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NASA NTRS2020

Mars Ascent Vehicle Hybrid Propulsion Configuration

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

Yaghoubi, Darius↗

NASA NTRS1994

A Theoretical Evaluation of Secondary Atomization Effects on Engine Performance for Aluminum Gel Propellants

A one-dimensional model of a gel-fueled rocket combustion chamber has been developed. This model includes the processes of liquid hydrocarbon burnout, secondary atomization. aluminum ignition, and aluminum combustion. Also included is a model of radiative heat transfer from the solid combustion products to the chamber walls. Calculations indicate that only modest secondary atomization is required to significantly reduce propellant burnout distances, aluminum oxide residual size and radiation heat wall losses. Radiation losses equal to approximately 2-13 percent of the energy released during combustion were estimated. A two-dimensional, two-phase nozzle code was employed to estimate radiation and nozzle two-phase flow effects on overall engine performance. Radiation losses yielded a 1 percent decrease in engine I(sub sp). Results also indicate that secondary atomization may have less effect on two-phase losses than it does on propellant burnout distance and no effect if oxide particle coagulation and shear induced droplet breakup govern oxide particle size. Engine I(sub sp) was found to decrease from 337.4 to 293.7 seconds as gel aluminum mass loading was varied from 0-70 wt percent. Engine I(sub sp) efficiencies, accounting for radiation and two-phase flow effects, on the order of 0.946 were calculated for a 60 wt percent gel, assuming a fragmentation ratio of 5.

Mueller, D. C.↗

NASA NTRS2000

Saving Lives With Rocket Power

Thiokol Propulsion uses NASA's surplus rocket fuel to produce a flare that can safely destroy land mines. Through a Memorandum of Agreement between Thiokol and Marshall Space Flight Center, Thiokol uses the scrap Reusable Solid Rocket Motor (RSRM) propellant. The resulting Demining Device was developed by Thiokol with the help of DE Technologies. The Demining Device neutralizes land mines in the field without setting them off. The Demining Device flare is placed next to an uncovered land mine. Using a battery-triggered electric match, the flare is then ignited. Using the excess and now solidified rocket fuel, the flare burns a hole in the mine's case and ignites the explosive contents. Once the explosive material is burned away, the mine is disarmed and no longer dangerous.

Source record↗

NASA NTRS1995

Low velocity opposed-flow frame spread in a transport-controlled environment DARTFire

The overall objectives of the DARTFire project are to uncover the underlying physics and increase understanding of the mechanisms that cause flames to propagate over solid fuels against a low velocity of oxidizer flow in a low-gravity environment. Specific objectives are (1) to analyze experimentally observed flame shapes, measured gas-phase field variables, spread rates, radiative characteristics, and solid-phase regression rates for comparison with previously developed model prediction capability that will be continually extended, and (2) to investigate the transition from ignition to either flame propagation or extinction in order to determine the characteristics of those environments that lead to flame evolution. To meet the objectives, a series of sounding rocket experiments has been designed to exercise several of the dimensional, controllable variables that affect the flame spread process over PMMA in microgravity, i.e., the opposing flow velocity (1-20 cm/s), the external radiant flux directed to the fuel surface (0-2 W/cm(exp 2)), and the oxygen concentration of the environment (35-70%). Because radiative heat transfer is critical to these microgravity flame spread experiments, radiant heating is imposed, and radiant heat loss will be measured. These are the first attempts at such an experimental control and measurement in microgravity. Other firsts associated with the experiment are (1) the control of the low velocity, opposed flow, which is of the same order as diffusive velocities and Stefan flows; (2) state-of-the-art quantitative flame imaging for species-specific emissions (both infrared and ultraviolet) in addition to novel intensified array imaging to obtain a color image of the very dim, low-gravity flames.

West, Jeff↗

NASA NTRS1981

Propulsion system ignition overpressure for the Space Shuttle

Liquid and solid rocket motor propulsion systems create an overpressure wave during ignition, caused by the accelerating gas particles pushing against or displacing the air contained in the launch pad or launch facility and by the afterburning of the fuel-rich gases. This wave behaves as a blast or shock wave characterized by a positive triangular-shaped first pulse and a negative half-sine wave second pulse. The pulse travels up the space vehicle and has the potential of either overloading individual elements or exciting overall vehicle dynamics. The latter effect results from the phasing difference of the wave from one side of the vehicle to the other. This overpressure phasing, or delta P environment, because of its frequency content as well as amplitude, becomes a design driver for certain panels (e.g., thermal shields) and payloads for the Space Shuttle. The history of overpressure effects on the Space Shuttle, the basic overpressure phenomenon, Space Shuttle overpressure environment, scale model overpressure testing, and techniques for suppressing the overpressure environments are considered.

Ryan, R. S.↗

NASA NTRS1946

Improving the performance of a compression ignition engine by directing flow of inlet air

The object of this report is to present the results of tests performed by the National Advisory Committee for Aeronautics to determine the effect on engine performance of directing the flow of the inlet air to a 5-inch by 7-inch cylinder, solid injection, compression ignition engine, After a few preliminary tests, comparative runs were made at a speed of 1500 r.p.m. with and without directed air flow. It was found that directing the flow of the inlet air toward the fuel injection valve gave steadier engine operation, and an appreciable increase in power, and decreased fuel consumption. The results indicate the possibility of improving the performance of a given type of combustion chamber without changing its shape and with no change in valve timing. They would also seem to prove that directional turbulence, set up before the inlet valve of a four-stroke cycle engine, continues in the engine cylinder throughout the compression stroke.

Kemper, Carlton↗

NASA NTRS1993

STS-51 pad abort. OV103-engine 2033 (ME-2) fuel flowmeter sensor open circuit

The STS-51 initial launch attempt of Discovery (OV-103) was terminated on KSC launch pad 39B on 12 Aug. 1993 at 9:12 AM E.S.T. due to a sensor redundancy failure in the liquid hydrogen system of ME-2 (Engine 2033). The event description and time line are summarized. Propellant loading was initiated on 12 Aug. 1993 at 12:00 AM EST. All space shuttle main engine (SSME) chill parameters and Launch Commit Criteria (LCC) were nominal. At engine start plus 1.34 seconds a Failure Identification (FID) was posted against Engine 2033 for exceeding the 1800 spin intra-channel (A1-A2) Fuel Flowrate sensor channel qualification limit. The engine was shut down at 1.50 seconds followed by Engines 2032 and 2030. All shut down sequences were nominal and the mission was safely aborted. SSME Avionics hardware and software performed nominally during the incident. A review of vehicle data table (VDT) data and controller software logic revealed no failure indications other than the single FID 111-101, Fuel Flowrate Intra-Channel Test Channel A disqualification. Software logic was executed according to requirements and there was no anomalous controller software operation. Immediately following the abort, a Rocketdyne/NASA failure investigation team was assembled. The team successfully isolated the failure cause to an open circuit in a Fuel Flowrate Sensor. This type of failure has occurred eight previous times in ground testing. The sensor had performed acceptably on three previous flights of the engine and SSME flight history shows 684 combined fuel flow rate sensor channel flights without failure. The disqualification of an Engine 2 (SSME No. 2033) Fuel Flowrate sensor channel was a result of an instrumentation failure and not engine performance. All other engine operations were nominal. This disqualification resulted in an engine shutdown and safe sequential shutdown of all three engines prior to ignition of the solid boosters.

Source record↗

NASA NTRSDate not supplied

Vehicle Modeling During the Burning of Thermally Thick Samples in the Saffire V Experiments

In order to design a safer spacecraft in terms of fire prevention, detection and cleanup, the transport of combustion products and heat must be predicted. Large-scale fire data was provided by the Saffire payload within Northrup Grumman’s Cygnus vehicle after a resupply mission to the ISS. Solid materials, including thick thermoplastic samples were ignited to study flame spread and the effect a fire has on a vehicle. Sensors that measured species and temperature were placed within Cygnus. A model using Pyrosim was developed to predict the thick fuel burn events from Saffire V by using sensor data from Cygnus. The heat transfer coefficient between the cabin air and cargo was previously calibrated using the cotton fuel burn event, and provided a good prediction of the temperature response within the vehicle during the two thick fuel experiments. The difference between the Saffire inlet CO 2 sensor, and the forward port standoff CO 2 sensor, which is the closest to the Saffire outlet, was used as an input into the model. This method provided an excellent prediction of the CO 2 response in the other parts of the Cygnus.

fire safety↗

NASA NTRSDate not supplied

Fire Safety Implications of Preliminary Results from Saffire IV and V Experiments on Large Scale Spacecraft Fires

The spread and growth of flames over large solid fuel samples and their effect on the pressurized spacecraft were studied inside the Cygnus spacecraft while in orbit after departing the International Space Station. These experiments were developed by NASA’s Advanced Exploration Systems Division in the Human Exploration and Operations Mission Directorate. The ignited materials consisted of poly-methyl methacrylate (PMMA), cotton fabric and a cotton/fiberglass fabric blend. The samples were all 40 cm wide and with various lengths ranging from 18 cm for the PMMA samples to 50 cm for the fabrics. The overall results from these tests and their impact on the spacecraft are presented with emphasis on the fire safety implications of the results. The experiments included, a post-fire cleanup system, vehicle internal volume measurements, and transport of acid gases (HCl and HF). Measurements included video images, flame spread rate, flame temperatures and radiant heat output; energy release through oxygen calorimetry; distributed measurements of CO2 concentration and temperature at six locations in the spacecraft; CO2, CO, O2, HF and HCl concentrations; vehicle pressurized volume; and aerosol concentrations. Details of the flame growth and spread are discussed in other papers as are details of the post-fire cleanup system performance. The fire events had a measurable impact on the vehicle pressure, temperature, and carbon dioxide concentration. However, despite having heat release rates up to 10 kW, the average vehicle conditions did not rise to unacceptable levels. The combined results of the experiments provide significant new understanding of the impact of sample and flow duct height on flame spread and growth in addition to an improved perspective of the impact of a fire event on a spacecraft.

micorgravity↗

NASA NTRSDate not supplied

Fire Safety Implications of Preliminary Results from Saffire IV and V Experiments on Large Scale Spacecraft Fires

microgravity fire safety↗

NASA NTRS1994

Ignition and combustion characteristics of metallized propellants, phase 2

Secondary atomization and ignition characteristics of aluminum/hydrocarbon gel propellants were investigated. Models of gel droplet shell formation were applied to aluminum/liquid hydrocarbon propellants to examine the effects of solid loading and ultimate particle size on the minimum droplet diameter permitting secondary atomization. A one-dimensional model of a gel-fueled rocket combustion chamber was developed. A model for radiant heat transfer from hot aluminum oxide particles to the chamber walls is included. A two-dimensional, two-phase nozzle code was used to estimate nozzle two-phase losses and overall engine performance.

Mueller, D. C.↗

NASA NTRS1995

Solid surface combustion experiment flame spread in a quiescent, microgravity environment implications of spread rate and flame structure

A unique environment in which flame spreading, a phenomenon of fundamental, scientific interest, has importance to fire safety is that of spacecraft in which the gravitational acceleration is low compared with that of the Earth, i.e., microgravity. Experiments aboard eight Space Shuttle missions between October 1990 and February 1995 were conducted using the Solid Surface Combustion Experiment (SSCE) payload apparatus in an effort to determine the mechanisms of gas-phase flame spread over solid fuel surfaces in the absence of any buoyancy induced or externally imposed oxidizer flow. The overall SSCE effort began in December of 1984. The SSCE apparatus consists of a sealed container, approximately 0.039 cu m, that is filled with a specified O2/N2 mixture at a prescribed pressure. Five of the experiments used a thin cellulosic fuel, ashless filter paper, 3 cm wide x 10 cm long, 0.00825 cm half-thickness, ignited in five different ambient conditions. Three of the experiments, the most recent, used thick polymethylmethacrylate (PMMA) samples 0.635 cm wide x 2 cm long, 0.32 cm half-thickness. Three experiments, STS 41, 40 and 43, were designed to evaluate the effect of ambient pressure on flame spread over the thin cellulosic fuel while flights STS 50 and 47 were at the same pressure as two of the earlier flights but at a lower oxygen concentration in order to evaluate the effect of ambient oxygen level on the flame spread process at microgravity. For the PMMA flights, two experiments, STS 54 and 63, were at the same pressure but different oxygen concentrations while STS 64 was at the same oxygen concentration as STS 63 but at a higher pressure. Two orthogonal views of the experiments were recorded on 16 mm cine-cameras operating at 24 frames/s. In addition to filmed images of the side view of the flames and surface view of the burning samples, solid- and gas-phase temperatures were recorded using thermocouples. The experiment is battery powered and follows an automated sequence upon activation by the Shuttle Crew. In this study we separate the SSCE data into two groups according to the fuel type: (1) thin cellulose; and (2) thick PMMA. The experimental spread rates are compared with prediction from a number of models in an effort to uncover the important physics that characterize microgravity flame spread. Both steady and unsteady solutions are employed to explore the flame evolution, especially for thick fuels. Finally, the flame structure in downward spread is compared with the microgravity flame structure and modeling results to delineate the difference between the two configurations and the influence of normal gravity.

Bundy, Matthew↗

NASA NTRS2015

Concurrent Flame Growth, Spread and Extinction over Composite Fabric Samples in Low Speed Purely Forced Flow in Microgravity

As a part of the NASA BASS and BASS-II experimental projects aboard the International Space Station, flame growth, spread and extinction over a composite cotton-fiberglass fabric blend (referred to as the SIBAL fabric) were studied in low-speed concurrent forced flows. The tests were conducted in a small flow duct within the Microgravity Science Glovebox. The fuel samples measured 1.2 and 2.2 cm wide and 10 cm long. Ambient oxygen was varied from 21% down to 16% and flow speed from 40 cm/s down to 1 cm/s. A small flame resulted at low flow, enabling us to observe the entire history of flame development including ignition, flame growth, steady spread (in some cases) and decay at the end of the sample. In addition, by decreasing flow velocity during some of the tests, low-speed flame quenching extinction limits were found as a function of oxygen percentage. The quenching speeds were found to be between 1 and 5 cm/s with higher speed in lower oxygen atmosphere. The shape of the quenching boundary supports the prediction by earlier theoretical models. These long duration microgravity experiments provide a rare opportunity for solid fuel combustion since microgravity time in ground-based facilities is generally not sufficient. This is the first time that a low-speed quenching boundary in concurrent spread is determined in a clean and unambiguous manner.

concurrent↗

NASA NTRS1981

Fuel/oxidizer-rich high-pressure preburners

The analyses, designs, fabrication, and cold-flow acceptance testing of LOX/RP-1 preburner components required for a high-pressure staged-combustion rocket engine are discussed. Separate designs of injectors, combustion chambers, turbine simulators, and hot-gas mixing devices are provided for fuel-rich and oxidizer-rich operation. The fuel-rich design addresses the problem of non-equilibrium LOX/RP-1 combustion. The development and use of a pseudo-kinetic combustion model for predicting operating efficiency, physical properties of the combustion products, and the potential for generating solid carbon is presented. The oxygen-rich design addresses the design criteria for the prevention of metal ignition. This is accomplished by the selection of materials and the generation of well-mixed gases. The combining of unique propellant injector element designs with secondary mixing devices is predicted to be the best approach.

Schoenman, L.↗

NASA NTRS2010

Propellant Readiness Level: A Methodological Approach to Propellant Characterization

A methodological approach to defining propellant characterization is presented. The method is based on the well-established Technology Readiness Level nomenclature. This approach establishes the Propellant Readiness Level as a metric for ascertaining the readiness of a propellant or a propellant combination by evaluating the following set of propellant characteristics: thermodynamic data, toxicity, applications, combustion data, heat transfer data, material compatibility, analytical prediction modeling, injector/chamber geometry, pressurization, ignition, combustion stability, system storability, qualification testing, and flight capability. The methodology is meant to be applicable to all propellants or propellant combinations; liquid, solid, and gaseous propellants as well as monopropellants and propellant combinations are equally served. The functionality of the proposed approach is tested through the evaluation and comparison of an example set of hydrocarbon fuels.

Bossard, John A.↗

NASA NTRS2001

Experiments Developed to Study Microgravity Smoldering Combustion

The overall objective of the Microgravity Smoldering Combustion (MSC) research program is to understand and predict smoldering combustion under normal and microgravity (near-zero-gravity) conditions to help prevent and control smolder-originated fires, in both environments. Smoldering is defined as a nonflaming, self-sustaining, propagating, exothermic surface reaction. If a material is sufficiently permeable, smoldering is not confined to its outer surface, but can propagate as a reaction wave through the interior of the material. The MSC program will accomplish its goals by conducting smolder experiments on the ground and in a space-based laboratory, and developing theoretical models of the process. Space-based experiments are necessary because smoldering is a very slow process and, consequently, its study in a microgravity environment requires extended periods of time that can only be achieved in space. Smoldering can occur in a variety of processes ranging from the smolder of porous insulating materials to underground coal combustion. Many materials can sustain smoldering, including wood, cloth, foams, tobacco, other dry organic materials, and charcoal. The ignition, propagation, transition to flaming, and extinction of the smolder reaction are controlled by complex, thermochemical mechanisms that are not well understood. As with many forms of combustion, gravity affects the availability of the oxidizer and the transport of heat, and therefore, the rate of combustion. The smoldering combustion of porous materials has been studied both experimentally and theoretically, usually in the context of fire safety. Smoldering encompasses a number of fundamental processes, including heat and mass transfer in a porous media; endothermic pyrolysis of combustible material; ignition, propagation, and extinction of heterogeneous exothermic reactions at the solid-gas pore interface; and the onset of gas phase reactions (flaming) from existing surface reactions. Smoldering presents a serious fire risk because the combustion can propagate slowly in a material's interior and go undetected for long periods of time. It typically yields a substantially higher conversion of fuel to toxic compounds than does flaming (though more slowly), and may undergo a sudden transition to flaming.

Vergilii, Franklin↗

NASA NTRS2001

Trioxane-Air Counterflow Diffusion Flames in Normal and Microgravity

Trioxane, a weakly bound polymer of formaldehyde (C3H6O3, m.p. 61 C, b.p. 115 C), is a uniquely suited compound for studying material flammability. Like many of the more commonly used materials for such tests (e.g., delrin, polyethylene, acrylic sheet, wood, and paper), it displays relevant phenomena (internal heat conduction, melting, vaporization, thermal decomposition, and gas phase reaction of the decomposition products). Unlike the other materials, however, it is non-sooting and has simple and well-known chemical kinetic pathways for its combustion. Hence it should prove to be much more useful for numerical modeling of surface combustion than the complex fuels typically used. We have performed the first exploratory tests of trioxane combustion in the counterflow configuration to determine its potential as a surrogate solid fuel which allows detailed modeling. The experiments were performed in the spring and summer of 1998 at the National Institute of Standards and Technology in Gaithersburg, MD, and at NASA-GRC in Cleveland. Using counterflow flames at 1-g, we measured the fuel consumption rate and the extinction conditions with added N2 in the air; at mg conditions, we observed the ignition characteristics and flame shape from video images. We have performed numerical calculations of the flame structure, but these are not described here due to space limitations. This paper summarizes some burning characteristics of trioxane relevant to its use for studying flame spread and fire suppression.

Linteris, Gregory T.↗

NASA NTRS1989

Hybrid propulsion technology program: Phase 1, volume 1

A number of booster propulsion system concepts are being considered for the next generation of manned and unmanned space launch vehicles. The one propulsion system concept that has potential for reducing costs with increased safety, reliability, and performance is hybrid propulsion (HP). A HP system may be thought of as a liquid propulsion system with solid fuel or a solid propulsion system with a liquid oxidizer. The liquid propulsion features that are most attractive are the higher specific impulse, clean exhaust, separated propellants, and oxidizer loading just prior to launch. The most attractive solid propulsion features includes low life cycle costs, no rotating machinery, compact size, and a robust case. In addition, a HP system has a robust LO2 tank; provides thrust control for ignition, to alleviate flight loads, and for thrust termination; and uses an inert grain that is not sensitive to anomalies such as cracks, voids, and separations. The object is to develop the technology to enable the application of HP to manned and unmanned space launch vehicles. This program will identify the necessary technology, acquire that technology, and demonstrate that technology. This volume is the executive summary.

Schuler, A. L.↗