Analysis of propellant outflow conditions during nuclear stage operation
Vapor fraction dependence on liquid hydrogen propellant outflow during NERVA operation under stored gas or autogenous pressurization, using computer simulation
Vernon, R. M.↗
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Advanced space engine preliminary design
Analysis and design of an optimum LO2/LH2, combustion topping cycle, 88,964 Newtons (20,000-pound) thrust, liquid rocket engine was conducted. The design selected is well suited to high-energy, upper-stage engine applications such as the Space Tug and embodies features directed toward optimization of vehicle performance. A configuration selection was conducted based on prior Air Force Contracts, and additional criteria for optimum stage performance. Following configuration selection, analyses and design of the major components and engine systems were conducted to sufficient depth to provide layout drawings suitable for subsequent detailing. In addition, engine packaging to a common interface and a retractable nozzle concept were defined. Alternative development plans and related costs were also established. The design embodies high-performance, low-weight, low NPSH requirements (saturated propellant inlet conditions at start), idle-mode operation, and autogenous pressurization. The design is the result of the significant past and current LO2/LH2 technology efforts of the NASA centers and the Air Force, as well as company-funded programs.
Zachary, A. T.↗
Long term orbital storage of cryogenic propellants for advanced space transportation missions
A comprehensive study has developed the major features of a large capacity orbital propellant depot for the space-based, cryogenic OTV. The study has treated both the Dual-Keel Space Station and co-orbiting platforms as the accommodations base for the propellant storage facilities, and trades have examined both tethered and hard-docked options. Five tank set concepts were developed for storing the propellants, and along with layout options for the station and platform, were evaluated from the standpoints of servicing, propellant delivery, boiloff, micrometeoroid/debris shielding, development requirements, and cost. These trades led to the recommendation that an all-passive storage concept be considered for the platform and an actively refrigerated concept providing for reliquefaction of all boiloff be considered for the Space Station. The tank sets are modular, each storing up to 45,400 kg of LO2/LH2, and employ many advanced features to provide for microgravity fluid management and to limit boiloff. The features include such technologies as zero-gravity mass gauging, total communication capillary liquid acquisition devices, autogenous pressurization, thermodynamic vent systems, thick multilayer insulation, vapor-cooled shields, solar-selective coatings, advanced micrometeoroid/debris protection systems, and long-lived cryogenic refrigeration systems.
Schuster, John R.↗
Advanced Space Transportation Concepts and Propulsion Technologies for a New Delivery Paradigm
This paper describes Advanced Space Transportation Concepts and Propulsion Technologies for a New Delivery Paradigm. It builds on the work of the previous paper "Approach to an Affordable and Productive Space Transportation System". The scope includes both flight and ground system elements, and focuses on their compatibility and capability to achieve a technical solution that is operationally productive and also affordable. A clear and revolutionary approach, including advanced propulsion systems (advanced LOX rich booster engine concept having independent LOX and fuel cooling systems, thrust augmentation with LOX rich boost and fuel rich operation at altitude), improved vehicle concepts (autogeneous pressurization, turbo alternator for electric power during ascent, hot gases to purge system and keep moisture out), and ground delivery systems, was examined. Previous papers by the authors and other members of the Space Propulsion Synergy Team (SPST) focused on space flight system engineering methods, along with operationally efficient propulsion system concepts and technologies. This paper continues the previous work by exploring the propulsion technology aspects in more depth and how they may enable the vehicle designs from the previous paper. Subsequent papers will explore the vehicle design, the ground support system, and the operations aspects of the new delivery paradigm in greater detail.
Robinson, John W.↗
Marshall Space Flight Center Faculty Fellowship Program
This paper presents a multi-node model of autogenous pressurization of liquid nitrogen in a flight tank using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code developed at NASA/Marshall Space Flight Center. This study considers two different models: (a) pressurization of the tank by nitrogen gas from a supply tank and (b) pressurization of the tank by using the boil-off propellant through an IVF (Integrated Vehicle Fluids) loop. The tank pressurization model considers two different liquid fill-levels of the tank (a) 75% and (b) 45%. Heat and mass transfer between the liquid and vapor has been modeled at the liquid vapor interface. Heat transfer between wall and vapor at the ullage has been accounted for by assuming heat transfer occurs by natural convection. The model also accounts for heat leak to the tank through the insulation and metal wall by heat conduction. The predicted pressures and temperatures are compared with the measured data and good agreement has been observed. In the second case, the tank is pressurized by using the boil-off fluid that recirculates through an IVF loop. Preliminary results from this model are also reported.
N.F. Six↗
Core Stage TVC Systems Engineering Challenges in Reusing Heritage Hardware
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.
Thrust Vector Control↗
Overview of the SLS Core Stage Thrust Vector Control System Design
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
Thrust Vector Control↗
Overview of the SLS Core Stage Thrust Vector Control System Design
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) consists of four independent hydraulic systems. The SLS CS TVC system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Each hydraulic system nominally provides hydraulic power to one RS-25 engine and two actuators. Additionally, each system provides redundant control capability to one actuator on each of its neighboring systems. The RS-25 uses hydraulic power to control propellant valves, and the TVC actuators are used to move the engine in the pitch and yaw gimbal planes. The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Solid Rocket Booster APU turbines are powered by hot gas produced by a catalyzed hydrazine decomposition. The SLS Core Auxiliary Power Unit (CAPU) is derived from the Space Shuttle Orbiter Auxiliary Power Unit (APU); on the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. The remaining hardware in the TVC system (hydraulic Filter Manifold (FM), hydraulic Supply Accumulator (SA), hydraulic Return Accumulator (RA), Hydraulic Reservoir, Exhaust Gas Heat Exchanger (EGHE)) as well as the avionics providing control and telemetry (TVC Actuator Controller (TAC) and CAPU Controller (CAPUC) are new components developed for SLS. This paper is the first installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the overall design architecture of the CS TVC is presented, with a focus on the interfaces between the TVC actuators, the engines, their hydraulic power systems, and the avionics that provide commands from the SLS Vehicle Management (VM) software to effect stable and robust flight control for the integrated SLS launch vehicle.
Thrust Vector Control↗
Space Launch System: Core Stage Thrust Vector Control Systems Engineering Challenges in Reusing Heritage Hardware
The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.
Thrust Vector Control↗
Comparison of Liquefaction Testing with Liquid Nitrogen and Liquid Oxygen
Liquid nitrogen is often used as a substitute for oxygen testing due to safety concerns, and the general similarity between their fluid properties. During the Cryogenic Fluid In-situ Liquefaction for Landers (CryoFILL) testing, an opportunity arose to compare liquid nitrogen and liquid oxygen behavior using the same test hardware in similar test conditions. Comparative testing would verify whether the system response to nitrogen and oxygen would behave in a similar manner. Tests that were investigated include system boil-off heat load determination, autogenous pressurization, cryocooler loop initiation, and cryocooler loop operations. Results from testing are shown and compared to verify that liquid nitrogen and liquid oxygen tests yield similar system responses, and that nitrogen can be used as a substitute for oxygen in developmental tests at cryogenic temperatures.
Cryogenic Fluid Management↗
CFD-Assisted Nodal Modeling of Sloshing in a Cryogenic Propellant Tank
During autogenous pressurization, tank sloshing causes a significant increase in pressurant consumption to maintain constant ullage pressure during draining of the tank. This increase in pressurant consumption is caused by a significant increase in condensation at the liquid-vapor interface. Sloshing strongly affects the liquid side heat transfer coefficient and thereby the condensation rate. Traditionally, sloshing is modeled by CFD code using the VOF (Volume of Fluid) method to track the liquid vapor interface during sloshing. CFD calculations require a very fine grid to accurately compute the heat and mass transfer at the interface. Therefore, computations are time consuming and prohibit performing many parametric studies often needed during the design of a new system. This paper describes an alternative approach by developing a CFD-assisted nodal model to predict system parameters more economically with reasonable accuracy. In this approach, a multi-node model of tank pressurization was developed using GFSSP. A multi-node model was needed to account for stratification. The model computes heat and mass transfer at the interface to calculate the condensation rate. The liquid side heat transfer is computed using the parameters of sloshing dynamics such as frequency, wave amplitude, and interface area. The parameters of sloshing dynamics are computed by the CFD code LOCI-Stream. The model predictions were compared with test data for several cases.
Cryogenic Tank Sloshing↗
Comparative results of autogenous ignition temperature measurements by ASTM G 72 and pressurized scanning calorimetry in gaseous oxygen
The autogenous ignition temperature of four materials was determined by ASTM (G 72) and pressurized differential scanning calorimetry at 0.68-, 3.4-, and 6.8-MPa oxygen pressure. All four materials were found to ignite at lower temperatures in the ASTM method. The four materials evaluated in this program were Neoprene, Vespel SP-21, Fluorel E-2160, and nylon 6/6.
Bryan, C. J.↗
Design study of RL10 derivatives. Volume 2: Engine design characteristics
The design characteristics of the RL-10 rocket engine are discussed. The results from critical elements evaluation, baseline engine design, parametric and special study tasks are presented. Critical element evaluation established the feasibility of various engine features such as tank head idle, pumped idle, autogenous tank pressurization, and two-phase pumping. Three baseline engines, derived from the RL-10 were conceptually designed. Parametric life and performance data were generated. Special studies were conducted to establish the impact on the engine design of environment, safety, interchangeability, and maintenance.
Adams, A.↗
Replacement Technologies for Precision Cleaning of Aerospace Hardware for Propellant Service
The NASA White Sands Test Facility (WSTF) is developing cleaning and verification processes to replace currently used chlorofluorocarbon-l13- (CFC-113-) based processes. The processes being evaluated include both aqueous- and solvent-based techniques. Replacement technologies are being investigated for aerospace hardware and for gauges and instrumentation. This paper includes the findings of investigations of aqueous cleaning and verification of aerospace hardware using known contaminants, such as hydraulic fluid and commonly used oils. The results correlate nonvolatile residue with CFC 113. The studies also include enhancements to aqueous sampling for organic and particulate contamination. Although aqueous alternatives have been identified for several processes, a need still exists for nonaqueous solvent cleaning, such as the cleaning and cleanliness verification of gauges used for oxygen service. The cleaning effectiveness of tetrachloroethylene (PCE), trichloroethylene (TCE), ethanol, hydrochlorofluorocarbon 225 (HCFC 225), HCFC 141b, HFE 7100(R), and Vertrel MCA(R) was evaluated using aerospace gauges and precision instruments and then compared to the cleaning effectiveness of CFC 113. Solvents considered for use in oxygen systems were also tested for oxygen compatibility using high-pressure oxygen autogenous ignition and liquid oxygen mechanical impact testing.
Harold Beeson↗
Mastering the Cryogenic Frontier: Predicting Sloshing in Cryogenic Propellant Tanks
In recent years, NASA has undertaken the development and validation of computation fluid dynamic (CFD) models for predicting cryogenic two-phase sloshing within propellant tanks. These models have been rigorously anchored against cryogenic ground tests that induce sloshing, as well as limited microgravity tests. The primary focus of these models is to accurately predict the two-phase condensation and, at times, evaporation within the cryogenic propellant. This approach is important for estimating the required autogenous and/or helium pressurant for completing propulsion system burns or ensuring adequate pressure for in-space propellant transfers. Unlike in hypergolic propulsion systems, where the propellant is stored at room temperature, cryogenic propellant is highly volatile. Therefore, ensuring the accurate estimation of pressurant necessitates the precise modeling of two-phase interfacial heat and mass transfer processes. This paper aims to provide an overview of NASA’s continuing efforts in developing and validating these CFD models, with particular emphasis on benchmark cases with sloshing that enhances phase change, tracing their historical development, and demonstrating their predictive accuracy when compared to test results.
low-gravity fluid modeling↗
Thermodynamic models for bounding pressurant mass requirements of cryogenic tanks
Thermodynamic models have been formulated to predict lower and upper bounds for the mass of pressurant gas required to pressurize a cryogenic tank and then expel liquid from the tank. Limiting conditions are based on either thermal equilibrium or zero energy exchange between the pressurant gas and initial tank contents. The models are independent of gravity level and allow specification of autogenous or non-condensible pressurants. Partial liquid fill levels may be specified for initial and final conditions. Model predictions are shown to successfully bound results from limited normal-gravity tests with condensable and non-condensable pressurant gases. Representative maximum collapse factor maps are presented for liquid hydrogen to show the effects of initial and final fill level on the range of pressurant gas requirements. Maximum collapse factors occur for partial expulsions with large final liquid fill fractions.
Vandresar, Neil T.↗
The oxygen sensitivity/compatibility ranking of several materials by different test methods
Eleven materials were evaluated for oxygen compatibility using the following test methods: heat of combustion (ASTM D 2015), liquid oxygen impact (ASTM D 2512), pneumatic impact (ASTM G 74), gaseous mechanical impact (ASTM G 86), autogenous ignition temperature by pressurized differential scanning calorimeter, and the determination of the 50 percent reaction level in liquid oxygen using silicon carbide as a reaction enhancer. The eleven materials evaluated were: Teflon TFE, Vespel SP-21, Krytox 240AC, Viton PLV5010B, Fluorel E2160, Kel F 81, Fluorogold, Fluorogreen E-600, Rulon A, Garlock 8573, nylon 6/6.
Lockhart, Billy J.↗
Pressurization System Modeling for a Generic Bimese Two- Stage-to-Orbit Reusable Launch Vehicle
A pressurization system model was developed for a generic bimese Two-Stage-to-orbit Reusable Launch Vehicle using a cross-feed system and operating with densified propellants. The model was based on the pressurization system model for a crossfeed subscale water test article and was validated with test data obtained from the test article. The model consists of the liquid oxygen and liquid hydrogen pressurization models, each made up of two submodels, Booster and Orbiter tank pressurization models. The tanks are controlled within a 0.2-psi band and pressurized on the ground with ambient helium and autogenously in flight with gaseous oxygen and gaseous hydrogen. A 15-psi pressure difference is maintained between the Booster and Orbiter tanks to ensure crossfeed check valve closure before Booster separation. The analysis uses an ascent trajectory generated for a generic bimese vehicle and a tank configuration based on the Space Shuttle External Tank. It determines the flow rates required to pressurize the tanks on the ground and in flight, and demonstrates the model's capability to analyze the pressurization system performance of a full-scale bimese vehicle with densified propellants.
Mazurkivich, Pete↗