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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 NTRS1992

Element Material Exposure Experiment by EFFU

The National Space Development Agency of Japan (NASDA) is planning to perform an 'Element Material Exposure Experiment' using the Exposed Facility Flyer Unit (EFFU). This paper presents an initial design of experiments proposed for this project by our company. The EFFU is installed on the Space Flyer Unit (SFU) as a partial model of the Space Station JEM exposed facility. The SFU is scheduled to be launched by H-2 rocket in January or February of 1994, then various tests will be performed for three months, on orbit of 500 km altitude, and it will be retrieved by the U.S. Space Shuttle and returned to the ground. The mission sequence is shown.

Hashimoto, Yoshihiro↗

NASA NTRS1993

Spacecraft propulsion research facility (B-2) at the Lewis Research Center, Plum Brook Station

The B-2 facility is designed to hot fire rocket engines or upper stage launch vehicles with up to 890,000 N thrust, after environmental conditioning of the test article in a simulated thermal vaccum space environment. The facility can handle cryogenic fuels and oxidizers. A steam ejector system maintains vacuum around the test article and on the engine discharge during the test firing. Two high speed computer systems control the test, monitor critical parameters and record all of the desired data.

Klein, William E.↗

NASA NTRS2013

Small Payload Launch Integrated Testing Services (SPLITS) - SPSDL

My experience working on the Small Payload Launch Integrated Testing Services project has been both educational and rewarding. I have been given the opportunity to work on and experiment with a number of exciting projects and initiatives, each offering different challenges and opportunities for teamwork and collaboration. One of my assignments is to aid in the design and construction of a small-scale two stage rocket as part of a Rocket University initiative. My duties include programming a microcontroller to control the various sensors on the rocket as well as process and transmit data. Additionally, I am writing a graphical user interface application for the ground station that will receive the transmitted data from the rocket and display the information on screen along with a 3D rendering displaying the rocket orientation. Another project I am working on is to design and develop the avionics that will be used to control a high altitude balloon flight that will test a sensor called a Micro Dosimeter that will measure the total ionizing dose absorbed by electrical components during a flight. This includes assembling and soldering the various sensors and components, programming a microcontroller to input and process data from the Micro Dosimeter, and transmitting the data down to a ground station as well as save the data to an on-board SD card. Additionally, I am aiding in the setup and development of ITOS (Integrated Test and Operations System) capability in the SPSDL (Spaceport Processing System Development Lab).

Intern↗

NASA NTRS1974

SERT D spacecraft study

The SERT D (Space Electric Rocket Test - D) study defines a possible spacecraft project that would demonstrate the use of electric ion thrusters for long-term (5 yr) station keeping and attitude control of a synchronous orbit satellite. Other mission objectives included in the study were: station walking to satellite rendezvous and inspection, use of low cost attitude sensing system, use of an advanced solar array orientation and slip ring system, and an ion thruster integrated directly with a solar array power source. The SERT D spacecraft, if launched, will become SERT 3 the third space electric thruster test.

Source record↗

NASA NTRS1994

John C. Stennis Space Center Overview

An overview of research being conducted at the John C. Stennis Space Center is given. The Space Center is not only a NASA Space Flight Center, but also houses facilities for 22 other governmental agencies. The programs described are Stennis' High Heat Flux Facility, the Component Test Facility (used to test propulsion rockets and for the development of the National Aerospace Plane), oceanographic and remote sensing research, and contributions to the development of Space Station Freedom.

Source record↗

NASA NTRS2004

Spreading the Word on Safety

Beginning with the Apollo Program in the early 1960s, the NASA White Sands Test Facility (WSTF) has supported every U.S. human exploration space flight program to date. Located in Las Cruces, New Mexico, WSTF is part of Johnson Space Center. The facility's primary mission is to provide the expertise and infrastructure to test and evaluate spacecraft materials, components, and rocket propulsion systems to enable the safe human exploration and utilization of space. WSTF stores, tests, and disposes of Space Shuttle and International Space Station propellants. Since aerospace fluids can have harmful reactions with the construction materials of the systems containing them, a major component of WSTF's work is the study of propellants and hazardous materials. WSTF has a wide variety of resources to draw upon in assessing the fire, explosion, compatibility, and safety hazards of these fluids, which include hydrogen, oxygen, hydrazine fuels, and nitrogen tetroxide. In addition to developing new test methods, WSTF has created technical manuals and training courses for the safe use of aerospace fluids.

Source record↗

NASA NTRS2009

Cold-Flow Testing of a Proposed Integrated Center-Body Diffuser/Steam Blocker Concept for Plum Brook Station's B-2 Test Facility

The center-body diffuser (CBD) steam blocker (SB) system is a concept that incorporates a set of secondary drive nozzles into the envelope of a CBD, such that both nozzle systems (i.e., the rocket engine and the steam blocking nozzles) utilize the same supersonic diffuser, and will operate either singularly or concurrently. In this manner, the SB performs as an exhaust system stage when the rocket engine is not operating, and virtually eliminates discharge flow on rocket engine shutdown. A 2.25-percent scale model of a proposed SB integrated into a diffuser for the Plum Brook B-2 facility was constructed and cold-flow tested for the purpose of evaluating performance characteristics of various design options. These specific design options addressed secondary drive nozzle design (method of steam injection), secondary drive nozzle location relative to CBD throat, and center-body throat length to diameter (L/D) ratios. The objective of the test program is to identify the desired configuration to carry forward should the next phase of design proceed. The tested scale model can provide data for various pressure ratios; however, its design is based on a proposed B-2 spray chamber (SC) operating pressure of 4.0 psia and a steam supply pressure of 165 psia. Evaluation of the test data acquired during these tests indicate that either the discrete axial or annular nozzle configuration integrated into a CBD, with an annular throat length of 1.5 L/D at the nominal injection position, would be suitable to carry forward from the SB's perspective. Selection between these two then becomes more a function of constructability and implementation than performance. L/D also has some flexibility, and final L/D selection can be a function of constructability issues within a limited range.

Edwards, Daryl A.↗

NASA NTRS1959

Effect of Six Missile-Bay Baffle Configurations and a Rocket End Plate on Ejection Releases of an MB-1 Rocket from a 0.05 Scale Model of the Convair F-106A Airplane

As a continuation of an investigation of the release characteristics of an MB-1 rocket carried internally by the Convair F-106A airplane, six missile-bay baffle configurations and a rocket end plate have been investigated in the 27- by 27-inch preflight jet of the NASA Wallops Station. The MB-1 rocket used had retractable fins and was ejected from a missile bay modified by the addition of six different baffle configurations. For some tests a rocket end plate was added to the model. Dynamically scaled models (0.04956 scale) were tested at a simulated altitude of 22,450 feet and Mach numbers of 0.86, 1.59, and 1.98, and at a simulated altitude of 29,450 feet and a Mach number of 1.98. The results of this investigation indicate that the missile-bay baffle configurations and the rocket end plate may be used to reduce the positive pitch amplitude of the MB-1 rocket after release. The initial negative pitching velocity applied to the MB-1 rocket might then be reduced in order to maintain a near-level-flight attitude after release. As the fuselage angle of attack is increased, the negative pitch amplitude of the rocket is decreased.

Hinson, William F.↗

NASA NTRS1982

Electric propulsion research and technology in the United States

Near-, mid-, and long-term technology goals for space electric propulsion systems are reviewed. Technological readiness has been demonstrated for 8 cm, 5 mN, and 30 cm, 30 mN electrostatic thrusters, with major use seen for GEO communications satellites in the near-term, and space station orbit adjustments later. Ion thrusters and/or MPD thrusters are projected to become viable if a space nuclear reactor system is operational in the 1990s, allowing the transport of thousands of kilograms to the outer planets. Basic research is proceeding on the electrothermal propulsion concept to provide resistojet thrusters suitable for a space station by 1986, although the program is hindered by insufficient funding. A flight test for the ion auxiliary propulsion system is detailed, and test results of the solar electric rocket (SERT II) are reported. Particular note is made of the progress on the solar electric propulsion system for the Shuttle and the Nuclear electric propulsion system for thermal-to-electric conversion for mid-1990s applications.

Hudson, W. R.↗

NASA NTRS2014

One Dimensional Analysis Model of a Condensing Spray Chamber Including Rocket Exhaust Using SINDA/FLUINT and CEA

Modeling droplet condensation via CFD codes can be very tedious, time consuming, and inaccurate. CFD codes may be tedious and time consuming in terms of using Lagrangian particle tracking approaches or particle sizing bins. Also since many codes ignore conduction through the droplet and or the degradating effect of heat and mass transfer if noncondensible species are present, the solutions may be inaccurate. The modeling of a condensing spray chamber where the significant size of the water droplets and the time and distance these droplets take to fall, can make the effect of droplet conduction a physical factor that needs to be considered in the model. Furthermore the presence of even a relatively small amount of noncondensible has been shown to reduce the amount of condensation. It is desirable then to create a modeling tool that addresses these issues. The path taken to create such a tool is illustrated. The application of this tool and subsequent results are based on the spray chamber in the Spacecraft Propulsion Research Facility (B2) located at NASA's Plum Brook Station that tested an RL-10 engine. The platform upon which the condensation physics is modeled is SINDAFLUINT. The use of SINDAFLUINT enables the ability to model various aspects of the entire testing facility, including the rocket exhaust duct flow and heat transfer to the exhaust duct wall. The ejector pumping system of the spray chamber is also easily implemented via SINDAFLUINT. The goal is to create a transient one dimensional flow and heat transfer model beginning at the rocket, continuing through the condensing spray chamber, and finally ending with the ejector pumping system. However the model of the condensing spray chamber may be run independently of the rocket and ejector systems detail, with only appropriate mass flow boundary conditions placed at the entrance and exit of the condensing spray chamber model. The model of the condensing spray chamber takes into account droplet conduction as well as the degrading effect of mass and heat transfer due to the presence of noncondensibles. The one dimension model of the condensing spray chamber makes no presupposition on the pressure profile within the chamber, allowing the implemented droplet physics of heat and mass transfer coupled to the SINDAFLUINT solver to determine a transient pressure profile of the condensing spray chamber. Model results compare well to the RL-10 engine pressure test data.

Chemical Equilibrium↗

NASA NTRS2014

One Dimensional Analysis Model of a Condensing Spray Chamber Including Rocket Exhaust Using SINDA/FLUINT and CEA

Modeling droplet condensation via CFD codes can be very tedious, time consuming, and inaccurate. CFD codes may be tedious and time consuming in terms of using Lagrangian particle tracking approaches or particle sizing bins. Also since many codes ignore conduction through the droplet and or the degradating effect of heat and mass transfer if noncondensible species are present, the solutions may be inaccurate. The modeling of a condensing spray chamber where the significant size of the water droplets and the time and distance these droplets take to fall, can make the effect of droplet conduction a physical factor that needs to be considered in the model. Furthermore the presence of even a relatively small amount of noncondensible has been shown to reduce the amount of condensation [Ref 1]. It is desirable then to create a modeling tool that addresses these issues. The path taken to create such a tool is illustrated. The application of this tool and subsequent results are based on the spray chamber in the Spacecraft Propulsion Research Facility (B2) located at NASA's Plum Brook Station that tested an RL-10 engine. The platform upon which the condensation physics is modeled is SINDAFLUINT. The use of SINDAFLUINT enables the ability to model various aspects of the entire testing facility, including the rocket exhaust duct flow and heat transfer to the exhaust duct wall. The ejector pumping system of the spray chamber is also easily implemented via SINDAFLUINT. The goal is to create a transient one dimensional flow and heat transfer model beginning at the rocket, continuing through the condensing spray chamber, and finally ending with the ejector pumping system. However the model of the condensing spray chamber may be run independently of the rocket and ejector systems detail, with only appropriate mass flow boundary conditions placed at the entrance and exit of the condensing spray chamber model. The model of the condensing spray chamber takes into account droplet conduction as well as the degrading effect of mass and heat transfer due to the presence of noncondensibles. The one dimension model of the condensing spray chamber makes no presupposition on the pressure profile within the chamber, allowing the implemented droplet physics of heat and mass transfer coupled to the SINDAFLUINT solver to determine a transient pressure profile of the condensing spray chamber. Model results compare well to the RL-10 engine pressure test data.

Condensing Spray Model↗

NASA NTRS2019

Return of Large Scale Upper Stage Rocket Thermal-Vacuum and Altitude Hot-Fire Test Capability to the U.S.

The National Aeronautics and Space Administration has undertaken a project to restore full-scale thermal-vacuum and altitude hot fire rocket testing capability within the United States by the end of 2020. The restoration of the In Space Propulsion (ISP) facility at the Glenn Research Center's Plum Brook Station in Sandusky Ohio will accommodate full-scale long duration cryogenic stage testing in a simulated space environment as well as hot-fire testing at altitudes up to 120,000 ft. The reference test article for the restoration is a 30,000lb thrust LOX/LH2 stage with a 300 second burn duration. This presentation will describe the scope and progress of the restoration, current capabilities, and planned and potential uses for the facility once fully restored.

Plum Brook Station↗

NASA NTRS2012

Development and Testing of a Green-Propellant Micro-Hybrid Thruster with Electrostatic Ignition

As early as 1937 German scientists at Peenemunde experimented with highly unstable fuel blends of nitrous oxide (N2O) and ethanol. These early tests mostly resulted in explosions and destroyed rocket engines. More recently several companies have developed experimental nitrous oxide fuel blends (NOFB) with Isp exceeding 300 sec. Although NOFBx has recently been cleared for tests on the International Space Station, this propellant remains highly experimental and has not been cleared for commercial transport by the US DOT. Recent work by Karabeyoglu et al. has raised concerns about the safety risks of mixing hydrocarbons with N2O. Liquid oxidizer/fuel blends are highly explosive and require extreme care in transport and servicing. By adding small amounts of a liquid organic fuel such as alcohol or a hydrocarbon, the odds of an explosive decomposition event are significantly increased.iv The proposed solution mitigates the explosion hazards of NOFB by separating the oxidizer from the hydrocarbon fuel formed as of a small cylindrical section of ABS thermoplastic. As N2O vapor flows across the grain segment, current enters a 1000 VDC high-tension lead in the ABS fuel grain and produces an inductive spark that vaporizes a small amount of the material. The ablated fuel vapor plus residual energy from the spark seed a localized exothermic N2O dissociation that produces sufficient heat to initiate combustion. The process is also effective when gaseous oxygen is used. A low TRL (2-3) prototype demonstrating the feasibility of controlled hydrocarbon-seeding was recently tested at Utah State University.v The unit features a miniature 2.5 cm ABS fuel grain fabricated using a Stratasys Dimension 3-D printer. The 9-N thruster was pulse-fired up to 27 consecutive times on a single ABS grain segment. Ignition was achieved by as little as 12-15 Joules energy input. This value is contrasted with the typical 30-minute pre-heat requirement for the ECAPS LMP-103S ADN-based monopropellant, requiring an energy input of 14,850 Joules for catalytic dissociation. The hydrocarbon-seeded micro-hybrid was also adapted as a non-pyrotechnic ignitor for a 900 N (200-lbf) thrust hybrid motor. The motor was successfully ignited 4 consecutive times with no hardware swaps or propellant additions. The amount of ABS seed material that can be fit into the injector cap is the only limit to the number of available repeat firings. This series of tests marks the first time a hybrid motor was ever ignited by other than a solid-propellant pyrotechnic charge or bi-propellant flame ignitor. Nitrous oxide hybrid motors are typically difficult to ignite and usually require multiple solid-propellant charges to initiate combustion, so this nonpyrotechnic ignition is a significant accomplishment. The controlled hydrocarbon-seeding approach is fundamentally different from all other green propellant solutions offered by the aerospace industry. Although the proposed system is more correctly a hybrid technology; the system retains all the simple features of a monopropellant design. To date no optimization study has been performed to identify the best grain geometry for electrostatic ignition. Fortunately, because the grain segments are fabricated using rapid-prototyping technology, changing the grain geometry is as simple as modifying the 3-D printer CAD-file. Vacuum Isp exceeding 270 seconds has been demonstrated (Ref v), a value significantly higher than those offered by competing green monopropellant options. The propellants of choice, N2O/GOX and ABS are 100% non-toxic, non-explosive, and environmentally benign. Because the inert oxidizer and fuel components are mixed only within the combustion chamber, the system retains the inherent safety of a hybrid rocket and can be piggy-backed as a secondary payload with no overall mission risk increase to the primary payload, an excellent characteristic for secondary launch systems.

Whitmore, Stephen A.↗

NASA NTRS2003

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

The Materials Contamination Team of the Environmental Effects Group, Materials, Processes, and Manufacturing Department, has been recognized for its contribution to space flight, including space transportation, space science and flight projects, such as the reusable solid rocket motor, Chandra X-Ray Observatory, and the International Space Station. The Materials Contamination Team s realm of responsibility encompasses all phases of hardware development including design, manufacturing, assembly, test, transportation, launch-site processing, on-orbit exposure, return, and refurbishment if required. Contamination is a concern in the Space Shuttle with sensitivity bondlines and reactive fluid (liquid oxygen) compatibility as well as for sensitive optics, particularly spacecraft such as Hubble Space Telescope and Chandra X-Ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The team of engineers and technicians also develop and evaluates new surface cleanliness inspection technologies. Databases are maintained by the team for proces! materials as well as outgassing and optical compatibility test results for specific environments.

Burns, H. D.↗

NASA NTRSDate not supplied

Eleven Countries, an Integrated Spacecraft: the Story of International Collaboration that Built the Orion Spacecraft and Powered the Success of the Artemis I Mission

The quest to return humans to the Moon in the next step towards humanity's exploration of space is more alive than ever. After a great deal of achievements, failures, and lessons learned, the Artemis I mission set o to the Moon on November 16, 2022, with the goal of testing a new rocket, the Space Launch System, and a new spacecraft, Orion: designed, assembled, and tested across two continents, and 11 countries. Behind this mission, decades of experience with the International Space Station, Autonomous Transfer Vehicle operations, and many other program collaborations built the know-how on how to succeed together in the toughest environment | deep space. The Artemis I mission proved to be an incredible success, meeting 161 total mission objectives, including 21 developed during the flight based on outperforming spacecraft. It was also a case-study in international collaboration, given that ESA, NASA, and industry partners Airbus and Lockheed Martin for the first time had to design, build, test, and fly a fully integrated human-rated spacecraft, with most critical functions dependent and interconnected across U.S. and European systems. The U.S.-built Orion Crew Module and Crew Module Adapter and European-built European Service Module (ESM) shared critical interfaces and commodities, from propulsion, avionics, active/passive thermal, electrical power generation, storage and distribution to the software that managed it all. In this paper, we will describe relevant aspects of the integrated spacecraft design, providing context for the challenges that the team faced in all phases required to get Orion ready to fly, and provide a direct account of how the joint team formed, trained, and supported the operations of the successful Artemis I mission. We will also explore the evolution of the partnerships, given that these allow a multi-national e ort to sustain the program production, share costs, leverage a broader base of engineering expertise, and build more diverse capabilities over the long haul to support the Artemis goals and objectives. Lastly, we will cover critical lessons learned and how the Orion Program has implemented these in preparation of the next Artemis missions to repeat the success of Artemis I. The purpose of this paper is to document knowledge we gained and lessons we learned through the development of an integrated Orion spacecraft, since it is imperative we build on this now, at the dawn of the Artemis Program, an international endeavor to push human space exploration.

Deep Space Exploration↗

NASA NTRS2019

Flight Servicing of Robotic Refueling Mission 3

The Robotic Refueling Mission 3 (RRM3) payload launched aboard a SpaceX rocket en route to the International Space Station on December 5th, 2018. The Goddard Space Flight Center designed payload carried approximately 50 liters of liquid methane onboard, with a mission to demonstrate long term storage and transfer of the cryogenic fluid in microgravity. Kennedy Space Center (KSC) was tasked to design, fabricate, test, and operate a system equipped to fill an RRM3 dewar with liquid methane prior to launch. Though KSC has a rich history of fueling rockets and payloads, no such operations had previously been accomplished using liquid methane. As such, all of the hardware and processes had to be developed from scratch. The completed ground system design, along with the verification and validation testing will be outlined in this paper. Several challenges that were met and overcome during procurement of the high purity methane are described. In addition, budget restrictions prohibited fueling operations from occurring in traditional processing facilities. The unique and creative solutions which were required to maintain payload cleanliness during cryogenic servicing are also detailed.

Cryogenics↗

NASA NTRS2019

Flight Servicing of Robotic Refueling Mission 3

Thermal Conductivity↗

NASA NTRS2019

Flight Servicing of Robotic Refueling Mission 3

Cryogenics↗