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NASA NTRS1987

Advanced propulsion activities in the USA

An evaluation is made of technology development prospects for launch vehicle, orbit transfer vehicle, satellite, and planetary exploration spacecraft propulsion systems being contemplated by NASA and its research contractors. Attention is given to such electric propulsion systems as arcjet, pulsed plasma, ion, and resistojet thrusters, as well as to solar thermal heat exchanger powerplants, beamed energy propulsion systems, and ultra-advanced nuclear fission and fusion propulsion concepts.

Garrison, P. W.↗

NASA NTRS1972

Comparison of advanced propulsion concepts for deep space exploration

Equations and charts are presented that permit rapid estimation of propulsion-system performance requirements for some typical deep-space missions. A number of advanced propulsion concepts for which performance estimates are available are compared with respect to their capability for flyby, rendezvous, and roundtrip planetary missions. Based on these estimates, the gas-core nuclear fission rocket and the pulsed fusion rocket yield the fastest trip times to the near planets. For round trips to Jupiter and beyond, the controlled fusion rocket shows progressively superior capabilities. Several propulsion concepts based on use of impinging laser beams are found to be noncompetitive with the other advanced concepts for deep space missions. Requirements for attainment of interstellar distances within a human lifetime are found to be some orders of magnitude beyond the capabilities of any propulsion concepts for which performance estimates are now possible.

Moeckel, W. E.↗

NASA NTRSDate not supplied

Atmospheric Mining in the Outer Solar System: Aerospacecraft Analysis, Propulsion, and Resource Capturing Implications

Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists. Analyses of orbital transfer vehicles (OTVs), landers, and in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points. Aerospacecraft with closed cycle gas core propulsion are used to capture the 3He and deuterium from the outer planet atmospheres. Additional analyses of aerospacecraft sizing led to important results, reducing the overall mining system mass by many thousands of metric tons. Earlier analyses had focused on small aerospacecraft payloads. Important influences on mining time in the atmosphere were also analyzed and will be presented.

In Situ Resource Utilization↗

NASA NTRSDate not supplied

Atmospheric Mining in the Outer Solar System: Outer Planet Moon Bases, Propulsion, In-Situ Resource Utilization, and Mining Implications

Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists. Analyses of orbital transfer vehicles (OTVs), landers, and in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points. Aerospacecraft with closed cycle gas core propulsion are used to capture the 3He and deuterium from the outer planet atmospheres. Water ice on the outer planet moons has been identified as critical resources for refueling the moon landers and the nuclear electric OTVs. Outer planet moon mining issues are addressed. The issues include the mass fraction of water ice on the moon’s surface, the volume of the mined regolith-water ice matter, and the time to capture the water ice.

In-situ resource utilization↗

NASA NTRS2009

Interstellar Propulsion Research: Realistic Possibilities and Idealistic Dreams

Though physically possible, interstellar travel will be exceedingly difficult. Both the known laws of physics and the limits of our current understanding of engineering place extreme limits on what may actually be possible. Our remote ancestors looked at the night sky and assumed those tiny points of light were campfires around which other tribes were gathered -- and they dreamed of someday making the trip to visit them. In our modern era, we've grown accustomed to humans regularly traveling into space and our robots voyaging ever-deeper into the outer edges of our solar system. Traveling to those distant campfires (stars) has been made to look easy by the likes of Captains Kirk and Picard as well as Han Solo and Commander Adama. Our understanding of physics and engineering has not kept up with our imaginations and many are becoming frustrated with the current pace at which we are exploring the universe. Fortunately, there are ideas that may one day lead to new physical theories about how the universe works and thus potentially make rapid interstellar travel possible -- but many of these are just ideas and are not even close to being considered a scientific theory or hypothesis. Absent any scientific breakthroughs, we should not give up hope. Nature does allow for interstellar travel, albeit slowly and requiring an engineering capability far beyond what we now possess. Antimatter, fusion and photon sail propulsion are all candidates for relatively near-term interstellar missions. The plenary lecture will discuss the dreams and challenges of interstellar travel, our current understanding of what may be possible and some of the "out of the box" ideas that may allow us to become an interstellar species someday in the future.

Johnson, Les↗

NASA NTRS1991

Coproduction of volatiles and metals from extraterrestrial materials

Two main efforts in support of the general goals of SERC/culpr are presented. Investigations of processes for the coproduction of metals from extra-terrestrial materials in conjunction with plausible schemes for oxygen extraction continue. The principal emphasis was on the extraction and purification of iron from the ilmenite reduction process for oxygen, from the cathode metal deposits made in the magma electrolysis process for oxygen, and from native ferrous metal alloys on the moon and asteroids. All work on the separation and purification of ferrous metals was focussed upon the gaseous carbonyl process, a scheme that involves only temperatures attainable by passive thermal control. The exploration of a variety of schemes was initiated, involving the use of several different propulsion options and both propulsive and aerobraking capture at earth, for return of extraterrestrial resources to earth orbits. In addition, the search for new opportunities in space resource utilization continues. Examples include the continuation of work underway on: (1) the feasibility of locating solar power satellites in highly eccentric earth orbit; (2) the energetics of extracting the potential clean fusion fuel He-3 from the atmosphere for return to earth; and (3) the utility of a nuclear steam rocket (using non-terrestrial water as the working fluid) for transportation in the inner solar system.

Lewis, John S.↗

NASA NTRSDate not supplied

Atmospheric Mining in the Outer Solar System: Interplanetary Transfer Vehicles, In-Situ Resource Utilization, and Moon Mining Issues

Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists. Analyses of orbital transfer vehicles (OTVs), landers, and in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points. Aerospacecraft with closed cycle gas core propulsion are used to capture the 3He and deuterium from the outer planet atmospheres. Water ice on the outer planet moons has been identified as critical resources for refueling the moon landers and the nuclear electric OTVs. The numbers of interplanetary transfer vehicles (ITVs) and the launch vehicles will be presented. Preliminary design parameters for the ITVs and their payload limits will be assessed. The number of mining machines and their associated issues are addressed.

chemical propulsion↗

NASA NTRS1991

Space nuclear power systems; Proceedings of the 8th Symposium, Albuquerque, NM, Jan. 6-10, 1991. Pts. 1-3

The present conference discusses NASA mission planning for space nuclear power, lunar mission design based on nuclear thermal rockets, inertial-electrostatic confinement fusion for space power, nuclear risk analysis of the Ulysses mission, the role of the interface in refractory metal alloy composites, an advanced thermionic reactor systems design code, and space high power nuclear-pumped lasers. Also discussed are exploration mission enhancements with power-beaming, power requirement estimates for a nuclear-powered manned Mars rover, SP-100 reactor design, safety, and testing, materials compatibility issues for fabric composite radiators, application of the enabler to nuclear electric propulsion, orbit-transfer with TOPAZ-type power sources, the thermoelectric properties of alloys, ruthenium silicide as a promising thermoelectric material, and innovative space-saving device for high-temperature piping systems. The second volume of this conference discusses engine concepts for nuclear electric propulsion, nuclear technologies for human exploration of the solar system, dynamic energy conversion, direct nuclear propulsion, thermionic conversion technology, reactor and power system control, thermal management, thermionic research, effects of radiation on electronics, heat-pipe technology, radioisotope power systems, and nuclear fuels for power reactors. The third volume discusses space power electronics, space nuclear fuels for propulsion reactors, power systems concepts, space power electronics systems, the use of artificial intelligence in space, flight qualifications and testing, microgravity two-phase flow, reactor manufacturing and processing, and space and environmental effects.

El-Genk, Mohamed S.↗

NASA NTRS2004

Implementation Challenges for Ceramic Matrix Composites in High Temperature Applications

Ceramic matrix composites are leading candidate materials for a number of applications in aeronautics, space, energy, electronics, nuclear, and transportation industries. In the aeronautics and space exploration systems, these materials are being considered for applications in hot sections of jet engines such as the combustor liner, nozzle components, nose cones, leading edges of reentry vehicles and space propulsion components. Applications in the energy and environmental industries include radiant heater tubes, heat exchangers, heat recuperators, gas and diesel particulate filters (DPFs), and components for land based turbines for power generation. These materials are also being considered for use in the first wall and blanket components of fusion reactors. There are a number of critical issues and challenges related to successful implementation of composite materials. Fabrication of net and complex shape components with high density and tailorable matrix properties is quite expensive, and even then various desirable properties are not achievable. In this presentation, microstructure and thermomechanical properties of composites fabricated by two techniques (chemical vapor infiltration and melt infiltration), will be presented. In addition, critical need for robust joining and assembly technologies in successful implementation of these systems will be discussed. Other implementation issues will be discussed along with advantages and benefits of using these materials for various components in high temperature applications.

Singh, Mrityunjay↗

NASA NTRS2003

Conceptual Design of In-Space Vehicles for Human Exploration of the Outer Planets

During FY-2002, a team of engineers from TD30/Advanced Concepts and TD40/Propulsion Research Center embarked on a study of potential crewed missions to the outer solar system. The study was conducted under the auspices of the Revolutionary Aerospace Systems Concepts activity administered by Langley Research Center (LaRC). The Marshall Space Flight Center (MSFC) team interacted heavily with teams from other Centers including Glenn Research Center, LaRC, Jet Propulsion Laboratory, and Johnson Space Center. The MSFC team generated five concept missions for this project. The concept missions use a variety of technologies, including magnetized target fusion (MTF), magnetoplasmadynamic thrusters, solid core reactors, and molten salt reactors in various combinations. The Technical Publication (TP) reviews these five concepts and the methods used to generate them. The analytical methods used are described for all significant disciplines and subsystems. The propulsion and power technologies selected for each vehicle are reviewed in detail. The MSFC team also expended considerable effort refining the MTF concept for use with this mission. The results from this effort are also contained within this TP. Finally, the lessons learned from this activity are summarized in the conclusions section.

Adams, R. B.↗

NASA NTRS2005

Meeting the Challenges of Exploration Systems: Health Management Technologies for Aerospace Systems With Emphasis on Propulsion

The constraints of future Exploration Missions will require unique Integrated System Health Management (ISHM) capabilities throughout the mission. An ambitious launch schedule, human-rating requirements, long quiescent periods, limited human access for repair or replacement, and long communication delays all require an ISHM system that can span distinct yet interdependent vehicle subsystems, anticipate failure states, provide autonomous remediation, and support the Exploration Mission from beginning to end. NASA Glenn Research Center has developed and applied health management system technologies to aerospace propulsion systems for almost two decades. Lessons learned from past activities help define the approach to proper ISHM development: sensor selection- identifies sensor sets required for accurate health assessment; data qualification and validation-ensures the integrity of measurement data from sensor to data system; fault detection and isolation-uses measurements in a component/subsystem context to detect faults and identify their point of origin; information fusion and diagnostic decision criteria-aligns data from similar and disparate sources in time and use that data to perform higher-level system diagnosis; and verification and validation-uses data, real or simulated, to provide variable exposure to the diagnostic system for faults that may only manifest themselves in actual implementation, as well as faults that are detectable via hardware testing. This presentation describes a framework for developing health management systems and highlights the health management research activities performed by the Controls and Dynamics Branch at the NASA Glenn Research Center. It illustrates how those activities contribute to the development of solutions for Integrated System Health Management.

Melcher, Kevin J.↗

NASA NTRS2015

Atmospheric Mining in the Outer Solar System: Aerial Vehicle Mission and Design Issues

Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists. The mining aerospacecraft (ASC) could fly through the outer planet atmospheres, for global weather observations, localized storm or other disturbance investigations, wind speed measurements, polar observations, etc. Analyses of orbital transfer vehicles (OTVs), landers, and in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points.

orbital mechanics↗

NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗

NASA NTRS2016

Study of Material Densification of In718 in the Higher Throughput Parameter Regime

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this project is to characterize how heat treatment affects density and porosity from a microscopic point of view. This is performs using higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. Density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, and hatch spacing) and material consolidation (assessed in terms of density and porosity). The study also considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the higher energy parameter regime. Metallurgical evaluation of specimens will also be presented. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Cordner, Samuel↗

NASA NTRS1972

Comparison of advanced propulsion concepts for deep space exploration.

Equations and charts are presented which permit rapid estimation of propulsion system performance requirements for some typical deep space missions. The simplicity results from use of gravity-free equations of motion, which are shown to yield good approximations to trip times obtained with solar gravity and planetary motion included. The agreement is satisfactory for missions that do not enter or depart from low orbits about the major planets. A number of advanced propulsion concepts for which performance estimates are available are compared with respect to their capability for fly-by, rendezvous, and round-trip planetary missions. Based on these estimates, the gas-core nuclear fission rocket and the pulsed fusion rocket yield the fastest trip times to the near planets. For round trips to Jupiter and beyond, the controlled fusion rocket shows progressively superior capabilities. Several propulsion concepts based on use of impinging laser beams are found to be noncompetitive with the other advanced concepts for deep space missions.

Moeckel, W. E.↗

NASA NTRS2014

Atmospheric Mining in the Outer Solar System:

Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and hydrogen can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and hydrogen (deuterium, etc.) were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. Additional supporting analyses were conducted to illuminate vehicle sizing and orbital transportation issues. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists. Additional aerospacecraft or other aerial vehicles (UAVs, balloons, rockets, etc.) could fly through the outer planet atmospheres, for global weather observations, localized storm or other disturbance investigations, wind speed measurements, polar observations, etc. Deep-diving aircraft (built with the strength to withstand many atmospheres of pressure) powered by the excess hydrogen or helium 4 may be designed to probe the higher density regions of the gas giants. Outer planet atmospheric properties, atmospheric storm data, and mission planning for future outer planet UAVs are presented.

planetary exploration↗

NASA NTRS2010

Nuclear Energy for Space Exploration

Nuclear power and propulsion systems can enable exciting space exploration missions. These include bases on the moon and Mars; and the exploration, development, and utilization of the solar system. In the near-term, fission surface power systems could provide abundant, constant, cost-effective power anywhere on the surface of the Moon or Mars, independent of available sunlight. Affordable access to Mars, the asteroid belt, or other destinations could be provided by nuclear thermal rockets. In the further term, high performance fission power supplies could enable both extremely high power levels on planetary surfaces and fission electric propulsion vehicles for rapid, efficient cargo and crew transfer. Advanced fission propulsion systems could eventually allow routine access to the entire solar system. Fission systems could also enable the utilization of resources within the solar system. Fusion and antimatter systems may also be viable in the future

Houts, Michael G.↗

NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗