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At least 73 records · Page 4

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NASA NTRS2005

Technology Challenges for Deep-Throttle Cryogenic Engines for Space Exploration

Historically, cryogenic rocket engines have not been used for in-space applications due to their additional complexity, the mission need for high reliability, and the challenges of propellant boil-off. While the mission and vehicle architectures are not yet defined for the lunar and Martian robotic and human exploration objectives, cryogenic rocket engines offer the potential for higher performance and greater architecture/mission flexibility. In-situ cryogenic propellant production could enable a more robust exploration program by significantly reducing the propellant mass delivered to low earth orbit, thus warranting the evaluation of cryogenic rocket engines versus the hypergolic bi-propellant engines used in the Apollo program. A multi-use engine. one which can provide the functionality that separate engines provided in the Apollo mission architecture, is desirable for lunar and Mars exploration missions because it increases overall architecture effectiveness through commonality and modularity. The engine requirement derivation process must address each unique mission application and each unique phase within each mission. The resulting requirements, such as thrust level, performance, packaging, bum duration, number of operations; required impulses for each trajectory phase; operation after extended space or surface exposure; availability for inspection and maintenance; throttle range for planetary descent, ascent, acceleration limits and many more must be addressed. Within engine system studies, the system and component technology, capability, and risks must be evaluated and a balance between the appropriate amount of technology-push and technology-pull must be addressed. This paper will summarize many of the key technology challenges associated with using high-performance cryogenic liquid propellant rocket engine systems and components in the exploration program architectures. The paper is divided into two areas. The first area describes how the mission requirements affect the engine system requirements and create system level technology challenges. An engine system architecture for multiple applications or a family of engines based upon a set of core technologies, design, and fabrication approaches may reduce overall programmatic cost and risk. The engine system discussion will also address the characterization of engine cycle figures of merit, configurations, and design approaches for some in-space vehicle alternatives under consideration. The second area evaluates the component-level technology challenges induced from the system requirements. Component technology issues are discussed addressing injector, thrust chamber, ignition system, turbopump assembly, and valve design for the challenging requirements of high reliability, robustness, fault tolerance, deep throttling, reasonable performance (with respect to weight and specific impulse).

Brown, Kendall K.↗

NASA NTRS2000

Ignition Resistance of Polymeric Materials to Particle Impact in High-Pressure Oxygen

Particle impact ignition has been the primary cause of numerous fires in oxygen systems. This ignition phenomenon is known to occur where particles are present in high-velocity gas, and where impact occurs on a flammable material. The particle impact ignition behavior of many metals has been widely studied, but the particle impact ignition behavior of polymeric materials is relatively unknown. Particle impact ignition in polymeric materials is a concern as these materials are commonly used in component seat and seal applications, where high-velocity particle impacts can occur. This study evaluates several polymeric materials and compares the minimum temperature required for ignition (threshold temperature) of these materials: Kel-F 81 (CTFE), Teflon (PTFE), PEEK, Vespel SP-21, and Nylon 6/6. The materials were configured as targets in the White Sands Test Facility high-velocity particle impact test system. Gaseous oxygen was flowed at 4000 psi and sonic velocity, and the targets were impacted with 2000-micron aluminum 2017 particles. This paper discusses the results of these tests and ranks the materials according to their threshold temperatures at these conditions.

Forsyth, Elliot T.↗

NASA NTRS1992

Space aging of solid rocket materials

Solid rocket propellant and rocket motor components were aged in a vented container on the interior of the LDEF. This paper will present the results of aging the Improved Performance Space Motor-II/Payload Assist Module-Delta II (IPSM-II/PAM-DII) space motor components. Ballistic and mechanical properties of the space aged main propellant, igniter propellant, and ignition system were compared with similar data from preflight and ground aged samples. Mechanical properties of the composite materials and bonded joints used in the motor case, insulation, liner, nozzle, exit cone, and skirt were similarly evaluated. The space aging results will be compared to data collected in a ground based vacuum aging program on similar components. The operation of the vacuum actuated venting valve and pressure actuated resealing of the container will also be addressed. The materials tested showed no significant changes due to space aging. These results indicate that properly designed solid rocket motors can be expected to perform reliably after extended periods of exposure to a space environment.

Dean M Lester↗

NASA NTRS1993

Design and fabrication of a hydrogen/oxygen thrust chamber assembly

The combustion system for the Advance Expander Test Bed engine consists of a thrust mount, an injector with a H2-O2 torch igniter, a combustion chamber, and a conical nozzle extension. These components constitute the thrust chamber assembly. The design, fabrication, and testing of these components are described in detail.

Hernacki, Thomas R.↗

NASA NTRS1999

Testing of a Spray-Bar Zero Gravity Cryogenic Vent System for Upper Stages

The capability to vent in zero gravity without resettling is a fundamental technology need that involves practically all uses of subcritical cryogenics in space. Venting without resettling would extend cryogenic orbital transfer vehicle capabilities. However, the lack of definition regarding liquid/ullage orientation coupled with the somewhat random nature of the thermal stratification and resulting pressure rise rates, lead to significant technical challenges. Typically a zero gravity vent concept, termed a thermodynamic vent system (TVS), consists of a tank mixer to destratify the propellant, combined with a Joule- Thomson (J-T) valve to extract then-nal energy from the propellant. In a cooperative effort, Marshall Space Flight Center's (MSFC's) Multipurpose Hydrogen Test Bed (N4HTB) was used to test a unique "spray bar" TVS system developed by Boeing. A schematic of this system is included in Figure 1. The system consists of a recirculation pump, a parallel flow concentric tube, heat exchanger, and a spray bar positioned close to the longitudinal axis of the tank. In the mixing mode, the recirculation pump withdraws liquid from the tank and sprays it radially into the tank liquid, ullage, and exposed tank surfaces. When energy extraction is required, a small portion of the recirculated liquid is passed sequentially through the J-T expansion valve, the spray bar heat exchanger element, and is vented overboard. The vented vapor cools the circulated bulk fluid, thereby removing thermal energy and reducing tank pressure. Figure 2 is a plot of ullage pressure (P4) and liquid vapor pressure (PSAI) versus time. The pump operates alone, cycling on and off, to destratify the tank liquid and ullage until the liquid vapor pressure reaches the lower set point. At that point, the J-T valve begins to cycle on and off with the pump. Thus, for short duration missions, only the mixer may operate, thus minimizing or even eliminating boil-off losses. The primary advantage of the spray bar configuration is that pressure reduction is achieved independent of liquid and vapor location, thereby enhancing the applicability of normal gravity test data to zero gravity conditions. The in-tank components are minimized with the proposed TVS design. Because the recirculation pump is external to the tank, no electrical power penetration of the tank is required for pump or valve operation. This is especially desirable for L02 tanks since the presence of an electrical ignition source in oxygen represents a critical failure mode. Also, since the critical components (pump, motor, valve, orifice) are external to the tank, system checkout and ground servicing/replacement are easier. For zero-g operation, component replacement external to the tank may be a significant benefit. In addition to satisfying the zero g TVS design objectives, the TVS concept tested offers additional benefits to the integrated subcritical cryogenic storage and launch system.

Lak, Tibor↗

NASA NTRS1991

Space aging of solid rocket materials

Solid rocket propellant and rocket motor components were aged in a vented container on the interior of the LDEF. The results of aging IPSM-II/PAM-DII space motor components are presented. Ballistic and mechanical properties of the space aged main propellant, igniter propellant, and ignition system were compared with similar data from preflight and ground aged samples. Mechanical properties of the composite materials and bonded joints used in the motor case, insulation, liner, nozzle, exit cone, and skirt were similarly evaluated. The space aging results are compared to data collected in a ground based vacuum aging program on similar components.

Lester, Dean M.↗

NASA NTRS2016

Evaluation of Additively Manufactured Metals for Use in Oxygen Systems Project

Space Launch System, Commercial Resupply, and Commercial Crew programs have published intent to use additively manufactured (AM) components in propulsion systems and are likely to include various life support systems in the future. Parts produced by these types of additive manufacturing techniques have not been fully evaluated for use in oxygen systems and the inherent risks have not been fully identified. Some areas of primary concern in the SLS process with respect to oxygen compatibility may be the porosity of the printed parts, fundamental differences in microstructure of an AM part as compared to traditional materials, or increased risk of shed metal particulate into an oxygen system. If an ignition were to occur the printed material could be more flammable than components manufactured from a traditional billet of raw material and/or present a significant hazards if not identified and rigorously studied in advance of implementation into an oxygen system.

Tylka, Jonathan↗

NASA NTRS1990

Flight set 360H005 (STS-28) seals, volume 4

The performance is assessed of the 360H005, Fifth flight, Redesigned Solid Rocket Motors (RSMR) in respect to joint sealing issues as seen from post flight inspection of the seals and sealing surfaces. The factory joint disassembly inspections have resumed for 360H005. The new factory joint grease application is in effect and now can be assessed during the disassembly process. The RSRM is illustrated consisting of capture feature field joints as is the J-joint insulation configuration. The nozzle-to-case joint design is also illustrated, which includes 100, 7/8 inch radial bolts in conjunction with a wiper O-ring and modified insulation design. The ignition system seals and a cross section of the igniter are illustrated. The configuration of all the internal nozzle joints are also shown. The postflight inspection of both motors showed the seal components to be in excellent condition except for the indentation found on the inner primary seal of the right hand inner igniter gasket, aft face. Detailed inspection results, and inspections performed by the O-ring Inspection Team are presented.

Curry, Jeffrey T.↗

NASA NTRS1982

Fibre-Optic Semiconductor Temperature Gage

"Safe" temperature gage for explosive liquids is based on optical transmission. Semiconductor crystal inserted between input and output optical fibers is temperature-sensing element in a new approach to measuring temperature of cryogens. Since no electrical components are immersed in liquid, new sensor minimizes danger of electrically ignited explosions in hazardous cryogens such as oxygen and hydrogen. Gage also useful for handling noncryogenic liquids in aircraft, automobiles, boats and water tanks.

Sharma, M.↗

NASA NTRS1995

Integration issues of a plasma contactor Power Electronics Unit

A hollow cathode-based plasma contactor is baselined on International Space Station Alpha (ISSA) for spacecraft charge control. The plasma contactor system consists of a hollow cathode assembly (HCA), a power electronics unit (PEU), and an expellant management unit (EMU). The plasma contactor has recently been required to operate in a cyclic mode to conserve xenon expellant and extend system life. Originally, a DC cathode heater converter was baselined for a continuous operation mode because only a few ignitions of the hollow cathode were expected. However, for cyclic operation, a DC heater supply can potentially result in hollow cathode heater component failure due to the DC electrostatic field. This can prevent the heater from attaining the proper cathode tip temperature for reliable ignition of the hollow cathode. To mitigate this problem, an AC cathode heater supply was therefore designed, fabricated, and installed into a modified PEU. The PEU was tested using resistive loads and then integrated with an engineering model hollow cathode to demonstrate stable steady-state operation. Integration issues such as the effect of line and load impedance on the output of the AC cathode heater supply and the characterization of the temperature profile of the heater under AC excitation were investigated.

Pinero, Luis R.↗

NASA NTRS2024

Reliable Ignition of LOX-LCH4 Propellants

No cryogenic Reaction Control System (RCS) has ever flown in space. Cryogenic propellants are baselined by HLS and CLPS partners and are the key use case for future ISRU manufactured propellants. A reliable LOX/LCH 4 RCS is an enabling technology for human Lunar and Mars exploration. In previous thermal vacuum (<275 F, <10 torr) testing at NASA GRC Plum Brook, the team uncovered anomalous LOX/LCH4 engine ignition phenomena where flame kernels quenched at these ultra cold hardware temperatures, leading to many pulses where the engines would not light. In 2022, the project was able to recreate the no light condition with an upgraded Frost-Mint test stand at JSC. This project implemented test stand improvements and procured propellants and follow on engine components for a hot fire campaign beginning in November 2024 which will attempt to ignite the RCS engine at ultra cold vacuum conditions by modifying the engine mixture ratio. New modeling techniques were implemented to account for past no lights and are an enabling method to make lunar surface go no go predictions based on hardware conditions. This was enabled by significant improvements to the Frost Mint system, which reduced moisture build up and leaks, increased propellant availability, leading to more attempts at thermal vacuum hot-fires.

Propulsion↗

NASA NTRS1999

A Method for Assessing Material Flammability for Micro-Gravity Environments

On a spacecraft, one of the greatest fears during a mission is the outbreak of a fire. Since spacecraft are enclosed spaces and depend highly on technical electronics, a small fire could cause a large amount of damage. NASA uses upward flame spread as a "worst case scenario" evaluation for materials and the Heat and Visible Smoke Release Rates Test to assess the damage potential of a fire. Details of these tests and the protocols followed are provided by the "Flammability, Odor, Offgassing, and Compatibility Requirements and Test Procedures for Materials in Environments that Support Combustion" document. As pointed by Ohlemiller and Villa, the upward flame spread test does not address the effect of external radiation on ignition and spread. External radiation, as that coming from an overheated electrical component, is a plausible fire scenario in a space facility and could result in a reversal of the flammability rankings derived from the upward flame spread test. The "Upward Flame Propagation Test" has been the subject of strong criticism in the last few years. In many cases, theoretical exercises and experimental results have demonstrated the possibility of a reversal in the material flammability rankings from normal to micro-gravity. Furthermore, the need to incorporate information on the effects of external radiation and opposed flame spread when ranking materials based on their potential to burn in micro-gravity has been emphasized. Experiments conducted in a 2.2 second drop tower with an ethane burner in an air cross flow have emphasized that burning at the trailing edge is deterred in micro-gravity due to the decreased oxygen transport. For very low air flow velocities (U<0.005 m/s) the flame envelopes the burner and a slight increase in velocity results in extinction of the trailing edge (U>0.01 m/s). Only for U>0.l m/s extinction is observed at the leading edge (blow-off). Three dimensional numerical calculations performed for thin cellulose centrally ignited with an axisymmetric source have shown that under the presence of a forced flow slower than 0.035 m/s flames spreads only opposing the flow. Extinction is observed at the trailing edge with no concurrent propagation. Experiments conducted by the same authors at the JAMIC 10 second drop tower verified these calculations. Reducing the oxygen supply to the flame also results in a decrease of the Damk6hler number which might lead to extinction. Greyson et al. and Ferkul conducted experiments in micro-gravity (5 second drop tower) with thin paper and observed that at very low flow velocities concurrent flame spread will stop propagating and the flame will reduce in size and extinguish. They noted that quenching differs significantly from blow-off in that the upstream leading edge will remain anchored to the burn out edge.

Steinhaus, T.↗

NASA NTRS1993

Fundamental rocket injector/spray programs at the Phillips Laboratory

The performance and stability of liquid rocket engines is determined to a large degree by atomization, mixing, and combustion processes. Control over these processes is exerted through the design of the injector. Injectors in liquid rocket engines are called upon to perform many functions. They must first of all mix the propellants to provide suitable performance in the shortest possible length. For main injectors, this is driven by the tradeoff between the combustion chamber performance, stability, efficiency, and its weight and cost. In gas generators and preburners, however, it is also driven by the possibility of damage to downstream components, for example piping and turbine blades. This can occur if unburned fuel and oxidant later react to create hot spots. Weight and cost considerations require that the injector design be simple and lightweight. For reusable engines, the injectors must also be durable and easily maintained. Suitable atomization and mixing must be produced with as small a pressure drop as possible, so that the size and weight of pressure vessels and turbomachinery can be minimized. However, the pressure drop must not be so small as to promote feed system coupled instabilities. Another important function of the injectors is to ensure that the injector face plate and the chamber and nozzle walls are not damaged. Typically this requires reducing the heat transfer to an acceptable level and also keeping unburned oxygen from chemically attacking the walls, particularly in reusable engines. Therefore the mixing distribution is often tailored to be fuel-rich near the walls. Wall heat transfer can become catastrophically damaging in the presence of acoustic instabilities, so the injector must prevent these from occurring at all costs. In addition to acoustic stability (but coupled with it), injectors must also be kinetically stable. That is, the flame itself must maintain ignition in the combustion chamber. This is not typically a problem with main injectors, but can be a consideration in preburners, where the desire to keep turbine inlet temperatures as cool as possible can make it advantageous for the preburners to operate as far from stoichiometry as can be tolerated. For some missions such as single stage to orbit, all of the above requirements must be maintained over a throttleable range, for example 5:1 to 10:1. Finally, the injectors must be ignitable during startup where pressures and temperatures are far from design conditions, and ignition transients must be minimized in order to avoid damage to engine components. In order to satisfy these various constraints, the injector designer must be able to perform design tradeoff studies, and it is important that this be done with minimal time and costs. In fact, it can easily be argued that reducing engine development time and costs is essential to maintaining U.S. competitiveness in space. The Propulsion Directorate of the Phillips Laboratory has invested in a number of programs to advance liquid rocket engine technology, and several of these are directed at improving design tools for liquid rocket injectors. The purpose of the presentation will be to describe some of these latter programs.

Talley, D. G.↗

NASA NTRS1978

Extensions to analysis of ignition transients of segmented rocket motors

The analytical procedures described in NASA CR-150162 were extended for the purpose of analyzing the data from the first static test of the Solid Rocket Booster for the Space Shuttle. The component of thrust associated with the rapid changes in the internal flow field was calculated. This dynamic thrust component was shown to be prominent during flame spreading. An approach was implemented to account for the close coupling between the igniter and head end segment of the booster. The tips of the star points were ignited first, followed by radial and longitudinal flame spreading.

Caveny, L. H.↗

NASA NTRSDate not supplied

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts

particle impact↗

NASA NTRS2024

Particle Impact Simulation and Ignition Prediction

An experimentally calibrated tool is needed to predict if a system is susceptible to failure by particle impact ignition (PI) based on use conditions, materials, and flow geometry. This tool will accelerate new components, evaluating existing hardware, and help disposition anomalies. - Conduct particle impact testing with in-situ diagnostics and complementary simulations on subset of key engineering materials (IN718, M400, 316L, 6061, Ti64, Zr) to develop a proof-of-concept predictive tool for assessing the risk of PI for idealized geometries (spherical particles) in realistic environments. - Assess particle/target interactions (coefficient of restitution, ignition, kindling) using instrumented particle impact rigs while systematically varying key parameters (materials, particle size, environment, target configuration). - Determine key field variables (temperature, strain, stress) in particle impacts using Multiphysics finite element and hydrocode simulations validated through comparison with experimental measurements and observations. - Synthesize experiments and simulations into constitutive models for PI that can be integrated with existing computational fluid dynamics (CFD) and Debris Transport Analysis (DTA) tools in future efforts.

Jonathan Tylka↗

NASA NTRS1986

Testing metals and alloys for use in oxygen systems

When oxygen is present in high concentrations or large quantities, as in oxygen-based life-support systems, the likelihood of combustion and the probable intensity of a conflagration increase, together with the severity of the damage caused. Even stainless steel will burn vigorously when ignited in a 1000-psi oxygen environment. The hazards involved in the use of oxygen increase with system operation at the elevated temperatures typical of propulsion systems. Fires in oxygen systems are generally catastrophic, causing a threat to life in manned vehicles. When mechanical components of a mechanism generate friction heat in the presence of oxygen, many commonly used metal alloys ignite and burn. Attention is presently given to frictional heating, particle impact, and flame propagation tests conducted in oxygen environments.

Stoltzfus, Joel M.↗

NASA NTRS1978

A simple laboratory method for determining ignitability of materials

A simple laboratory method for determining ignitability of materials is described. The apparatus consists of a Mellen high-flux heater capable of producing up to 13 W/sq cm heat flux, a Medtherm water-cooled radiometer for measuring heat flux, a mounting frame to hold all components in proper position, and specimen holders of the type used for the NBS smoke test. Time to ignition at different heat flux levels is recorded. Test results are presented for a variety of materials.

Hilado, C. J.↗