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NASA Marshall Space Flight Center In-Space Cryogenic Propulsion Capabilities and Applications to Human Exploration

The current focus on lunar exploration and future human missions to Mars is driving in-space propulsion system requirements toward higher performance cryogenic systems with long-duration storage and operational capabilities. Not only do these systems offer higher performance than storable propellant options, but they also enable the potential for in-situ propellant production. Future Mars transit systems are envisioned to utilize either high-thrust nuclear thermal propulsion (with liquid hydrogen propellant), or hybrid systems with both cryogenic chemical systems (likely LOX/CH 4 ) for high acceleration manoeuvres and nuclear electric systems for long duration high Isp manoeuvres. Exploration architectures based on either of these options require the use of high-performance cryogenic propellants with long-duration storage capabilities for both in-space transportation as well as planetary descent and ascent functions. Current efforts focusing on lunar exploration also rely on cryogenic propellants (either LOX/LCH 4 or LOX/LH 2 ) for lunar transit and descent/ascent transportation functions. In-space cryogenic propulsion systems pose numerous technology challenges with respect to long-duration propellant storage and usage, including advanced insulation, tank stratification and pressure management, cryogenic refrigeration to reduce propellant loss through boil off, low leakage cryogenic valves, low temperature liquid acquisition, and cryogenic propellant transfer. NASA has invested in technology development efforts, demonstrating individual technologies and systems-level operations. NASA Marshal Space Flight Center has also invested in multiple test facilities and modular test rigs that allow ground demonstration of numerous integrated technologies and systems concepts of operations. Additional investments have been made to mature analytical capabilities and design tools. These capabilities (both test/demonstration & engineering design/analysis) are available to support both internal efforts and industrial partners in the development of exploration and science mission systems. With this increased interest, it is critical to understand the current state of in-space cryogenic propulsion technology, determine risks to its successful application to human exploration, and prepare the engineering, test, and evaluation capabilities to support the ambitious plans for future systems. This paper provides a survey of recent developments in in-space cryogenic propulsion and cryogenic propellant management technologies, as well as facilities and engineering/analytical capabilities ready to support current and future exploration efforts.

Cryogenic propulsion↗

NASA Marshall Space Flight Center In-Space Cryogenic Propulsion Capabilities and Applications to Human Exploration

The current focus on lunar exploration and future human missions to Mars is driving in-space propulsion system requirements toward higher performance cryogenic systems with long-duration storage and operational capabilities. Not only do these systems offer higher performance than storable propellant options, but they also enable the potential for in-situ propellant production. Future Mars transit systems are envisioned to utilize either high-thrust nuclear thermal propulsion (with liquid hydrogen propellant), or hybrid systems with both cryogenic chemical systems (likely LOX/CH 4 ) for high acceleration manoeuvres and nuclear electric systems for long duration high Isp manoeuvres. Exploration architectures based on either of these options require the use of high-performance cryogenic propellants with long-duration storage capabilities for both in-space transportation as well as planetary descent and ascent functions. Current efforts focusing on lunar exploration also rely on cryogenic propellants (either LOX/LCH 4 or LOX/LH 2 ) for lunar transit and descent/ascent transportation functions. In-space cryogenic propulsion systems pose numerous technology challenges with respect to long-duration propellant storage and usage, including advanced insulation, tank stratification and pressure management, cryogenic refrigeration to reduce propellant loss through boil off, low leakage cryogenic valves, low temperature liquid acquisition, and cryogenic propellant transfer. NASA has invested in technology development efforts, demonstrating individual technologies and systems-level operations. NASA Marshal Space Flight Center has also invested in multiple test facilities and modular test rigs that allow ground demonstration of numerous integrated technologies and systems concepts of operations. Additional investments have been made to mature analytical capabilities and design tools. These capabilities (both test/demonstration & engineering design/analysis) are available to support both internal efforts and industrial partners in the development of exploration and science mission systems. With this increased interest, it is critical to understand the current state of in-space cryogenic propulsion technology, determine risks to its successful application to human exploration, and prepare the engineering, test, and evaluation capabilities to support the ambitious plans for future systems. This paper provides a survey of recent developments in in-space cryogenic propulsion and cryogenic propellant management technologies, as well as facilities and engineering/analytical capabilities ready to support current and future exploration efforts.

Cryogenic propulsion↗

Description and test results of a water basin to determine ground effect in hover using small models

A water basin test facility was established capable of measuring forces and moments of small models of VTOL aircraft, simulating hover in and out of ground effect. Because the models and the operation of the facility are inexpensive, the water basin is particularly suitable for testing the relative characteristics of a great number of model configurations for preliminary design development. Results from a variety of models are given. Lift, pitching moments, and rolling moments are given with and without engine failure simulation in ground effect, and with and without pitched and banked conditions.

Renselaer, D. J.↗

Performance of the Spacecraft Propulsion Research Facility During Altitude Firing Tests of the Delta 3 Upper Stage

The Spacecraft Propulsion Research Facility at the NASA Lewis Research Center's Plum Brook Station was reactivated in order to conduct flight simulation ground tests of the Delta 3 cryogenic upper stage. The tests were a cooperative effort between The Boeing Company, Pratt and Whitney, and NASA. They included demonstration of tanking and detanking of liquid hydrogen, liquid oxygen and helium pressurant gas as well as 12 engine firings simulating first, second, and third burns at altitude conditions. A key to the success of these tests was the performance of the primary facility systems and their interfaces with the vehicle. These systems included the structural support of the vehicle, propellant supplies, data acquisition, facility control systems, and the altitude exhaust system. While the facility connections to the vehicle umbilical panel simulated the performance of the launch pad systems, additional purge and electrical connections were also required which were unique to ground testing of the vehicle. The altitude exhaust system permitted an approximate simulation of the boost-phase pressure profile by rapidly pumping the test chamber from 13 psia to 0.5 psia as well as maintaining altitude conditions during extended steady-state firings. The performance of the steam driven ejector exhaust system has been correlated with variations in cooling water temperature during these tests. This correlation and comparisons to limited data available from Centaur tests conducted in the facility from 1969-1971 provided insight into optimizing the operation of the exhaust system for future tests. Overall, the facility proved to be robust and flexible for vehicle space simulation engine firings and enabled all test objectives to be successfully completed within the planned schedule.

Meyer, Michael L.↗

Aeroacoustic performance of a scoop inlet

Results of a low speed wind tunnel test program are presented which demonstrate the aerodynamic and acoustic performance of a scoop inlet. Engine noise that would normally propagate toward the ground is directed upward by the extended lower lip of the scoop inlet. In addition, more of the scoop airflow comes in from above the inlet than below, leading to relatively higher surface velocities on the upper lip and lower surface velocities on the lower lip. These lower velocities on the lower lip result in a higher attainable angle of attack before internal flow separation occurs.

Abbott, J. M.↗

Observations of directional gamma prime coarsening during engine operation

Two alloys, NASAIR 100 and a modified NASAIR 100 called Alloy 3, were run as turbine blades in an experimental ground-based Garrett TFE731 engine for up to 200 hours. The stress induced directional coarsening of gamma-prime (rafting) that developed during engine testing was analyzed and compared to previous research from laboratory tests. The blades were found to have formed a lamellar structure, the lamellae being normal to the centrifugal stress axis over much of the span. However, near the surfaces, the blades were found to have formed lamellae parallel to the centrifugal stress axis for certain cycles. Representative photomicrographs of the blades and the effects of stress and temperature on lamellae formation are shown.

Draper, S.↗

V/STOL gets a lift

The concept of a supersonic STOVL that could offer enhanced mission capability, survivability, operational flexibility, and utility over conventional aircraft is presented. Emphasis is currently on design studies, CFD work, small- and large-scale wind tunnel tests, simulation activities, flight experiments, and ground environment experiments. Propulsion system technology centers about the adaptation of existing or off-the-shelf engines. Concepts under study include separate flow in hover, gas-driven lift fan, and shaft-driven lift fan. NASA is examining generic valve and ducting configurations with airflow at ambient temperature and at temperatures up to 1000 F to gather pressure loss and heat transfer data. Advanced civil rotorcraft technologies examined include high-efficiency/dual-mode components such as torque converters; lightweight, quiet transmissions; and variable geometry power turbines; along with dual-function or convertible engines.

Biesiadny, Tom↗

Aeronautical engineering: A continuing bibliography with indexes (supplement 277)

This bibliography lists 467 reports, articles, and other documents introduced into the NASA scientific and technical information system in Mar. 1992. Subject coverage includes: the engineering and theoretical aspects of design, construction, evaluation, testing, operation, and performance of aircraft (including aircraft engines); and associated aircraft components, equipment, and systems. It also includes research and development in ground support systems, theoretical and applied aspects of aerodynamics, and general fluid dynamics.

Source record↗

The MARS pathfinder end-to-end information system: A pathfinder for the development of future NASA planetary missions

The development of the Mars pathfinder is considered with emphasis on the End-to-End Information System (EEIS) development approach. The primary mission objective is to successfully develop and deliver a single flight system to the Martian surface, demonstrating entry, descent and landing. The EEIS is a set of functions distributed throughout the flight, ground and Mission Operation Systems (MOS) that inter-operate in order to control, collect, transport, process, store and analyze the uplink and downlink information flows of the mission. Coherence between the mission systems is achieved though the EEIS architecture. The key characteristics of the system are: a concurrent engineering approach for the development of flight, ground and mission operation systems; the fundamental EEIS architectural heuristics; a phased incremental EEIS development and test approach, and an EEIS design deploying flight, ground and MOS operability features, including integrated ground and flight based toolsets.

Cook, Richard A.↗

Modeling Cyclic Phase Change and Energy Storage in Solar Heat Receivers

Numerical results pertaining to cyclic melting and freezing of an encapsulated phase change material (PCM), integrated into a solar heat receiver, have been reported. The cyclic nature of the present melt/freeze problem is relevant to latent heat thermal energy storage (LHTES) systems used to power solar Brayton engines in microgravity environments. Specifically, a physical and numerical model of the solar heat receiver component of NASA Lewis Research Center's Ground Test Demonstration (GTD) project was developed and results compared with available experimental data. Multi-conjugate effects such as the convective fluid flow of a low-Prandtl-number fluid, coupled with thermal conduction in the phase change material, containment tube and working fluid conduit were accounted for in the model. A single-band thermal radiation model was also included to quantify reradiative energy exchange inside the receiver and losses through the aperture. The eutectic LiF-CaF2 was used as the phase change material (PCM) and a mixture of He/Xe was used as the working fluid coolant. A modified version of the computer code HOTTube was used to generate results for comparisons with GTD data for both the subcooled and two-phase regimes. While qualitative trends were in close agreement for the balanced orbit modes, excellent quantitative agreement was observed for steady-state modes.

Hall, Carsie A., III↗

Parametric Analysis of Cyclic Phase Change and Energy Storage in Solar Heat Receivers

A parametric study on cyclic melting and freezing of an encapsulated phase change material (PCM), integrated into a solar heat receiver, has been performed. The cyclic nature of the present melt/freeze problem is relevant to latent heat thermal energy storage (LHTES) systems used to power solar Brayton engines in microgravity environments. Specifically, a physical and numerical model of the solar heat receiver component of NASA Lewis Research Center's Ground Test Demonstration (GTD) project was developed. Multi-conjugate effects such as the convective fluid flow of a low-Prandtl-number fluid, coupled with thermal conduction in the phase change material, containment tube and working fluid conduit were accounted for in the model. A single-band thermal radiation model was also included to quantify reradiative energy exchange inside the receiver and losses through the aperture. The eutectic LiF-CaF2 was used as the phase change material (PCM) and a mixture of He/Xe was used as the working fluid coolant. A modified version of the computer code HOTTube was used to generate results in the two-phase regime. Results indicate that parametric changes in receiver gas inlet temperature and receiver heat input effects higher sensitivity to changes in receiver gas exit temperatures.

Hall, Carsie A., III↗

NASA's Constellation Program: Milestones Towards the Frontier

This slide presentation reviews the status and progress made in the Constellation Program's work towards the goal of lunar and Martian exploration flights. It includes views of the various components of the program, and reviews the status of the engine tests, and the development of the Ares I-X towards test launch, the Orion Crew Module, the launch abort system, and the ground operations facilities.

Hanley, Jeffrey M.↗

Investigation of a laser Doppler velocimeter system to measure the flow field around a large scale V/STOL aircraft in ground effect

The flow field measured around a hovering 70 percent scale vertical takeoff and landing (V/STOL) aircraft model is described. The velocity measurements were conducted with a ground based laser Doppler velocimeter. The remote sensing instrumentation and experimental tests of the velocity surveys are discussed. The distribution of vertical velocity in the fan jet and fountain; the radial velocity in the wall jet and the horizontal velocity along the aircraft underside are presented for different engine rpms and aircraft height above ground. Results show that it is feasible to use a mobile laser Doppler velocimeter to measure the flow field generated by a large scale V/STOL aircraft operating in ground effect.

Zalay, A. D.↗

Large Liquid Rocket Testing: Strategies and Challenges

Rocket propulsion development is enabled by rigorous ground testing in order to mitigate the propulsion systems risks that are inherent in space flight. This is true for virtually all propulsive devices of a space vehicle including liquid and solid rocket propulsion, chemical and non-chemical propulsion, boost stage and in-space propulsion and so forth. In particular, large liquid rocket propulsion development and testing over the past five decades of human and robotic space flight has involved a combination of component-level testing and engine-level testing to first demonstrate that the propulsion devices were designed to meet the specified requirements for the Earth to Orbit launchers that they powered. This was followed by a vigorous test campaign to demonstrate the designed propulsion articles over the required operational envelope, and over robust margins, such that a sufficiently reliable propulsion system is delivered prior to first flight. It is possible that hundreds of tests, and on the order of a hundred thousand test seconds, are needed to achieve a high-reliability, flight-ready, liquid rocket engine system. This paper overviews aspects of earlier and recent experience of liquid rocket propulsion testing at NASA Stennis Space Center, where full scale flight engines and flight stages, as well as a significant amount of development testing has taken place in the past decade. The liquid rocket testing experience discussed includes testing of engine components (gas generators, preburners, thrust chambers, pumps, powerheads), as well as engine systems and complete stages. The number of tests, accumulated test seconds, and years of test stand occupancy needed to meet varying test objectives, will be selectively discussed and compared for the wide variety of ground test work that has been conducted at Stennis for subscale and full scale liquid rocket devices. Since rocket propulsion is a crucial long-lead element of any space system acquisition or development, the appropriate plan and strategy must be put in place at the outset of the development effort. A deferment of this test planning, or inattention to strategy, will compromise the ability of the development program to achieve its systems reliability requirements and/or its development milestones. It is important for the government leadership and support team, as well as the vehicle and propulsion development team, to give early consideration to this aspect of space propulsion and space transportation work.

Rahman, Shamim A.↗

Flight Avionics Sequencing Telemetry (FAST) DIV Latching Display

The NASA Engineering (NE) Directorate at Kennedy Space Center provides engineering services to major programs such as: Space Shuttle, Inter national Space Station, and the Launch Services Program (LSP). The Av ionics Division within NE, provides avionics and flight control syste ms engineering support to LSP. The Launch Services Program is respons ible for procuring safe and reliable services for transporting critical, one of a kind, NASA payloads into orbit. As a result, engineers mu st monitor critical flight events during countdown and launch to asse ss anomalous behavior or any unexpected occurrence. The goal of this project is to take a tailored Systems Engineering approach to design, develop, and test Iris telemetry displays. The Flight Avionics Sequen cing Telemetry Delta-IV (FAST-D4) displays will provide NASA with an improved flight event monitoring tool to evaluate launch vehicle heal th and performance during system-level ground testing and flight. Flight events monitored will include data from the Redundant Inertial Fli ght Control Assembly (RIFCA) flight computer and launch vehicle comma nd feedback data. When a flight event occurs, the flight event is ill uminated on the display. This will enable NASA Engineers to monitor c ritical flight events on the day of launch. Completion of this project requires rudimentary knowledge of launch vehicle Guidance, Navigatio n, and Control (GN&C) systems, telemetry, and console operation. Work locations for the project include the engineering office, NASA telem etry laboratory, and Delta launch sites.

Moore, Charlotte↗

Qualification and Performance of a High-Efficiency Laser Transmitter for Deep-Space Optical Communications

A high-power Laser Transmitter Assembly (LTA) was developed to support the Deep Space Optical Communications (DSOC) technology demonstration being developed by the Jet Propulsion Laboratory. NASA’s Psyche Mission plans to host the DSOC flight subsystem for testing space-to-ground high-bandwidth laser communications en route to the 16 Psyche asteroid. We review the design, performance, and qualification of the LTA Engineering Model and Flight Model (EM and FM) delivered to JPL. The LTA uses a master-oscillator power amplifier (MOPA) design and delivers up to 4.5 W at 1550 nm, with a highly efficient, cladding-pumped, polarization-maintaining erbium-ytterbium fiber amplifier. The master oscillator generates a range of pulse widths and repetition rates to support modulation formats from 16- to 128-PPM for optical data transmission at >100 Mbps. The LTA was designed for high reliability and radiation hardness, and includes redundant signal and pumping paths to reduce single points of failure, hardware interlocks to ensure safe operation and protection against damage, closed-loop control of optical power, and detailed health and status via telemetry. The LTA EM and FM were subjected to unit-appropriate space qualification testing. We describe the performance testing of the EM and FM, for the characterization of key metrics such as wavelength stability, signal linewidth, optical pulse width, jitter, and extinction ratio, and polarization extinction ratio. The management of optical nonlinearities (self-phase modulation, Brillouin scattering, or pulse-to-pulse energy variation), which could result in an optical link penalty or damage to the LTA, is also detailed, and factors affecting the power efficiency are discussed.

Jaques, J.↗

Interior noise levels of two propeller-driven light aircraft

The relationships between aircraft operating conditions and interior noise and the degree to which ground testing can be used in lieu of flight testing for performing interior noise research were studied. The results show that the noise inside light aircraft is strongly influenced by the rotational speed of the engine and propeller. Both the overall noise and low frequency spectra levels were observed to decrease with increasing high speed rpm operations during flight. This phenomenon and its significance is not presently understood. Comparison of spectra obtained in flight with spectra obtained on the ground suggests that identification of frequency components and relative amplitude of propeller and engine noise sources may be evaluated on stationary aircraft.

Catherines, J. J.↗

Medical Systems Engineering to Support Mars Mission Crew Autonomy

Human spaceflight missions to Mars face exceptionally challenging resource limitations that far exceed those faced before. Increasing transit times, decreasing opportunity for resupply, communications challenges, and extended time to evacuate a crew to definitive medical care dictate a level of crew autonomy in medical care that is beyond the current medical model. To approach this challenge, a medical systems engineering approach is proposed that relies on a clearly articulated Concept of Operations and risk analysis tools that are in development at NASA. This paper proposes an operational clinical model with key terminology and concepts translated to a controls theory paradigm to frame a common language between clinical and engineering teams. This common language will be used for design and validation of an exploration medical system that is fully integrated into a Mars transit vehicle. This approach merges medical simulation, human factors evaluation techniques, and human-in-the-loop testing in ground based analogs to tie medical hardware and software subsystem performance and overall medical system functionality to metrics of operational medical autonomy. Merging increases in operational clinical autonomy with a more restricted vehicle system resource scenario in interplanetary spaceflight will require an unprecedented level of medical and engineering integration. Full integration of medical capabilities into a Mars vehicle system may require a new approach to integrating medical system design and operations into the vehicle Program structure. Prior to the standing-up of a Mars Mission Program, proof of concept is proposed through the Human Research Program.

Antonsen, Erik↗