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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Hydrogen Peroxide-Water-Ethanol-Monopropellant Blend for CubeSat Propulsion

Monopropellant propulsion that provides high performance and low hazards compared to state-of-art hydrazine are being investigated under NASA, DOD and commercially sponsored green propellant research and development programs. This NASAeffort looks at phosphate stabilized 50% hydrogen peroxide/water –ethanol blends to evaluate their stability and combustion behavior in submillimeter diameter microtube combustion apparatus for cubesat propulsion applications. Exploratory 7-day stabilitytests find no pressure rise in a sealed test tube environment at room temperature indicating at least short term stability of the mixture. Temperature rise during combustion testing in resistively heated nickel microtube apparatus shows that micro-combustion is achieved in the tube. Propellant density is approximately 1.2 g/cm3compared to 1.0 g/cm3for hydrazine. Theoretical specific impulse of the stoichiometric blend is 219 s at a chamber pressure of 20 psia and an area ratio of 30:1. Density-specific impulseof this blendis263 swhile hydrazine is only about 215-220 sin small reaction control system thrusters. This provides about 20-22% more density-specific impulse for the cubesat compared to hydrazine. The theoreticalcombustion temperature is2168°F, whichis thermally compatible with stainless steel materials of constructionand the nickel catalystused in the tests. Combustion test results are given for stoichiometric, as well as fuel-leanand fuel-richpropellant formulations. Thesetests focus on thermally and catalytically supported combustionin the microtube, whichrequires a microtube preheat temperature of about 900°F and sufficient residence time to achieve combustion that is stable and anchored in the tubewithout blowing through the tube unreacted. Thrust class is expected to be in the 10 mN range based on flow rate and estimated specific impulse.Power requirements are generally below 25 Wto heat the tube. Steady state combustion testing is typically conducted for 3 minutes and shows littledegradation of the hardware over multiple test cyclesindicating thatthere is little catalyst degradation over time and littlecatalyst deactivation due tothe phosphate stabilizer inthe hydrogen peroxide.

Monopropellant↗
NASA NTRSDate not supplied

Hydrogen Peroxide-Water-Ethanol Monopropellant Blend for CubeSat Propulsion

Monopropellant propulsion that provides high performance and low hazards compared to state-of-art hydrazine are being investigated under NASA, DOD and commercially sponsored green propellant research and development programs. This NASA effort looks at phosphate stabilized 50% hydrogen peroxide/water –ethanol blends to evaluate their stability and combustion behavior in submillimeter diameter microtube combustion apparatus for cubesat propulsion applications. Exploratory 7-day stability tests find no pressure rise in a sealed test tube environment at room temperature indicating at least short term stability of the mixture. Temperature rise during combustion testing in resistively heated nickel microtube apparatus shows that micro-combustion is achieved in the tube. Propellant density is approximately 1.2 g/cu.cm compared to 1.0 g/cu.cm for hydrazine. Theoretical specific impulse of the stoichiometric blend is 219 s at a chamber pressure of 20 psia and an area ratio of 30:1. Density-specific impulse of this blend is 263 s while hydrazine is only about 215-220 s in small reaction control system thrusters. This provides about 20-22% more density-specific impulse for the cube sat compared to hydrazine. The the oretical combustion temperature is 2168°F, which is thermally compatible with stainless steel materials of construction and the nickel catalyst used in the tests. Combustion test results are given for stoichiometric, as well as fuel-lean and fuel-rich propellant formulations. These tests focus on thermally and catalytically supported combustion in the microtube, which requires a microtube preheat temperature of about 900°F and sufficient residence time to achieve combustion that is stable and anchored in the tube without blowing through the tube unreacted. Thrust class is expected to be in the 10 m N range based on flow rate and estimated specific impulse. Power requirements are generally below 25 W to heat the tube. Steady state combustion testing is typically conducted for 3 minutes and shows little degradation of the hardware over multiple test cycles indicating that there is little catalyst degradation over time and little catalyst deactivation due to the phosphate stabilizer in the hydrogen peroxide.

Monopropellant↗
NASA NTRSDate not supplied

Surface Instability of Liquid Propellants in Microgravity During Pulsed Settling Operations

Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.

Faraday Waves↗
NASA NTRSDate not supplied

Surface Instability of Liquid Propellants in Microgravity During Pulsed Settling Operations

Pulsing reaction control system (RCS) thrusters, vent valves, or other propulsion devices can preserve propellant resources in space, but this operation also effectively introduces a vibration to the vehicle. When the vibration is perpendicular to the liquid propellant surface, Faraday waves may be generated at the liquid-vapor interface. These Faraday instabilities can perturb or break up the liquid surface of cryogenic tanks, leading to inefficiencies in thermal management or even ullage collapse. Drawing from theory and experiments, an engineering model defining the allowable design regions for pulsed settling in microgravity was assembled and verified with computational fluid dynamics (CFD) simulations. A traditional settling metric, the Bond number, was also overlaid in the model to indicate which duty cycles were insufficient to overcome surface tension and aggregate propellant. Mission planners and engineers can consult the tool to rapidly evaluate the stability of a liquid-vapor interface given the pulse frequency and the excitation acceleration. Expressions developed for Faraday waves induced by a sinusoidal forcing input at standard gravity were found to provide excellent predictive capabilities for pulsed, or rectangular, waveforms in the absence of a consistent gravitational acceleration. This study extends the usage of these equations to an alternative forcing function and microgravity environments for the purpose of estimating natural frequencies, surface mode shapes, surface wave amplitudes, and the onset of droplet ejection. CFD simulations with the Loci/STREAM-VoF (Volume of Fluid) solver were initially validated against experimental results in standard gravity. Discrete points on the design map were then investigated with CFD and confirmed that the engineering model reliably indicates surface stability and most Faraday wave characteristics without requiring higher-fidelity tools. The engineering model is highly extensible and can be adapted for various propellant fill fractions, fluid properties, and tank sizes.

Faraday Waves↗
NASA NTRS2010

A Flight-Calibrated Methodology for Determination of Cassini Thruster On-Times for Reaction Wheel Biases

This paper describes a methodology for accurate and flight-calibrated determination of the on-times of the Cassini spacecraft Reaction Control System (RCS) thrusters, without any form of dynamic simulation, for the reaction wheel biases. The hydrazine usage and the delta V vector in body frame are also computed from the respective thruster on-times. The Cassini spacecraft, the largest and most complex interplanetary spacecraft ever built, continues to undertake ambitious and unique scientific observations of planet Saturn, Titan, Enceladus, and other moons of Saturn. In order to maintain a stable attitude during the course of its mission, this three-axis stabilized spacecraft uses two different control systems: the RCS and the reaction wheel assembly control system. The RCS is used to execute a commanded spacecraft slew, to maintain three-axis attitude control, control spacecraft's attitude while performing science observations with coarse pointing requirements, e.g. during targeted low-altitude Titan and Enceladus flybys, bias the momentum of reaction wheels, and to perform RCS-based orbit trim maneuvers. The use of RCS often imparts undesired delta V on the spacecraft. The Cassini navigation team requires accurate predictions of the delta V in spacecraft coordinates and inertial frame resulting from slews using RCS thrusters and more importantly from reaction wheel bias events. It is crucial for the Cassini spacecraft attitude control and navigation teams to be able to, quickly but accurately, predict the hydrazine usage and delta V for various reaction wheel bias events without actually having to spend time and resources simulating the event in flight software-based dynamic simulation or hardware-in-the-loop simulation environments. The methodology described in this paper, and the ground software developed thereof, are designed to provide just that. This methodology assumes a priori knowledge of thrust magnitudes and thruster pulse rise and tail-off time constants for eight individual attitude control thrusters, the spacecraft's wet mass and its center of mass location, and a few other key parameters.

Earth Mean Equatorial↗
NASA NTRS2007

Analysis of Eddy Current Capabilities for the Detection of Outer Diameter Stress Corrosion Cracking in Small Bore Metallic Structures

The use of eddy current techniques for the detection of outer diameter damage in tubing and many complex aerospace structures often requires the use of an inner diameter probe due to a lack of access to the outside of the part. In small bore structures the probe size and orientation are constrained by the inner diameter of the part, complicating the optimization of the inspection technique. Detection of flaws through a significant remaining wall thickness becomes limited not only by the standard depth of penetration, but also geometrical aspects of the probe. Recently, an orthogonal eddy current probe was developed for detection of such flaws in Space Shuttle Primary Reaction Control System (PRCS) Thrusters. In this case, the detection of deeply buried stress corrosion cracking by an inner diameter eddy current probe was sought. Probe optimization was performed based upon the limiting spatial dimensions, flaw orientation, and required detection sensitivity. Analysis of the probe/flaw interaction was performed through the use of finite and boundary element modeling techniques. Experimental data for the flaw detection capabilities, including a probability of detection study, will be presented along with the simulation data. The results of this work have led to the successful deployment of an inspection system for the detection of stress corrosion cracking in Space Shuttle Primary Reaction Control System (PRCS) Thrusters.

Wincheski, Buzz↗
NASA NTRS2011

Failure Investigation of an Intra-Manifold Explosion in a Horizontally-Mounted 870 lbf Reaction Control Thruster

In June 2010, an 870 lbf Space Shuttle Orbiter Reaction Control System Primary Thruster experienced an unintended shutdown during a test being performed at the NASA White Sands Test Facility. Subsequent removal and inspection of the thruster revealed permanent deformation and misalignment of the thruster valve mounting plate. Destructive evaluation determined that after three nominal firing sequences, the thruster had experienced an energetic event within the fuel (monomethylhydrazine) manifold at the start of the fourth firing sequence. The current understanding of the phenomenon of intra-manifold explosions in hypergolic bipropellant thrusters is documented in literature where it is colloquially referred to as a ZOT. The typical ZOT scenario involves operation of a thruster in a gravitational field with environmental pressures above the triple point pressure of the propellants. Post-firing, when the thruster valves are commanded closed, there remains a residual quantity of propellant in both the fuel and oxidizer (nitrogen tetroxide) injector manifolds known as the "dribble volume". In an ambient ground test configuration, these propellant volumes will drain from the injector manifolds but are impeded by the local atmospheric pressure. The evacuation of propellants from the thruster injector manifolds relies on the fluids vapor pressure to expel the liquid. The higher vapor pressure oxidizer will evacuate from the manifold before the lower vapor pressure fuel. The localized cooling resulting from the oxidizer boiling during manifold draining can result in fuel vapor migration and condensation in the oxidizer passage. The liquid fuel will then react with the oxidizer that enters the manifold during the next firing and may produce a localized high pressure reaction or explosion within the confines of the oxidizer injector manifold. The typical ZOT scenario was considered during this failure investigation, but was ultimately ruled out as a cause of the explosion. Converse to the typical ZOT failure mechanism, the failure of this particular thruster was determined to be the result of liquid oxidizer being present within the fuel manifold.

Durning, Joseph G., III↗
NASA NTRS2010

Determining Atmospheric-Density Profile of Titan

A method was developed for measuring the atmospheric density of Titan, the largest moon of Saturn, to create an accurate density profile as a function of altitude. This will allow mission planners to select safe flyby altitudes, and for navigation engineers to accurately predict the delta-v associated with those flybys. The spacecraft angular rate vector profile as a function of time is collected via telemetry from the onboard attitude estimator once every 2 seconds. The telemetry for thruster times, as a function of time, for eight Reaction Control System (RCS) thrusters is gathered, once a second, from the Propulsion Manager algorithm of the Cassini onboard attitude-control flight software. Using these data, the ground software computes the angular momentum vector profile and the per-axis external torque as a function of time imparted from the spacecraft only due to the atmospheric drag. The software can then determine the Titan atmospheric density profile as a function of time and altitude with the known values of spacecraft center of mass, the Titan-relative range and velocity data, the projected area, and the aerocenter, along with the estimated drag coefficient in a free molecular flow field.

Sarani, Siamak↗
NASA NTRS2007

Development of Eddy Current Techniques for the Detection of Cracking in Space Shuttle Primary Reaction Control Thrusters

A recent identification of cracking in the Space Shuttle Primary Reaction Control System (PRCS) thrusters triggered an extensive nondestructive evaluation effort to develop techniques capable of identifying such damage on installed shuttle hardware. As a part of this effort, specially designed eddy current probes inserted into the acoustic cavity were explored for the detection of such flaws and for evaluation of the remaining material between the crack tip and acoustic cavity. The technique utilizes two orthogonal eddy current probes which are scanned under stepper motor control in the acoustic cavity to identify cracks hidden with as much as 0.060 remaining wall thickness to the cavity. As crack growth rates in this area have been determined to be very slow, such an inspection provides a large safety margin for continued operation of the critical shuttle hardware. Testing has been performed on thruster components with both actual and fabricated defects. This paper will review the design and performance of the developed eddy current inspection system. Detection of flaws as a function of remaining wall thickness will be presented along with the proposed system configuration for depot level or on-vehicle inspection capabilities.

Wincheski, Buzz A.↗
NASA NTRS2006

Development of Eddy Current Technique for the Detection of Stress Corrosion Cracking in Space Shuttle Primary Reaction Control Thrusters

A recent identification of stress corrosion cracking in the Space Shuttle Primary Reaction Control System (PRCS) thrusters triggered an extensive nondestructive evaluation effort to develop techniques capable of identifying such damage on installed shuttle hardware. As a part of this effort, specially designed eddy current probes inserted into the acoustic cavity were explored for the detection of such flaws and for evaluation of the remaining material between the crack tip and acoustic cavity. The technique utilizes two orthogonal eddy current probes which are scanned under stepper motor control in the acoustic cavity to identify cracks hidden with as much as 0.060 remaining wall thickness to the cavity. As crack growth rates in this area have been determined to be very slow, such an inspection provides a large safety margin for continued operation of the critical shuttle hardware. Testing has been performed on thruster components with both actual and fabricated defects. This paper will review the design and performance of the developed eddy current inspection system. Detection of flaws as a function of remaining wall thickness will be presented along with the proposed system configuration for depot level or on-vehicle inspection capabilities.

Wincheski, Buzz↗
NASA NTRS2005

Artificial Neural Network Test Support Development for the Space Shuttle PRCS Thrusters

A significant anomaly, Fuel Valve Pilot Seal Extrusion, is affecting the Shuttle Primary Reaction Control System (PRCS) Thrusters, and has caused 79 to fail. To help address this problem, a Shuttle PRCS Thruster Process Evaluation Team (TPET) was formed. The White Sands Test Facility (WSTF) and Boeing members of the TPET have identified many discrete valve current trace characteristics that are predictive of the problem. However, these are difficult and time consuming to identify and trend by manual analysis. Based on this exhaustive analysis over months, 22 thrusters previously delivered by the Depot were identified as high risk for flight failures. Although these had only recently been installed, they had to be removed from Shuttles OV103 and OV104 for reprocessing, by directive of the Shuttle Project Office. The resulting impact of the thruster removal, replacement, and valve replacement was significant (months of work and hundreds of thousands of dollars). Much of this could have been saved had the proposed Neural Network (NN) tool described in this paper been in place. In addition to the significant benefits to the Shuttle indicated above, the development and implementation of this type of testing will be the genesis for potential Quality improvements across many areas of WSTF test data analysis and will be shared with other NASA centers. Future tests can be designed to incorporate engineering experience via Artificial Neural Nets (ANN) into depot level acceptance of hardware. Additionally, results were shared with a NASA Engineering and Safety Center (NESC) Super Problem Response Team (SPRT). There was extensive interest voiced among many different personnel from several centers. There are potential spin-offs of this effort that can be directly applied to other data acquisition systems as well as vehicle health management for current and future flight vehicles.

Lehr, Mark E.↗
NASA NTRS2000

Factors Contributing to Pilot Valve Fuel Seal Extrusion in Orbiter PRCS Thrusters

Extrusion of the polytetrafluoroethylene (PTFE) pilot seal used in the monomethylhydrazine (fuel) valve of the Orbiter Primary Reaction Control System (PRCS) thrusters has been implicated in numerous on-orbit thruster failures and on-ground valve failures. Two extrusion mechanisms have been proposed, one or both may be occurring. The first mechanism is attributed to thermal expansion mismatch between adjacent PTFE and metal parts used in the fuel valve, and is referred to as thermal extrusion. The second mechanism is attributed to nitrogen tetroxide (oxidizer) leakage from the adjacent oxidizer valve on the same thruster during ground turnaround, and is referred to as oxidizer-induced extrusion. Model calculations of PTFE pilot seal in an exact pilot valve configuration show that extrusion can be caused by differential thermal expansion, without the intervening influence of oxidizer. Experimental data on semitrapped PTFE and TFM (modified PTFE) specimens simulating a fuel pilot valve configuration show that thermal extrusion 1) is incremental and irreversible, 2) increases with the size of the thermal excursion, 3) decreases with successive thermal cycling, and 4) is accompanied by gap formation. Both PTFE and TFM exhibit a higher affinity for oxidizer than fuel. The property changes associated with oxidizer uptake may explain why oxidizer seals do not exhibit extrusion. Impression replicas of fuel pilot seals removed from the Orbiter fleet show two types of extrusion: extrusion of the entire seal (loaded extrusion), or extrusion of non-sealing surface (unloaded extrusion). Both extrusion types may arise from differences in service history, rather than in failure mechanism. The plausibility oxidizer-induced extrusion was evaluated. Preliminary calculations suggest that enough energy, heat, or gas may be liberated under certain operational scenarios to cause catastrophic extrusion. However, given the lack of supporting data, conclusions implicating oxidizer leakage as a factor in extrusion must be made with caution.

Waller, J.M.↗
NASA NTRS2013

Fault Protection Design and Testing for the Cassini Spacecraft in a "Mixed" Thruster Configuration

NASA's Cassini Spacecraft, launched on October 15th, 1997 and arrived at Saturn on June 30th, 2004, is the largest and most ambitious interplanetary spacecraft in history. In order to meet the challenging attitude control and navigation requirements of the orbit profile at Saturn, Cassini is equipped with a monopropellant thruster based Reaction Control System (RCS), a bipropellant Main Engine Assembly (MEA) and a Reaction Wheel Assembly (RWA). In 2008, after 11 years of reliable service, several RCS thrusters began to show signs of end of life degradation, which led the operations team to successfully perform the swap from the A-branch to the B-branch RCS system. If similar degradation begins to occur on any of the B-branch thrusters, Cassini might have to assume a "mixed" thruster configuration, where a subset of both A and B branch thrusters will be designated as prime. The Cassini Fault Protection FSW was recently updated to handle this scenario. The design, implementation, and testing of this update is described in this paper.

propellant↗
NASA NTRS2007

Validation Test Results for Orthogonal Probe Eddy Current Thruster Inspection System

Recent nondestructive evaluation efforts within NASA have focused on an inspection system for the detection of intergranular cracking originating in the relief radius of Primary Reaction Control System (PCRS) Thrusters. Of particular concern is deep cracking in this area which could lead to combustion leakage in the event of through wall cracking from the relief radius into an acoustic cavity of the combustion chamber. In order to reliably detect such defects while ensuring minimal false positives during inspection, the Orthogonal Probe Eddy Current (OPEC) system has been developed and an extensive validation study performed. This report describes the validation procedure, sample set, and inspection results as well as comparing validation flaws with the response from naturally occuring damage.

Wincheski, Russell A.↗
NASA NTRS2010

Enceladus Plume Density Modeling and Reconstruction for Cassini Attitude Control System

In 2005, Cassini detected jets composed mostly of water, spouting from a set of nearly parallel rifts in the crust of Enceladus, an icy moon of Saturn. During an Enceladus flyby, either reaction wheels or attitude control thrusters on the Cassini spacecraft are used to overcome the external torque imparted on Cassini due to Enceladus plume or jets, as well as to slew the spacecraft in order to meet the pointing needs of the on-board science instruments. If the estimated imparted torque is larger than it can be controlled by the reaction wheel control system, thrusters are used to control the spacecraft. Having an engineering model that can predict and simulate the external torque imparted on Cassini spacecraft due to the plume density during all projected low-altitude Enceladus flybys is important. Equally important is being able to reconstruct the plume density after each flyby in order to calibrate the model. This paper describes an engineering model of the Enceladus plume density, as a function of the flyby altitude, developed for the Cassini Attitude and Articulation Control Subsystem, and novel methodologies that use guidance, navigation, and control data to estimate the external torque imparted on the spacecraft due to the Enceladus plume and jets. The plume density is determined accordingly. The methodologies described have already been used to reconstruct the plume density for three low-altitude Enceladus flybys of Cassini in 2008 and will continue to be used on all remaining low-altitude Enceladus flybys in Cassini's extended missions.

Sarani, Siamak↗
NASA NTRS2010

Cassini Spacecraft In-Flight Swap to Backup Attitude Control Thrusters

NASA's Cassini Spacecraft, launched on October 15th, 1997 and arrived at Saturn on June 30th, 2004, is the largest and most ambitious interplanetary spacecraft in history. In order to meet the challenging attitude control and navigation requirements of the orbit profile at Saturn, Cassini is equipped with a monopropellant thruster based Reaction Control System (RCS), a bipropellant Main Engine Assembly (MEA) and a Reaction Wheel Assembly (RWA). In 2008, after 11 years of reliable service, several RCS thrusters began to show signs of end of life degradation, which led the operations team to successfully perform the swap to the backup RCS system, the details and challenges of which are described in this paper. With some modifications, it is hoped that similar techniques and design strategies could be used to benefit other spacecraft.

Bates, David M.↗