehicle, slosh, and nozzle dynamics model for the vehicle stack that simulates large rigid body translations and rotations along with small elastic deformations. Highly effective matrix math operations on a distributed, threaded high-performance simulation node allow ARTEMIS to retain up to 30 modes of flex for real-time simulation. Stage elements that separate from the stack during flight are propagated as independent rigid six degrees of freedom (6DOF) bodies. This paper will present the formulation of the resulting equations of motion, solutions to example problems, and describe the resulting dynamics simulation engine within ARTEMIS.

Tobbe, Patrick A.↗
NASA NTRS1996

Ignition and Combustion of Bulk Metals in a Microgravity Environment

This annual report summarizes the latest results obtained in a NASA-supported project to investigate the effect of gravity on the ignition and combustion of bulk metals. The experimental arrangement used for this purpose consists of a 1000-W xenon lamp that irradiates the top surface of cylindrical titanium and magnesium specimens, 4 mm in diameter and 4 mm in height, in a quiescent, pure-oxygen environment at 1 atm. Reduced gravity is obtained from the NASA LeRC DC-9 aircraft flying parabolic trajectories. Values of critical and ignition temperatures are obtained from thermocouple records. Qualitative observations and propagation rates are extracted from high-speed cinematography. Emission spectra of gas-phase reactions are obtained with an imaging spectrograph/diode array system. It was found that high applied heating rates and large internal conduction losses generate critical and ignition temperatures that are several hundred degrees above the values obtained from isothermal experiments. Because of high conduction and radiation heat losses, no appreciable effect on ignition temperatures with reduced convection in low gravity is detected. Lower propagation rates of the molten interface on titanium and of ignition waves on magnesium are obtained at reduced gravity. These rates are compared to theoretical results from heat conduction analyses with a diffusion/convection controlled reaction. The close agreement found between experimental and theoretical values indicates the importance of the influence of natural convection-enhanced oxygen transport on combustion rates. Lower oxygen flux and lack of oxide product removal in the absence of convective currents appear to be responsible for longer burning times of magnesium diffusion flames at reduced gravity. The accumulation of condensed oxide particles in the flame front at low gravity produces a previously unreported unsteady explosion phenomenon in bulk magnesium flames. This spherically symmetric explosion phenomenon seems to be driven by increased radiation heat transfer from the flame front to an evaporating metal core covered by a porous, flexible oxide coating. These important results have revealed the significant role of gravity on the burning of metals, and are now being used as the database for future experiments to be conducted with different metals at various pressures, oxygen concentrations and gravity levels.

Branch, M. C.↗
NASA NTRS2005

STS-114 Flight Day 2 Highlights

Video coverage of NASA's Return to Flight continues with highlights from Day 2 of STS-114. After a wake-up song from Mission Control Center, the crew of Space Shuttle Discovery (Commander Eileen Collins, Pilot James Kelly, Mission Specialists Soichi Noguchi, Stephen Robinson, Andrew Thomas, Wendy Lawrence, and Charles Camarda) inspects the orbiter for damage using a camera on the Shuttle Remote Manipulator System (SRMS). The SRMS, a robot arm, extends its length by grappling the new Orbiter Boom Sensor System, in order to image Discovery's wing leading edges and the underside of its nose. After the boom is stowed in the payload bay, the top and sides of the crew cabin are then imaged, including the Reaction Control System jets. The Shuttle's Ku-band antenna is then deployed. The video includes scenes of the payload bay contents, and crew members on the flight deck.

Source record↗
NASA NTRS2020

Mars Ascent Vehicle Solid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system, which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. Although the initial MSR architecture called for a hybrid-based propulsion MAV featuring solid wax fuel with liquid oxidizer, a configuration using more traditional solid propulsion was developed as an additional risk mitigation option. Though lacking in the single stage to orbit (SSTO) and throttle flexibility of a hybrid configuration, a solid configuration vehicle allows a simpler design with significantly longer flight heritage and higher Technology Readiness Level (TRL). This paper describes the design of the solid propulsion configuration. An additional paper will be published describing the design of the hybrid propulsion configuration. The solid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features two stages with a modified STAR-17 motor for the second stage and a traditional electromechanical actuator Thrust Vector Controller (TVC). The vehicle was designed to deliver approximately 0.47kg of Martian geological samples to a circular orbit at Mars of 343km at a 25° inclination. Although solid motor designs in general are at a relatively high TRL, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40°C. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), TVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗
NASA NTRS2020

Mars Ascent Vehicle Solid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system, which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. Although the initial MSR architecture called for a hybrid-based propulsion MAV featuring solid wax fuel with liquid oxidizer, a configuration using more traditional solid propulsion was developed as an additional risk mitigation option. Though lacking in the single stage to orbit (SSTO) and throttle flexibility of a hybrid configuration, a solid configuration vehicle allows a simpler design with significantly longer flight heritage and higher Technology Readiness Level (TRL). This paper describes the design of the solid propulsion configuration. An additional paper will be published describing the design of the hybrid propulsion configuration. The solid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features two stages with a modified STAR-17 motor for the second stage and a traditional electromechanical actuator Thrust Vector Controller (TVC). The vehicle was designed to deliver approximately 0.47kg of Martian geological samples to a circular orbit at Mars of 343km at a 25° inclination. Although solid motor designs in general are at a relatively high TRL, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40°C. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), TVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗
NASA NTRS2003

Catalyzed Combustion In Micro-Propulsion Devices: Project Status

In recent years, there has been a tendency toward shrinking the size of spacecraft. New classes of spacecraft called micro-spacecraft have been defined by their mass, power, and size ranges. Spacecraft in the range of 20 to 100 kg represent the class most likely to be utilized by most small sat users in the near future. There are also efforts to develop 10 to 20 kg class spacecraft for use in satellite constellations. More ambitious efforts will be to develop spacecraft less than 10 kg, in which MEMS fabrication technology is required. These new micro-spacecraft will require new micro-propulsion technology. Although micro-propulsion includes electric propulsion approaches, the focus of this proposed program is micro-chemical propulsion which requires the development of microcombustors. As combustors are scaled down, the surface to volume ratio increases. The heat release rate in the combustor scales with volume, while heat loss rate scales with surface area. Consequently, heat loss eventually dominates over heat release when the combustor size becomes smaller, thereby leading to flame quenching. The limitations imposed on chamber length and diameter has an immediate impact on the degree of miniaturization of a micro-combustor. Before micro-combustors can be realized, such a difficulty must be overcome. One viable combustion alternative is to take advantage of surface catalysis. Micro-chemical propulsion for small spacecraft can be used for primary thrust, orbit insertion, trajectory-control, and attitude control. Grouping micro-propulsion devices in arrays will allow their use for larger thrust applications. By using an array composed of hundreds or thousands of micro-thruster units, a particular configuration can be arranged to be best suited for a specific application. Moreover, different thruster sizes would provide for a range of thrust levels (from N s to mN s) within the same array. Several thrusters could be fired simultaneously for thrust levels higher than the basic units, or in a rapid sequence in order to provide gradual but steady low-g acceleration. These arrays of micro-propulsion systems would offer unprecedented flexibility and redundancy for satellite propulsion and reaction control for launch vehicles. A high-pressure bi-propellant micro-rocket engine is already being developed using MEMS technology. High pressure turbopumps and valves are to be incorporated onto the rocket chip . High pressure combustion of methane and O2 in a micro-combustor has been demonstrated without catalysis, but ignition was established with a spark. This combustor has rectangular dimensions of 1.5 mm by 8 mm (hydraulic diameter 3.9 mm) and a length of 4.5 mm and was operated at 1250 kPa with plans to operate it at 12.7 MPa. These high operating pressures enable the combustion process in these devices, but these pressures are not practical for pressure fed satellite propulsion systems. Note that the use of these propellants requires an ignition system and that the use of a spark would impose a size limitation to this micro-propulsion device because the spark unit cannot be shrunk proportionately with the thruster. Results presented in this paper consist of an experimental evaluation of the minimum catalyst temperature for initiating/supporting combustion in sub-millimeter diameter tubes. The tubes are resistively heated and reactive premixed gases are passed through the tubes. Tube temperature and inlet pressure are monitored for an indication of exothermic reactions and composition changes in the gases.

Sung, C. J.↗
NASA NTRS1993

Simulation of the Attitude Determination System for Space Station berthing dynamics research

Langley has developed a simulator of the Space Station coupled to the Space Shuttle via the Remote Manipulator System for use in evaluating handling during Station assembly. To date, evaluations of this scenario had included the Station Attitude Control System (ACS), assuming that the Station Attitude Determination System (ADS) provides perfect information on the coupled configuration. Herein, the complete Station digital autopilot (DAP) is considered including both the ADS and ACS systems. The ADS, its modelling and simulation are briefly overviewed and studies concerning the closed-loop operation of the DAP during local-coordinate, orbital attitude hold are presented. Results show that the presence of a type 0 filter in the ADS angular velocity signal processing has an adverse effect on attitude estimation because of the error in steady-state tracking of the angular velocity following reaction control jet firings. This error propagates into the attitude estimate almost linearly with time and star tracker updates are required at frequent, 3-second intervals if a .001 degree accuracy is to be maintained.

Montgomery, Raymond C.↗
NASA NTRS1982

Selected stability and control derivatives from the first three Space Shuttle entries

Stability and control derivative estimates obtained from the first three Space Shuttle entries are presented. The derivative estimates were obtained using the established modified maximum likelihood estimation program (MMLE3). The method of analysis used by the MMLE3 program is reviewed, the Shuttle configuration and data system are described, and the various types of maneuvers analyzed from the three entries are illustrated. Finally, the paper presents selected derivative results and compares them with predictions. Most of the flight-derived estimates agreed fairly well with predictions, considering the lack of experience in these new flight regimes. The most notable exception was the aerodynamic interference caused by firing the reaction control jets in the atmosphere. The flight results showed this interference to be considerably smaller than predicted.

Maine, R. E.↗
NASA NTRS2020

Mars Ascent Vehicle Hybrid Propulsion Configuration

As part of a Mars Sample Return (MSR) campaign, two Mars Ascent Vehicle (MAV) configurations have been designed in parallel. Each ascent vehicle configuration has a different propulsion system which ultimately leads to two unique vehicle designs. As part of a Preliminary Architecture Assessment (PAA), these vehicle designs were developed to the same level of maturity in order to inform the selection of one of the vehicles as the point of departure design for the campaign. The selection will be made in November 2019. The initial MSR architecture called for a hybrid-based propulsion MAV. This type of propulsion system calls for a solid wax motor that would utilize liquid MON-25 as an oxidizer. Hybrid rocket propulsion allows for more flexibility than traditional solid or liquid propulsion options, and typically benefits from the advantages of both. A hybrid motor can be throttled and shut down easily, and avoids significant risk in manufacturing and handling. On a theoretical level, hybrid motors perform at a higher specific impulse (Isp) than solid motors. The primary disadvantage of hybrid motors comes from additional complexity and significantly less flight heritage and low Technology Readiness Level (TRL). This paper describes the design of the hybrid propulsion configuration. An additional paper will be published describing the design of the solid propulsion configuration1. The hybrid propulsion configuration MAV was developed in 2019 by NASA Marshall Space Flight Center (MSFC) in association with NASA Jet Propulsion Laboratory (JPL). It features a Single Stage to Orbit (SSTO) design with an SP7A solid wax fuel and MON-25 liquid oxidizer. The liquid portion of the vehicle allows for a Liquid Injection Thrust Vector Controller (LITVC) as well as hypergolic propellant additives for ignition. The vehicle was designed to deliver approximately 0.31kg of Martian geological samples to a circular orbit at Mars of 343km at a 25o inclination. Although hybrid propulsion in general has been used on launch vehicles in the past, the integrated vehicle subsystems that operate in conjunction with these propulsion elements do not typically operate in a Martian environment, which in this application can get as cold as -40oC. The PAA advanced the maturity of these subsystems by performing detailed design and analysis on the vehicle with respect to structures and mechanisms, Guidance/Navigation/Control (GNC) systems, avionics, Reaction Control System (RCS), LITVC, thermal environments, and advanced Computational Fluid Dynamics (CFD). This paper will summarize the results of these studies.

Yaghoubi, Darius↗
NASA NTRS2010

Orion Touchdown Heading Control

At touchdown Orion must be aligned so that the crew person's feet are forward in the direction of the horizontal velocity. To ensure that this requirement is met active heading control is being implemented on the Orion crew module. This technique reduces probability of roll-over during splashdown, assures axial loads on the crew at touchdown, and alleviates structural requirements on impact allowing for a light-weight structural design. On-board sensors are used to measure current vehicle orientation and horizontal velocity used in generation of the heading error signal. Linear velocity measured by the IMU drifts while under parachutes due to wind gusts and has to be corrected by GPS; this makes GPS critical for successful landing. Jet fire logic is achieved by use of a phase-plane and commands are realized by using roll jets from the reaction control system (RCS); using pre existing hardware eliminates additional hardware and structural requirements. Touchdown performance is measured by an orientation envelope that was co-developed with structures so that the performance requirements overlap adding system redundancy. Heading control also introduces new difficulties to be addressed such as parachute line twist torque as well as increasing vehicle sensitivity to wind shifts and sea states. Solving these difficulties requires added complexity to flight software as well as increasing the propellant required to achieve successful touchdown. while offering promising results, the criticality of GPS along with a significant propellant cost raises questions on the effectiveness of using touchdown heading control.

Kane, Mark A.↗
NASA NTRS1994

Comment on 'Guidance for an Aerocapture Maneuver

It is stated that the aerodynamic forces on the vehicle being aerocaptured are controlled by "altering the angle of attack" and thereby controlling the lift coefficient. Furthermore, the resulting variation of drag coefficient with angle of attack was ignored. The purpose of this Comment is to point out that an aerodynamic control method that is much more effective than the pitch modulation has been studied and utilized during entries for many years. During aerocapture, it is desirable to have a large range of lift coefficients available, while keeping the vehicle's ballistic coefficients constant. This is accomplished by modulating the vehicle's bank angle, i.e., by rolling the vehicle about its velocity vector. By this method, the angle of attack can be held constant (at the trim angle, if desired), and the C(sub D) and the ballistic coefficient remain constant. Furthermore, the vertical component of the normal force vector (essentially the lift) can be varied over its entire range, from maximum positive to maximum negative values. Reaction controls, rather than aerodynamic ones, are usually utilized to change the bank angle of the vehicle, thus requiring the use of fuel. However, the fuel expenditure that is required to change the bank angle is far less than the amount that would have to be used to continuously hold the vehicle at pitch angles that differ significantly from its trim angle of attack. Also, it has been shown that bank angle modulation to vary the lift can enlarge the entry corridor by increasing the entry angle for the undershoot boundary, where both the heating rate and deceleration reach a maximum. Finally, the crew's deceleration tolerance can be increased somewhat when the bank angle is varied, as opposed to the pitch angle. For bank modulation, the deceleration force vector can be kept at a constant angle with respect to the occupants whose tolerance to g loads is highest when the force is applied in a direction normal to the upper torso. The advantages of bank angle variation to modulate the lift vector were recognized long ago, and this method of control was used successfully on the Apollo command module during lunar return' and, more recently, for the Space Shuttle Orbiter.

Tauber, Michael E.↗
NASA NTRS1972

Apollo 16 Mission Anomaly Report No. 1: Oxidizer Deservicing Tank Failure

The command module reaction control system is emptied of all remaining propellant using ground support equipment designed to provide an acid/base neutralization of the propellant in both the liquid and gaseous phases so that it may be disposed of safely. During the deactivation operation of the oxidizer from the Apollo 16 command module on 7 May 1972, the scrubber tank of the decontamination unit exploded, destroying the ground support equipment unit and damaging the building that housed the operation. Only minor injuries were received by the personnel in the area and the command module was not damaged. Test results show that the failure was caused by an insufficient quantity of neutralizer for the quantity of oxidizer. This insufficiency lead to exothermic nitration-type reactions which produced large quantities of gas at a very high rate and failed the decontamination tank.

Source record↗
NASA NTRS2016

Green Propellant Test Capabilities of the Altitude Combustion Stand at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC) is committed to providing simulated altitude rocket test capabilities to NASA programs, other government agencies, private industry partners, and academic partners. A primary facility to support those needs is the Altitude Combustion Stand (ACS). ACS provides the capability to test combustion components at a simulated altitude up to 100,000 ft. (approx.0.2 psia/10 Torr) through a nitrogen-driven ejector system. The facility is equipped with an axial thrust stand, gaseous and cryogenic liquid propellant feed systems, data acquisition system with up to 1000 Hz recording, and automated facility control system. Propellant capabilities include gaseous and liquid hydrogen, gaseous and liquid oxygen, and liquid methane. A water-cooled diffuser, exhaust spray cooling chamber, and multi-stage ejector systems can enable run times up to 180 seconds to 16 minutes. The system can accommodate engines up to 2000-lbf thrust, liquid propellant supply pressures up to 1800 psia, and test at the component level. Engines can also be fired at sea level if needed. The NASA GRC is in the process of modifying ACS capabilities to enable the testing of green propellant (GP) thrusters and components. Green propellants are actively being explored throughout government and industry as a non-toxic replacement to hydrazine monopropellants for applications such as reaction control systems or small spacecraft main propulsion systems. These propellants offer increased performance and cost savings over hydrazine. The modification of ACS is intended to enable testing of a wide range of green propellant engines for research and qualification-like testing applications. Once complete, ACS will have the capability to test green propellant engines up to 880 N in thrust, thermally condition the green propellants, provide test durations up to 60 minutes depending on thrust class, provide high speed control and data acquisition, as well as provide advanced imaging and diagnostics such as infrared (IR) imaging.

Testing↗
NASA NTRS2004

Causes and Mitigation of Fuel Pilot Operated Valve Pilot Seal Extrusion in Space Shuttle Orbiter Primary RCS Thrusters

Extrusion of a polytetrafluoroethylene (PTFE) pilot seal located in the Space Shuttle Orbiter Primary Reaction Control Subsystem (PRCS) thruster fuel valve has been implicated in 68 ground and on-orbit fuel valve failures. A rash of six extrusion-related in-flight anomalies over a six-mission span from December 2001 to October 2002 led to heightened activity at various NASA centers, and the formation of a multidisciplinary team to solve the problem. Empirical and theoretical approaches were used. For example, thermomechanical analysis (TMA) and exposure tests showed that some extrusion is produced by thermal cycling; however, a review of thruster service histories did not reveal a strong link between thermal cycling and extrusion. Calculations showed that the amount of observed extrusion often exceeded the amount allowed by thermally-induced stress relief. Failure analysis of failed hardware also revealed the presence of fuel-oxidizer reaction product (FORP) inside the fuel valve pilot seal cavity, and differential scanning calorimetry (DSC) showed that the FORP was intimately associated with the pilot seal material. Component-level exposure tests showed that FORP of similar composition could be produced by adjacent oxidizer valve leakage in the absence of thruster firing. Specific gravity data showed that extruded fuel valve pilot seals were less dense than new pilot seals or oxidizer valve pilot seals, indicating permanent modification of the PTFE occurred during service. It is concluded that some thermally-induced extrusion is unavoidable; however, oxidizer leakage-induced extrusion is mostly avoidable and can be mitigated. Several engineering level mitigation strategies are discussed.

Waller, Jess M.↗
NASA NTRS2001

The Oxidation Kinetics of Continuous Carbon Fibers in a Cracked Ceramic Matrix Composite

Experimental observations and results suggest two primary regimes as a function of temperature, i.e., diffusion and reaction controlled kinetics. Thermogravimetric analysis of carbon fiber in flowing oxygen gave an activation energy of 64.1 kJ/mol in the temperature range of 500 to 600 C and an apparent activation energy of 7.6 kJ/mol for temperatures from 600 to 1400 C. When C/SiC composite material was unstressed, matrix effects at temperatures from 900 to 1400 C protected the internal fibers. When under stress, self-protection was not observed. Increasing the stress from 10 to 25 ksi caused a 67 to 82 percent reduction in times to failure at temperatures from 750 to 1500 C. Based on experimental results, observation, and theory, a finite difference model was developed, which simulates the diffusion of oxygen into a matrix crack that is bridged by carbon fibers. The model allows the influence of important variables on oxidation kinetics to be studied systematically, i.e., temperature, reaction rate constant, diffusion coefficient, environment, and sample geometry.

Halbig, Michael C.↗
NASA NTRS2013

HESTIA Commodities Exchange Pallet and Sounding Rocket Test Stand

During my Spring 2016 internship, my two major contributions were the design of the Commodities Exchange Pallet and the design of a test stand for a 100 pounds-thrust sounding rocket. The Commodities Exchange Pallet is a prototype developed for the Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA) program. Under the HESTIA initiative the Commodities Exchange Pallet was developed as a method for demonstrating multi-system integration thru the transportation of In-Situ Resource Utilization produced oxygen and water to a human habitat. Ultimately, this prototype's performance will allow for future evaluation of integration, which may lead to the development of a flight capable pallet for future deep-space exploration missions. For HESTIA, my main task was to design the Commodities Exchange Pallet system to be used for completing an integration demonstration. Under the guidance of my mentor, I designed, both, the structural frame and fluid delivery system for the commodities pallet. The fluid delivery system includes a liquid-oxygen to gaseous-oxygen system, a water delivery system, and a carbon-dioxide compressors system. The structural frame is designed to meet safety and transportation requirements, as well as the ability to interface with the ER division's Portable Utility Pallet. The commodities pallet structure also includes independent instrumentation oxygen/water panels for operation and system monitoring. My major accomplishments for the commodities exchange pallet were the completion of the fluid delivery systems and the structural frame designs. In addition, parts selection was completed in order to expedite construction of the prototype, scheduled to begin in May of 2016. Once the commodities pallet is assembled and tested it is expected to complete a fully integrated transfer demonstration with the ISRU unit and the Environmental Control and Life Support System test chamber in September of 2016. In addition to the development of the Commodities Exchange Pallet, I also assisted in preparation for testing the upper stage of a sounding rocket developed as a Center Innovation Fund project. The main objective of this project is to demonstrate the integration between a propulsion system and a solid oxide fuel cell (SOFC). The upper stage and SOFC are scheduled to complete an integrated test in August of 2016. As part of preparation for scheduled testing, I was responsible for designing the upper stage's test stand/support structure and main engine plume deflector to be used during hot-fire testing (fig. 3). The structural components of the test stand need to meet safety requirements for operation of the propulsion system, which consist of a 100 pounds-thrust main engine and two 15 pounds-thrust reaction control thrusters. My main accomplishment for this project was the completion of the design and the parts selection for construction of the structure, scheduled to begin late April of 2016.

Chaparro, Javier↗