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NASA NTRS2001

Space Shuttle Main Engine (SSME) Evolution

The SSME when developed in the 1970's was a technological leap in space launch propulsion system design. The engine has safely supported the space shuttle for the last two decades and will be required for at least another decade to support human space flight to the international space station. This paper discusses the continued improvements and maturing of the system to its current state and future considerations for its critical role in the nations space program. Discussed are the initiatives of the late 1980's, which lead to three major upgrades through the 1990's. The current capabilities of the propulsion system are defined in the areas of highest programmatic importance: ascent risk, in-flight abort thrust, reusability, and operability. Future initiatives for improved shuttle safety, the paramount priority of the Space Shuttle program are discussed.

Worlund, Len A.↗
NASA NTRS1999

Upper-Stage Flight Experiment

For propulsion applications that require that the propellants are storable for long periods, have a high density impulse, and are environmentally clean and non-toxic, the best choice is a combination of high-concentration hydrogen peroxide (High Test Peroxide, or HTP) and a liquid hydrocarbon (LHC) fuel. The HTP/LHC combination is suitable for low-cost launch vehicles, space taxi and space maneuvering vehicles, and kick stages. Orbital Sciences Corporation is under contract with the NASA Marshall Space Flight Center in cooperation with the Air Force Research Lab to design, develop and demonstrate a new low-cost liquid upper stage based on HTP and JP-8. The Upper Stage Flight Experiment (USFE) focuses on key technologies necessary to demonstrate the operation of an inherently simple propulsion system with an innovative, state-of-the-art structure. Two key low-cost vehicle elements will be demonstrated - a 10,000 lbf thrust engine and an integrated composite tank structure. The suborbital flight test of the USFE is scheduled for 2001. Preceding the flight tests are two major series of ground tests at NASA Stennis Space Center and a subscale tank development program to identify compatible composite materials and to verify their compatibility over long periods of time. The ground tests include a thrust chamber development test series and an integrated stage test. This paper summarizes the results from the first phase of the thrust chamber development tests and the results to date from the tank material compatibility tests. Engine and tank configurations that meet the goals of the program are described.

Anderson, W. E.↗
NASA NTRS1993

Minimum Hamiltonian Ascent Trajectory Evaluation (MASTRE) program (update to automatic flight trajectory design, performance prediction, and vehicle sizing for support of Shuttle and Shuttle derived vehicles) engineering manual

The Minimum Hamiltonian Ascent Trajectory Evaluation (MASTRE) program and its predecessors, the ROBOT and the RAGMOP programs, have had a long history of supporting MSFC in the simulation of space boosters for the purpose of performance evaluation. The ROBOT program was used in the simulation of the Saturn 1B and Saturn 5 vehicles in the 1960's and provided the first utilization of the minimum Hamiltonian (or min-H) methodology and the steepest ascent technique to solve the optimum trajectory problem. The advent of the Space Shuttle in the 1970's and its complex airplane design required a redesign of the trajectory simulation code since aerodynamic flight and controllability were required for proper simulation. The RAGMOP program was the first attempt to incorporate the complex equations of the Space Shuttle into an optimization tool by using an optimization method based on steepest ascent techniques (but without the min-H methodology). Development of the complex partial derivatives associated with the Space Shuttle configuration and using techniques from the RAGMOP program, the ROBOT program was redesigned to incorporate these additional complexities. This redesign created the MASTRE program, which was referred to as the Minimum Hamiltonian Ascent Shuttle TRajectory Evaluation program at that time. Unique to this program were first-stage (or booster) nonlinear aerodynamics, upper-stage linear aerodynamics, engine control via moment balance, liquid and solid thrust forces, variable liquid throttling to maintain constant acceleration limits, and a total upgrade of the equations used in the forward and backward integration segments of the program. This modification of the MASTRE code has been used to simulate the new space vehicles associated with the National Launch Systems (NLS). Although not as complicated as the Space Shuttle, the simulation and analysis of the NLS vehicles required additional modifications to the MASTRE program in the areas of providing additional flexibility in the use of the program, allowing additional optimization options, and providing special options for the NLS configuration.

Lyons, J. T.↗
NASA NTRS2014

NASA's Space Launch System Development Status

Development of the National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) heavy lift rocket is shifting from the formulation phase into the implementation phase in 2014, a little more than 3 years after formal program establishment. Current development is focused on delivering a vehicle capable of launching 70 metric tons (t) into low Earth orbit. This "Block 1" configuration will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017, followed by its first crewed flight in 2021. SLS can evolve to a130t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. Benefits associated with its unprecedented mass and volume include reduced trip times and simplified payload design. Every SLS element achieved significant, tangible progress over the past year. Among the Program's many accomplishments are: manufacture of core stage test barrels and domes; testing of Solid Rocket Booster development hardware including thrust vector controls and avionics; planning for RS- 25 core stage engine testing; and more than 4,000 wind tunnel runs to refine vehicle configuration, trajectory, and guidance. The Program shipped its first flight hardware - the Multi-Purpose Crew Vehicle Stage Adapter (MSA) - to the United Launch Alliance for integration with the Delta IV heavy rocket that will launch an Orion test article in 2014 from NASA's Kennedy Space Center. The Program successfully completed Preliminary Design Review in 2013 and will complete Key Decision Point C in 2014. NASA has authorized the Program to move forward to Critical Design Review, scheduled for 2015 and a December 2017 first launch. The Program's success to date is due to prudent use of proven technology, infrastructure, and workforce from the Saturn and Space Shuttle programs, a streamlined management approach, and judicious use of new technologies. The result is a safe, affordable, sustainable, and evolutionary path to development of an unprecedented capability for future missions across the solar system. In an environment of economic challenges, the nationwide SLS team continues to meet ambitious budget and schedule targets. This paper will discuss SLS Program and technical accomplishments over the past year and provide a look at the milestones and challenges ahead.

Lyles, Garry↗
NASA NTRS1983

Effects of rotor inertia and rpm control on helicopter handling qualities

The effects of thrust-response characteristics on helicopter handling qualities have until recently remained largely undefined. A multiphase program is being conducted to study, in a generic sense and through ground simulation, the effects of engine and rotor response characteristics, excess power, and vertical damping on specific maneuvers included in nap-of-the-earth (NOE) operations. This paper describes the most recent of these phases: a simulation in which the effects on handling qualities of rotor inertia and rpm changes were considered. Thrust- and height-response characteristics to step-control inputs are included to document the configurations investigated. Results indicate that with a given engine response and unlimited power, large changes in rotor inertia have little effect on handling qualities for certain low-speed tasks and hover tasks. The effects on handling qualities of requiring the pilot to maintain proper rotor rpm limits were also studied. This investigation revealed that large fluctuations in rotor rpm degrade handling qualities; as a result, continued study of the use of methods to automate control of rotor rpm is recommended.

Corliss, L. D.↗
NASA NTRS2012

Small Fast Spectrum Reactor Designs Suitable for Direct Nuclear Thermal Propulsion

Advancement of U.S. scientific, security, and economic interests through a robust space exploration program requires high performance propulsion systems to support a variety of robotic and crewed missions beyond low Earth orbit. Past studies, in particular those in support of the Space Exploration Initiative (SEI), have shown nuclear thermal propulsion systems provide superior performance for high mass high propulsive delta-V missions. The recent NASA Design Reference Architecture (DRA) 5.0 Study re-examined mission, payload, and transportation system requirements for a human Mars landing mission in the post-2030 timeframe. Nuclear thermal propulsion was again identified as the preferred in-space transportation system. A common nuclear thermal propulsion stage with three 25,000-lbf thrust engines was used for all primary mission maneuvers. Moderately lower thrust engines may also have important roles. In particular, lower thrust engine designs demonstrating the critical technologies that are directly extensible to other thrust levels are attractive from a ground testing perspective. An extensive nuclear thermal rocket technology development effort was conducted from 1955-1973 under the Rover/NERVA Program. Both graphite and refractory metal alloy fuel types were pursued. Reactors and engines employing graphite based fuels were designed, built and ground tested. A number of fast spectrum reactor and engine designs employing refractory metal alloy fuel types were proposed and designed, but none were built. The Small Nuclear Rocket Engine (SNRE) was the last engine design studied by the Los Alamos National Laboratory during the program. At the time, this engine was a state-of-the-art graphite based fuel design incorporating lessons learned from the very successful technology development program. The SNRE was a nominal 16,000-lbf thrust engine originally intended for unmanned applications with relatively short engine operations and the engine and stage design were constrained to fit within the payload volume of the then planned space shuttle. The SNRE core design utilized hexagonal fuel elements and hexagonal structural support elements. The total number of elements can be varied to achieve engine designs of higher or lower thrust levels. Some variation in the ratio of fuel elements to structural elements is also possible. Options for SNRE-based engine designs in the 25,000-lbf thrust range were described in a recent (2010) Joint Propulsion Conference paper. The reported designs met or exceeded the performance characteristics baselined in the DRA 5.0 Study. Lower thrust SNRE-based designs were also described in a recent (2011) Joint Propulsion Conference paper. Recent activities have included parallel evaluation and design efforts on fast spectrum engines employing refractory metal alloy fuels. These efforts include evaluation of both heritage designs from the Argonne National Laboratory (ANL) and General Electric Company GE-710 Programs as well as more recent designs. Results are presented for a number of not-yet optimized fast spectrum engine options.

Schnitzler, Bruce G.↗
NASA NTRS2000

4.5-kW Hall Effect Thruster Evaluated

As part of an Interagency Agreement with the Air Force Research Lab (AFRL), a space simulation test of a Russian SPT 140 Hall Effect Thruster was completed in September 1999 at Vacuum Facility 6 at the NASA Glenn Research Center at Lewis Field. The thruster was subjected to a three-part test sequence that included thrust and performance characterization, electromagnetic interference, and plume contamination. SPT 140 is a 4.5-kW thruster developed under a joint agreement between AFRL, Atlantic Research Corp, and Space Systems/Loral, and was manufactured by the Fakal Experimental Design Bureau of Russia. All objectives were satisfied, and the thruster performed exceptionally well during the 120-hr test program, which comprised 33 engine firings. The Glenn testing provided a critical contribution to the thruster development effort, and the large volume and high pumping speed of this vacuum facility was key to the test s success. The low background pressure (1 10 6 torr) provided a more accurate representation of space vacuum than is possible in most vacuum chambers. The facility had been upgraded recently with new cryogenic pumps and sputter shielding to support the active electric propulsion program at Glenn. The Glenn test team was responsible for all test support equipment, including the thrust stand, power supplies, data acquisition, electromagnetic interference measurement equipment, and the contamination measurement system.

Mason, Lee S.↗
NASA NTRS1992

Electric propulsion system technology

The work performed in fiscal year (FY) 1991 under the Propulsion Technology Program RTOP (Research and Technology Objectives and Plans) No. (55) 506-42-31 for Low-Thrust Primary and Auxiliary Propulsion technology development is described. The objectives of this work fall under two broad categories. The first of these deals with the development of ion engines for primary propulsion in support of solar system exploration. The second with the advancement of steady-state magnetoplasmadynamic (MPD) thruster technology at 100 kW to multimegawatt input power levels. The major technology issues for ion propulsion are demonstration of adequate engine life at the 5 to 10 kW power level and scaling ion engines to power levels of tens to hundreds of kilowatts. Tests of a new technique in which the decelerator grid of a three-grid ion accelerator system is biased negative of neutralizer common potential in order to collect facility induced charge-exchange ions are described. These tests indicate that this SAND (Screen, Accelerator, Negative Decelerator) configuration may enable long duration ion engine endurance tests to be performed at vacuum chamber pressures an order of magnitude higher than previously possible. The corresponding reduction in pumping speed requirements enables endurance tests of 10 kW class ion engines to be performed within the resources of existing technology programs. The results of a successful 5,000-hr endurance of a xenon hollow cathode operating at an emission current of 25 A are described, as well as the initial tests of hollow cathodes operating on a mixture of argon and 3 percent nitrogen. Work performed on the development of carbon/carbon grids, a multi-orifice hollow cathode, and discharge chamber erosion reduction through the addition of nitrogen are also described. Critical applied-field MPD thruster technical issues remain to be resolved, including demonstration of reliable steady-state operation at input powers of hundreds to thousands of kilowatts, achievement of thruster efficiency and specific impulse levels required for missions of interest, and demonstration of adequate engine life at these input power, efficiency, and specific impulse levels. To address these issues we have designed, built, and tested a 100 kW class, radiation-cooled applied-field MPD thruster and a unique dual-beam thrust stand that enables separate measurements of the applied- and self-field thrust components. We have also initiated the development of cathode thermal and plasma sheath models that will eventually be used to guide the experimental program. In conjunction with the cathode modeling, a new cathode test facility is being constructed. This facility will support the study of cathode thermal behavior and erosion mechanisms, the diagnosis of the near-cathode plasma and the development and endurance testing of new, high-current cathode designs. To facilitate understanding of electrode surface phenomenon, we have implemented a telephoto technique to obtain photographs of the electrodes during engine operation. In order to reduce the background vacuum tank pressure during steady-state engine operation in order to obtain high fidelity anode thermal data, we have developed and are evaluating a gas-dynamic diffuser. A review of experience with alkali metal propellants for MPD thrusters led to the conclusion that alkali metals, particularly lithium, offer the potential for significant engine performance and lifetime improvements. These propellants are also condensible at room temperature, substantially reducing test facility pumping requirements. The most significant systems-level issue is the potential for spacecraft contamination. Subsequent experimental and theoretical efforts should be directed toward verifying the performance and lifetime gains and characterizing the thruster flow field to assess its impact on spacecraft surfaces. Consequently, we have begun the design and development of a new facility to study engine operation with alkali metal propellants.

Brophy, John R.↗
NASA NTRS2006

Analytical Assessment of the Reciprocating Feed System

A preliminary analysis tool has been created in Microsoft Excel to determine deliverable payload mass, total system mass, and performance of spacecraft systems using various types of propellant feed systems. These mass estimates are conducted by inserting into the user interface the basic mission parameters (e.g., thrust, burn time, specific impulse, mixture ratio, etc.), system architecture (e.g., propulsion system type and characteristics, propellants, pressurization system type, etc.), and design properties (e.g., material properties, safety factors, etc.). Different propellant feed and pressurization systems are available for comparison in the program. This gives the user the ability to compare conventional pressure fed, reciprocating feed system (RFS), autogenous pressurization thrust augmentation (APTA RFS), and turbopump systems with the deliverable payload, inert mass, and total system mass being the primary comparison metrics. Analyses of several types of missions and spacecraft were conducted and it was found that the RFS offers a performance improvement, especially in terms of delivered payload, over conventional pressure fed systems. Furthermore, it is competitive with a turbopump system at low to moderate chamber pressures, up to approximately 1,500 psi. Various example cases estimating the system mass and deliverable payload of several types of spacecraft are presented that illustrate the potential system performance advantages of the RFS. In addition, a reliability assessment of the RFS was conducted, comparing it to simplified conventional pressure fed and turbopump systems, based on MIL-STD 756B; these results showed that the RFS offers higher reliability, and thus substantially longer periods between system refurbishment, than turbopump systems, and is competitive with conventional pressure fed systems. This is primarily the result of the intrinsic RFS fail-operational capability with three run tanks, since the system can operate with just two run tanks.

Eddleman, David E.↗
NASA NTRS2016

Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.

Garcia, C. P.↗
NASA NTRS2014

Development, Verification and Validation of Parallel, Scalable Volume of Fluid CFD Program for Propulsion Applications

There are many instances involving liquid/gas interfaces and their dynamics in the design of liquid engine powered rockets such as the Space Launch System (SLS). Some examples of these applications are: Propellant tank draining and slosh, subcritical condition injector analysis for gas generators, preburners and thrust chambers, water deluge mitigation for launch induced environments and even solid rocket motor liquid slag dynamics. Commercially available CFD programs simulating gas/liquid interfaces using the Volume of Fluid approach are currently limited in their parallel scalability. In 2010 for instance, an internal NASA/MSFC review of three commercial tools revealed that parallel scalability was seriously compromised at 8 cpus and no additional speedup was possible after 32 cpus. Other non-interface CFD applications at the time were demonstrating useful parallel scalability up to 4,096 processors or more. Based on this review, NASA/MSFC initiated an effort to implement a Volume of Fluid implementation within the unstructured mesh, pressure-based algorithm CFD program, Loci-STREAM. After verification was achieved by comparing results to the commercial CFD program CFD-Ace+, and validation by direct comparison with data, Loci-STREAM-VoF is now the production CFD tool for propellant slosh force and slosh damping rate simulations at NASA/MSFC. On these applications, good parallel scalability has been demonstrated for problems sizes of tens of millions of cells and thousands of cpu cores. Ongoing efforts are focused on the application of Loci-STREAM-VoF to predict the transient flow patterns of water on the SLS Mobile Launch Platform in order to support the phasing of water for launch environment mitigation so that vehicle determinantal effects are not realized.

West, Jeff↗
NASA NTRS1995

Propulsion Controlled Aircraft design and development

This paper describes the design, development, and ground testing of the propulsion controlled aircraft (PCA) flight control system. A backup flight control system which uses only engine thrust, the PCA system utilizes collective and differential thrust changes to steer an aircraft that experiences partial or complete failure of the hydraulically actuated control surfaces. The objective of the program was to investigate, in flight, the throttles-only control capability of the F-15, using manual control, and also an augmented PCA mode in which computer-controlled thrust was used for flight control. The objective included PCA operation in up-and-away flight and, if performance was adequate, a secondary objective to make actual PCA landings. The PCA design began with a feasibility study which evaluated many control law designs. The study was done using off-line control analysis, simulation, and on-line manned flight simulator tests. Control laws, cockpit displays, and cockpit controls were evaluated by NASA test pilots. A flight test baseline configuration was selected based on projected flight performance, applicability to transport and fighter aircraft, and funding costs. During the PCA software and hardware development, the initial design was updated as data became available from throttle-only flight experiments conducted by NASA on the F-15. This information showed basic airframe characteristics that were not observed in the F-15 flight simulator and resulted in several design changes. After the primary objectives of the PCA flight testing were accomplished, additional PCA modes of operation were developed and implemented. The evolution of the PCA system from the initial feasibility study, control law design, simulation, hardware-in-the-loop tests, pilot-in-the-loop tests, and ground tests is presented.

Wells, Edward A.↗
NASA NTRS1989

Transputer parallel processing at NASA Lewis Research Center

The transputer parallel processing lab at NASA Lewis Research Center (LeRC) consists of 69 processors (transputers) that can be connected into various networks for use in general purpose concurrent processing applications. The main goal of the lab is to develop concurrent scientific and engineering application programs that will take advantage of the computational speed increases available on a parallel processor over the traditional sequential processor. Current research involves the development of basic programming tools. These tools will help standardize program interfaces to specific hardware by providing a set of common libraries for applications programmers. The thrust of the current effort is in developing a set of tools for graphics rendering/animation. The applications programmer currently has two options for on-screen plotting. One option can be used for static graphics displays and the other can be used for animated motion. The option for static display involves the use of 2-D graphics primitives that can be called from within an application program. These routines perform the standard 2-D geometric graphics operations in real-coordinate space as well as allowing multiple windows on a single screen.

Ellis, Graham K.↗
NASA NTRS1988

Application of a Comprehensive Analytical Model of Rotor Aerodynamics and Dynamics (CAMRAD) to the McDonnell Douglas AH-64A helicopter

A model of the AH-64A helicopter was generated in a Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics (CAMRAD) in an effort to validate its analytical capabilities for modeling a current advanced Army helicopter. The initial phase of the effort involved the generation of CAMRAD input files necessary for the complete aerodynamic, structural, and dynamic definition of the production AH-64A helicopter. The input files were checked by making comparisons of CAMRAD full helicopter trim and main rotor blade natural frequency predictions with those of full helicopter trim program, Blade Element Trim (BETRIM), and dynamic analysis code, Dynamic Analysis Research Tool (DART), respectively. The main thrust concerned the application of the AH-64A CAMRAD model thus developed and verified for main rotor blade structural loads predictions and comparison with DART analytical results. The investigation provided insight not only into the usefulness of CAMRAD for the AH-64A performance and dynamics prediction, but also into the limitations of the program for modeling advanced rotor and fuselage systems. The model development effort is discussed, the results of the CAMRAD correlation studies presented, and some general conclusions are offered on the applicability of CAMRAD for rotor aeroelastic loads prediction for current and future rotorcraft configurations.

Callahan, Cynthia B.↗
NASA NTRS1973

Hydrogen-oxygen auxiliary propulsion for the space shuttle. Volume 1: High pressure thrusters

Technology for long life, high performing, gaseous hydrogen-gaseous oxygen rocket engines suitable for auxiliary propulsion was provided by a combined analytical and experimental program. Propellant injectors, fast response valves, igniters, and regeneratively and film-cooled thrust chambers were tested over a wide range of operating conditions. Data generated include performance, combustion efficiency, thermal characteristics film cooling effectiveness, dynamic response in pulsing, and cycle life limitations.

Source record↗
NASA NTRS1976

Overview of the QCSEE program

Externally blown flap and upper surface blown flap powered lift concepts were investigated in the Quiet Clean Short-Haul Experimental Engine Program and briefly discussed along with propulsion system requirements. Noise limits, emission standards, thrust requirements, and thrust-to-weight ratios are among the factors considered.

Ciepluch, C. C.↗
NASA NTRS1984

Optimal low-thrust, three-burn orbit transfers with large plane changes

Optimal low-thrust, three-burn solutions have been obtained for orbit transfers between a 28.5-degree inclined low earth orbit and a series of 63.4-degree inclined circular orbits as well as a series of 63.4-degree inclined elliptical orbits with twelve hour periods. Solutions have also been obtained for orbit transfers between 97-degree inclined orbits and a 57-degree inclined low earth orbit. Thrust to weight ratios as low as 0.02 were considered. A hybrid nonlinear programming method was used to obtain the solutions. Analysis of the optimal steering during various burns reveals a natural division of the steering strategies into two categories based on whether a burn results in a change predominantly in semi-major axis or orbit plane. The similarity of these optimal steering strategies to previously obtained simple near-optimal steering strategies is discussed.

Zondervan, K. P.↗