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Characterization, Operation and Analysis of Test Motors Containing Aluminized Hybrid Fuels

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. Testing for fuel regression rate comprised a two-level, full factorial design available over Aluminum loading level, mass flow rate, pressure, and diameter. The data taken significantly surpasses the previous available data on regression rate of aluminized HTPB fuel burning with gaseous oxygen. It encompasses higher mass fluxes, and appears to generate more consistent data. The good test article and facility design and testing work of the Penn State HPCL combined with careful analysis of the data and good planning has made this possible. This should be able to assist with developing rate laws that are useful both for research planning and for developing flight system sizing relationships that can help optimize hybrid rocket concepts for trade studies. The successful approach of this DOE and test setup is applicable to other propellant combinations as well.

Kibbey, Timothy P.↗

Characterization, Operation and Analysis of Test Motors Containing Aluminized Hybrid Fuels

NASA Marshall Space Flight Center's Materials and Processes Department, with support from the Propulsion Systems Department, has renewed the development and maintenance of a hybrid test bed for exposing ablative thermal protection materials to an environment similar to that seen in solid rocket motors (SRM). The Solid Fuel Torch (SFT), operated during the Space Shuttle program, utilized gaseous oxygen for oxidizer and an aluminized hydroxyl-terminated polybutadiene (HTPB) fuel grain to expose a converging section of phenolic material to a 400 psi, 2-phase flow combustion environment. The configuration allows for up to a 2 foot long, 5 inch diameter fuel grain cartridge. Wanting to now test rubber insulation materials with a turn-back feature to mimic the geometry of an aft dome being impinged by alumina particles, the throat area has now been increased by several times to afford flow similarity. Combined with the desire to maintain a higher operating pressure, the oxidizer flow rate is being increased by a factor of 10. Out of these changes has arisen the need to characterize the fuel/oxidizer combination in a higher mass flux condition than has been previously tested at MSFC, and at which the literature has little to no reporting as well. Testing for fuel regression rate comprised a two-level, full factorial design available over Aluminum loading level, mass flow rate, pressure, and diameter. The data taken significantly surpasses the previous available data on regression rate of aluminized HTPB fuel burning with gaseous oxygen. It encompasses higher mass fluxes, and appears to generate more consistent data. The good test article and facility design and testing work of the Penn State HPCL combined with careful analysis of the data and good planning has made this possible. This should be able to assist with developing rate laws that are useful both for research planning and for developing flight system sizing relationships that can help optimize hybrid rocket concepts for trade studies. The successful approach of this DOE and test setup is applicable to other propellant combinations as well.

Kibbey, Timothy P.↗

Down-Selection of Four Common Habitat Variants

The Common Habitat is a large habitat that uses the Space Launch System core stage liquid oxygen tank as its primary structure. It has a gravity-independent internal architecture, such that identical units can be used on the lunar surface, Mars surface, and in microgravity. In developing the habitat, two key architectural questions emerged. Should the internal layout use a vertical or horizontal orientation of the tank? Should the crew size be four or eight? This led to the design of four variants: a four-crew horizontal, four-crew vertical, eight-crew horizontal, and eight-crew vertical. The primary consideration applied for down-selection was the crew experience living and working in the habitat, inclusive of crew productivity, well-being, and survivability. Based on this consideration, a series of seven assessments was performed to compare the four variants. A stowage assessment developed a standard logistics module and then considered the amounts of water to be stored in each variant. It then estimated how much stowage could be carried onboard each Common Habitat and how many logistics modules are required by each variant for a given mission duration. A functional analysis identified and compared the living and working functions across the four habitat, ranking them relative to each other. A crew time assessment first estimated the total crew time, building a weekly crew timeline for both four and eight-person crews. It then allocated time to activities linked to living and working functions, comparing how much time was available for each function in each variant. A science productivity assessment developed a relative metric using crew time, science stowage, and assumed rates of experiment consumables use to analytically compare the four variants. It also comparatively ranked the habitats with respect to a number of subjective parameters and a workstation acceptability rating. A maintenance capacity assessment identified and compared eleven generic maintenance capabilities across the four variants and also ranked the variants for their predicted ability to complete twelve fabrication, maintenance, and repair scenarios. A contingency responsiveness analysis examined twelve serious in-flight contingencies. For each scenario, the number of crew needed to respond was predicted and acceptability of various aspects of contingency response was evaluated, comparing the four variants against each other. Finally, in a habitability assessment, 120 habitability characteristics reflecting 13 major categories were evaluated for each habitat. These results were compared to identify the most acceptable habitat in each category. Ultimately, the data was shown to favor the horizontal orientation over the vertical and an eight-person crew over four. Implications of selecting this variant are discussed, including specific architectural challenges that result from the use of the full SLS liquid oxygen tank.

Habitability↗

Space transfer concepts and analysis for exploration missions. Implementation plan and element description document. Volume 1: Major trades. Book 1: Draft final

This document presents trade studies and reference concept designs accomplished during a study of Space Transfer Concepts and Analyses for Exploration Missions (STCAEM). This volume contains the major top level trades, level 2 trades conducted in support of NASA's Lunar/Mars Exploration Program Office, and a synopsis of the vehicles for different propulsion systems under trade consideration. The vehicles are presented in more detail in other volumes of this report. Book 1 of Volume 1 covers the following analyses: lunar/Mars commonality trades, lunar/Mars mission operations, and Mars transfer systems.

Source record↗

Small Launch Vehicle Concept Development for Affordable Multi-Stage Inline Configurations

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a study of two configurations of a three-stage, inline, liquid propellant small launch vehicle concept developed on the premise of maximizing affordability by targeting a specific payload capability range based on current industry demand. The initial configuration, NESC-1, employed liquid oxygen as the oxidizer and rocket propellant grade kerosene as the fuel in all three stages. The second and more heavily studied configuration, NESC-4, employed liquid oxygen and RP-1 on the first and second stages and liquid oxygen and liquid methane fuel on the third stage. On both vehicles, sensitivity studies were first conducted on specific impulse and stage propellant mass fraction in order to baseline gear ratios and drive the focus of concept development. Subsequent sensitivity and trade studies on the NESC-4 concept investigated potential impacts to affordability due to changes in gross liftoff weight and/or vehicle complexity. Results are discussed at a high level to understand the impact severity of certain sensitivities and how those trade studies conducted can either affect cost, performance, or both.

Beers, Benjamin R.↗

Small Launch Vehicle Concept Development for Affordable Multi-Stage Inline Configurations

The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a study of two configurations of a three-stage, inline, liquid propellant small launch vehicle concept developed on the premise of maximizing affordability by targeting a specific payload capability range based on current and future industry demand. The initial configuration, NESC-1, employed liquid oxygen as the oxidizer and rocket propellant grade kerosene as the fuel in all three stages. The second and more heavily studied configuration, NESC-4, employed liquid oxygen and rocket propellant grade kerosene on the first and second stages and liquid oxygen and liquid methane fuel on the third stage. On both vehicles, sensitivity studies were first conducted on specific impulse and stage propellant mass fraction in order to baseline gear ratios and drive the focus of concept development. Subsequent sensitivity and trade studies on the NESC-4 concept investigated potential impacts to affordability due to changes in gross liftoff mass and/or vehicle complexity. Results are discussed at a high level to understand the impact severity of certain sensitivities and how those trade studies conducted can either affect cost, performance, or both.

Beers, Benjamin R.↗

Satellite Power System (SPS) concept definition study (Exhibit D). Volume 2: Systems/subsystems analyses

Modifications to the reference concept were studied and the best approaches defined. The impact of the high efficiency multibandgap solar array on the reference concept design is considered. System trade studies for several solid state concepts, including the sandwich concept and a separate antenna/solar concept, are described. Two solid state concepts were selected and a design definition is presented for each. Magnetrons as an alternative to the reference klystrons for dc/RF conversion are evaluated. System definitions are presented for the preferred klystron and solid state concepts. Supporting systems are analyzed, with major analysis in the microwave, structures, and power distribution areas. Results of studies for thermal control, attitude control, stationkeeping, and details of a multibandgap solar cell study are included. Advanced laser concepts and the meteorological effects of a laser beam power transmission concept are considered.

Hanley, G. M.↗

Ammonia Leak Locator Study

The thermal control system of International Space Station Alpha will use liquid ammonia as the heat exchange fluid. It is expected that small leaks (of the order perhaps of one pound of ammonia per day) may develop in the lines transporting the ammonia to the various facilities as well as in the heat exchange equipment. Such leaks must be detected and located before the supply of ammonia becomes critically low. For that reason, NASA-JSC has a program underway to evaluate instruments that can detect and locate ultra-small concentrations of ammonia in a high vacuum environment. To be useful, the instrument must be portable and small enough that an astronaut can easily handle it during extravehicular activity. An additional complication in the design of the instrument is that the environment immediately surrounding ISSA will contain small concentrations of many other gases from venting of onboard experiments as well as from other kinds of leaks. These other vapors include water, cabin air, CO2, CO, argon, N2, and ethylene glycol. Altogether, this local environment might have a pressure of the order of 10(exp -7) to 10(exp -6) torr. Southwest Research Institute (SwRI) was contracted by NASA-JSC to provide support to NASA-JSC and its prime contractors in evaluating ammonia-location instruments and to make a preliminary trade study of the advantages and limitations of potential instruments. The present effort builds upon an earlier SwRI study to evaluate ammonia leak detection instruments [Jolly and Deffenbaugh]. The objectives of the present effort include: (1) Estimate the characteristics of representative ammonia leaks; (2) Evaluate the baseline instrument in the light of the estimated ammonia leak characteristics; (3) Propose alternative instrument concepts; and (4) Conduct a trade study of the proposed alternative concepts and recommend promising instruments. The baseline leak-location instrument selected by NASA-JSC was an ion gauge.

Dodge, Franklin T.↗

Systems evaluation of thermal bus concepts

Thermal bus concepts, to provide a centralized thermal utility for large, multihundred kilowatt space platforms, were studied and the results are summarized. Concepts were generated, defined, and screened for inclusion in system level thermal bus trades. Parametric trade studies were conducted in order to define the operational envelope, performance, and physical characteristics of each. Two concepts were selected as offering the most promise for thermal bus development. All of four concepts involved two phase flow in order to meet the required isothermal nature of the thermal bus. Two of the concepts employ a mechanical means to circulate the working fluid, a liquid pump in one case and a vapor compressor in another. Another concept utilizes direct osmosis as the driving force of the thermal bus. The fourth concept was a high capacity monogroove heat pipe. After preliminary sizing and screening, three of these concepts were selected to carry into the trade studies. The monogroove heat pipe concept was deemed unsuitable for further consideration because of its heat transport limitations. One additional concept utilizing capillary forces to drive the working fluid was added. Parametric system level trade studies were performed. Sizing and weight calculations were performed for thermal bus sizes ranging from 5 to 350 kW and operating temperatures in the range of 4 to 120 C. System level considerations such as heat rejection and electrical power penalties and interface temperature losses were included in the weight calculations.

Stalmach, D. D.↗

Geostationary platform systems concepts definition study. Volume 2: Technical, book 1

The initial selection and definition of operational geostationary platform concepts is discussed. Candidate geostationary platform missions and payloads were identified from COMSAT, Aerospace, and NASA studies. These missions and payloads were cataloged; classified with to communications, military, or scientific uses; screened for application and compatibility with geostationary platforms; and analyzed to identify platform requirements. Two platform locations were then selected (Western Hemisphere - 110 deg W, and Atlantic - 15 deg W), and payloads allocated based on nominal and high traffic models. Trade studies were performed leading to recommendation of selected concepts. Of 30 Orbit Transfer Vehicle (0TV) configuration and operating mode options identified, 18 viable candidates compatible with the operational geostationary platform missions were selected for analysis. Each was considered using four platform operational modes - 8 or 16 year life, and serviced or nonserviced, providing a total of 72 OTV/platform-mode options. For final trade study concept selection, a cost program was developed considering payload and platform costs and weight; transportation unit and total costs for the shuttle and OTV; and operational costs such as assembly or construction time, mating time, and loiter time. Servicing costs were added for final analysis and recommended selection.

Source record↗

Trade study for water and waste management concepts. Task 7: Support special analysis

Cost analyses and tradeoff studies are given for waste management in the Space Station, Lunar Surface Bases, and interplanetary space missions. Crew drinking water requirements are discussed and various systems to recycle water are examined. The systems were evaluated for efficiency and weight savings. The systems considered effective for urine water recovery were vapor compression, flash evaporation, and air evaporation with electrolytic pretreatment. For wash water recovery, the system of multifiltration was selected. A wet oxidation system, which can process many kinds of wastes, is also considered.

Source record↗

Design of a Vehicle Based Intervention System to Prevent Ozone Loss

This project was designed to be completed over a period of three years. Overall project goals were: (1) To understand the processes that contribute to stratospheric ozone loss; (2) To determine the best prevention scheme for loss; (3) To design a delivery vehicle to accomplish the prevention scheme. The 1994-1995 design objectives included: (1) To review the results of the 1993-1994 design team, including a reevaluation of the major assumptions and criteria selected to choose a vehicle; (2) To evaluate preliminary vehicle concepts and perform quantitative trade studies to select the optimal vehicle concept.

Cole, Robin↗

Trade Study of System Level Ranked Radiation Protection Concepts for Deep Space Exploration

A strategic focus area for NASA is to pursue the development of technologies which support exploration in space beyond the current inhabited region of low earth orbit. An unresolved issue for crewed deep space exploration involves limiting crew radiation exposure to below acceptable levels, considering both solar particle events and galactic cosmic ray contributions to dosage. Galactic cosmic ray mitigation is not addressed in this paper, but by addressing credible, easily implemented, and mass efficient solutions for the possibility of solar particle events, additional margin is provided that can be used for cosmic ray dose accumulation. As a result, NASA s Advanced Engineering Systems project office initiated this Radiation Storm Shelter design activity. This paper reports on the first year results of an expected 3 year Storm Shelter study effort which will mature concepts and operational scenarios that protect exploration astronauts from solar particle radiation events. Large trade space definition, candidate concept ranking, and a planned demonstration comprised the majority of FY12 activities. A system key performance parameter is minimization of the required increase in mass needed to provide a safe environment. Total system mass along with operational assessments and other defined protection system metrics provide the guiding metrics to proceed with concept developments. After a downselect to four primary methods, the concepts were analyzed for dosage severity and the amount of shielding mass necessary to bring dosage to acceptable values. Besides analytical assessments, subscale models of several concepts and one full scale concept demonstrator were created. FY12 work terminated with a plan to demonstrate test articles of two selected approaches. The process of arriving at these selections and their current envisioned implementation are presented in this paper.

Cerro, Jeffrey A↗

Advanced Integrated Power and Attitude Control System (IPACS) study

Integrated Power and Attitude Control System (IPACS) studies performed over a decade ago established the feasibility of simultaneously satisfying the demands of energy storage and attitude control through the use of rotating flywheels. It was demonstrated that, for a wide spectrum of applications, such a system possessed many advantages over contemporary energy storage and attitude control approaches. More recent technology advances in composite material rotors, magnetic suspension systems, and power control electronics have triggered new optimism regarding the applicability and merits of this concept. This study is undertaken to define an advanced IPACS and to evaluate its merits for a space station application. System and component designs are developed to establish the performance of this concept and system trade studies conducted to examine the viability of this approach relative to conventional candidate systems. It is clearly demonstrated that an advanced IPACS concept is not only feasible, but also offers substantial savings in mass and life-cycle cost for the space station mission.

Oglevie, R. E.↗

Novel Composites for Wing and Fuselage Applications: Novel Wing Design Concepts - Task 1

Design trade studies were conducted to arrive at advanced wing designs that integrated new material forms with innovative structural concepts and cost-effective fabrication methods. A representative spar was selected for design, fabrication, and test to validate the predicted performance. Textile processes, such as knitting, weaving and stitching, were used to produce fiber preforms that were later fabricated into composite span through epoxy Resin Transfer Molding (RTM), Resin Film Infusion (RFI), and consolidation of commingled thermoplastic and graphite tows. The target design ultimate strain level for these innovative structural design concepts was 6000 mu in. per in. The spars were subjected to four-point beam bending to validate their structural performance. The various material form /processing combination Y-spars were rated for their structural efficiency and acquisition cost. The acquisition cost elements were material, tooling, and labor.

Suarez, J. A.↗

Comet/Asteroid Protection System: Concept Study Executive Summary

Many of the major issues have been identified for a futuristic capability to protect against impacting comets and asteroids, and a preliminary space-based concept has been envisioned. Some of the basic concept elements, approaches, methodologies, and features have been identified. When contemplating the ability to monitor comets and asteroids continuously, there are many trade-offs between orbiting observatories and detection systems on planetary bodies without an atmosphere. Future orbit modification techniques have the potential for rapid and controlled alteration of NEO orbits, provided that high-power, compatible thermal management systems are developed. Much additional work and analysis are required to identify a final system concept, and many trade studies need to be performed to select the best mix of system capability, reliability, maintainability, and cost. Finally, it is fully appreciated that at the present time space systems are much more costly than terrestrial-based systems. Hopefully, this will change in the future. Regardless, understanding what it would take to defend against a much wider range of the impact threat will foster ideas, innovations, and technologies that could one day enable the development of such a system. This understanding is vital to provide ways of reducing the costs and quantifying the benefits that are achievable with a system like CAPS.

Mazanek, Daniel D.↗

Fission Surface Power System Initial Concept Definition

Under the NASA Exploration Technology Development Program (ETDP) and in partnership with the Department of Energy (DOE), NASA has embarked on a project to develop Fission Surface Power (FSP) technology. The primary goals of the project are to 1) develop FSP concepts that meet expected surface power requirements at reasonable cost with added benefits over other options, 2) establish a hardwarebased technical foundation for FSP design concepts and reduce overall development risk, 3) reduce the cost uncertainties for FSP and establish greater credibility for flight system cost estimates, and 4) generate the key products to allow NASA decision-makers to consider FSP as a preferred option for flight development. The FSP project was initiated in 2006 as the Prometheus Program and the Jupiter Icy Moons Orbiter (JIMO) mission were phased-out. As a first step, NASA Headquarters commissioned the Affordable Fission Surface Power System Study to evaluate the potential for an affordable FSP development approach. With a cost-effective FSP strategy identified, the FSP team evaluated design options and selected a Preliminary Reference Concept to guide technology development. Since then, the FSP Preliminary Reference Concept has served as a point-of-departure for several NASA mission architecture studies examining the use of nuclear power and has provided the foundation for a series of "Pathfinder" hardware tests. The long-term technology goal is a Technology Demonstration Unit (TDU) integrated system test using full-scale components and a non-nuclear reactor simulator. The FSP team consists of Glenn Research Center (GRC), Marshall Space Flight Center (MSFC) and the DOE National Laboratories at Los Alamos (LANL), Idaho (INL), Oak Ridge (ORNL), and Sandia (SNL). The project is organized into two main elements: Concept Definition and Risk Reduction. Under Concept Definition, the team performs trade studies, develops analytical tools, and formulates system concepts. Under Risk Reduction the team develops hardware prototypes and conducts laboratory-based testing.

Source record↗

Development of thermoplastic composite aircraft structures

Efforts focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. In support of these designs, mechanics developments were conducted in two areas. First, a dissipative strain energy approach to material characterization and failure prediction, developed at the Naval Research Laboratory, was evaluated as a design/analysis tool. Second, a finite element formulation for thick composites was developed and incorporated into a lug analysis method which incorporates pin bending effects. Manufacturing concepts were developed for an upper fuel cell cover. A detailed trade study produced two promising concepts: fiber placement and single-step diaphragm forming. Based on the innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldine concepts. Manufacturing techniques included autoclave consolidation, single diaphragm consolidation (SDCC) and roll-forming.

Renieri, Michael P.↗